dash (see Figure 19).

Remove four screws

Figure 19 - Remove the Dash and Screws
PAGE 11 OF 29

SERVICE BULLETIN
1.20.

SAV.1E.2012MA

BS4040ER3

On the front end fiberglass canopy, drill through the rivets, using a punch and hammer if necessary to remove
the rivets. Cut the seal between the canopy and the roof, lifting the canopy with nylon blocks to facilitate
cutting the seal, and use a scissor lift to remove the canopy (3-4 people required). Use a scraper to clean
the roof and canopy (see Figure 20).

Drill through rivets

Clean the roof and the canopy

Figure 20 - Remove the Canopy

PAGE 12 OF 29

SERVICE BULLETIN
1.21.

SAV.1E.2012MA

BS4040ER3

Remove the vertical door seal and cut it at the intersection of the horizontal seal. Remove the horizontal seal
from its location. Cut the front shell in such a way that will allow easy access for cutting both sides of the Sika
seal. Keep the driver's side pillar as it will be used as a reference template when transferring the VIN plates
and decals onto the new pillar (see Figure 21).
Remove the vertical door seal
Remove the horizontal seal

Cut the front shell

Cut the Sika seal

Driver's side pillar

Figure 21 - Remove the Front Shell

PAGE 13 OF 29

SERVICE BULLETIN
1.22.

SAV.1E.2012MA

BS4040ER3

Cut the tie wraps on the destination sign cables and disconnect the cables. Remove the speaker over the
driver's seat. Place foam protection on the dashboard, remove the destination sign screws and lower the
destination sign (3-4 people required) onto the dash board, (see Figure 22).

Foam protection

Front destination sign

Figure 22 - Remove the Front Destination Sign

1.23.

Clean the bus structure by removing all remnants of sika and ensuring all surfaces are flat.

1.24.

New front shell preparation:
1.24.1. Use the template to make the wiper holes (see Figure 23).
1.24.2. Use the template to make the windshield washer nozzle holes (see Figure 23).
1.24.3. Use the template to make the license plate holes (see Figure 23).
1.24.4. Use the template to make the side door camera holes (see Figure 23)

Wiper holes

Side door
camera

License plate

Windshield
washer nozzles

Figure 23 - Front Shell Preparation

PAGE 14 OF 29

SERVICE BULLETIN

1.25.

SAV.1E.2012MA

BS4040ER3

Do a dry fit to confirm that the front shell fits well (3-4 people required). Use masking tape and a marker to
indicate the proper positioning and alignment for final installation (see Figure 24).

Positioning and alignment

Figure 24 - Front Shell Dry Fit

PAGE 15 OF 29

SERVICE BULLETIN
1.26.

SAV.1E.2012MA

BS4040ER3

Clean the inner surfaces of the front shell and the bus structure with Sika Aktivator in the area where Sika
adhesive will be used. Wait 10 minutes (see Figure 25).

Clean inner surfaces of front shell

Figure 25 - Front Shell Cleaning

1.27.

Paint the inner surfaces of the front shell and the bus structure with black Sika Primer to ensure a good bond
with the Sika (see Figure 26).

Paint inner surfaces of front shell

Figure 26 - Front Shell Priming

PAGE 16 OF 29

SERVICE BULLETIN
1.28.

SAV.1E.2012MA

BS4040ER3

Use masking tape to protect the gelcoat along the Sika joints to prevent the Sika from spreading (see Figure 27).

Use masking tape to protect the gel coat

Figure 27 - Protect GelCoat with Masking Tape

1.29.

Apply white Sika on the area that will meet the front shell and apply black Sika on the metal structure above
the front bumper (see Figure 28).

Apply white sika

Apply black Sika

Figure 28 - Apply White and Black Sika

PAGE 17 OF 29

SERVICE BULLETIN

1.30.

SAV.1E.2012MA

BS4040ER3

Install the front shell (3-4 people required), install the tow plugs to help hold the shell in place, ensure all
alignment marks are in position and clamp the shell in place. Wipe excess Sika, do not let the sika spread
on the gelcoat (see Figure 29).

Install the front shell

Clamp the shell in place

Tow plugs

Figure 29 - Install the Front Shell

PAGE 18 OF 29

SERVICE BULLETIN
1.31.

SAV.1E.2012MA

BS4040ER3

Apply white Sika between the front shell and the bus structure on both the left and right sides. Use nylon
blocks to pull the shell away from the structure while Sika is applied, align the reference marks and clamp
the shell (see Figure 30).
Apply white Sika

Figure 30 - Apply Sika Between the Front Shell and the Bus Structure

1.32.

Using masking tape to avoid spreading Sika on the gelcoat, apply black Sika on the joint above the front
bumper and apply white Sika on all other joints. Use finishing tools to obtain a clean finish (see Figure 31).

Apply white Sika. Use
masking tape on either
side of the joint to
avoid spreading Sika
on the gelcoat

Apply black Sika. Use
masking tape on either
side of the joint to
avoid spreading Sika
on the gelcoat

Figure 31 - Apply Masking Tape Prior to Applying Sika to Joints

PAGE 19 OF 29

SERVICE BULLETIN
1.33.

SAV.1E.2012MA

BS4040ER3

Install masking tape around the outer edge of the canopy to avoid spreading sika on the gelcoat. Verify that
the roof and canopy have been cleaned of all Sika, that all surfaces are flat and thet they have been cleaned
with aktivator. Wait 10 minutes prior to applying Sika on the roof and install the canopy on the roof (2-3 people
required). Apply Sika in every rivet hole, install the rivets with a rivet gun and install masking tape on the roof
in preparation for the Sika joint. Apply white Sika all the way around the canopy, making sure to cover all the
rivet heads with Sika to prevent water infiltration (see Figure 32).

Apply white Sika

Figure 32 - Canopy Installation

1.34.

Install the speaker over the driver's seat. Connect and tie wrap the cables. Avoid pinching the cables.

1.35.

Install the dashboard and the 4 dashboard screws (see Figure 33).

Install four screws

Figure 33 - Dashboard Installation

PAGE 20 OF 29

SERVICE BULLETIN
1.36.

SAV.1E.2012MA

BS4040ER3

Install the windshield seal on the front shell. Using window lubricant and a plastic chisel, install the windshield
with suction cups (2-3 people required). Begin with the curb side by inserting the windshield into the seal
groove approximately 3 inches from the lower corner. Place the opposite corner of the windshield into the seal
groove and guide it into the seal, working the plastic chisel all the way around the windshield (see Figure 34).

Install windshield

Figure 34 - Install Windshield

1.37.

Install the destination sign window with suction cups (2-3 people required). Begin 3 inches from the lower
curb side corner by inserting the window into the seal groove. Place the opposite corner of the window into
the seal groove and guide it into the seal, working with the plastic chisel and window lubricant all the way
around the window. Use the seal locking tool to install the locking seal around the windshield and destination
sign window (see Figure 35).

Install destination sign window

Figure 35 - Install Destination Sign Window

PAGE 21 OF 29

SERVICE BULLETIN
1.38.

SAV.1E.2012MA

BS4040ER3

Install quarter windows with suction cups. Using a plastic chisel and window lubricant, insert the glass into
the seal groove beginning at the top (see Figure 36).

Install quarter windows

Figure 36 - Install Quarter Windows

1.39.

Apply black butyl sealant around the window opening. Install the driver's side window using suction cups
(2 people required), install the window frame and tighten the screws from inside the bus (see Figure 37).

Figure 37 - Install Driver's Window

PAGE 22 OF 29

SERVICE BULLETIN
1.40.

SAV.1E.2012MA

BS4040ER3

Install the driver's control panel with its screws (see Figure 38).

Figure 38 - Install the Driver's Control Panel

1.41.

Install the front right door post capping with all its screws (see Figure 39).

Figure 39 - Install the Front Right Door Post Capping

PAGE 23 OF 29

SERVICE BULLETIN
1.42.

SAV.1E.2012MA

BS4040ER3

Use a heat gun to remove the plates and decals from the old front shell. Do not overheat; use only to warm
and soften the adhesive to ease removal. Install the phone, microphone and sun shade (see Figure 40).

Figure 40 - Install the Plates, Decals, Phone, Microphone and Sun Shade

1.43.

Install the driver's seat on its base, screw in the bolts and connect the pneumatic hose and the electric cables
(see Figure 41).

Figure 41 - Install the Driver's Seat
PAGE 24 OF 29

SERVICE BULLETIN
1.44.

SAV.1E.2012MA

BS4040ER3

Install the side door camera. To install the driver's side camera, drill holes from inside the bus prior to installing.
Install masking tape around the cameras and apply a white Sika joint to prevent water infiltration (see Figure 42).

Side door camera

Driver's side camera

Figure 42 - Install the Cameras

1.45.

Use the gutters as a template to drill holes in the front shell prior to rivet installation (2 people recommended).
Apply white Sika in every hole and behind each gutter. Install the gutters with rivets and cover each rivet
with Sika to prevent water infiltration. Install masking tape and apply white Sika joint along the gutters (see
Figure 43).

Street side gutters
Curb side gutter

Figure 43 - Install the Gutters

PAGE 25 OF 29

SERVICE BULLETIN
1.46.

SAV.1E.2012MA

BS4040ER3

Install the side mirror brackets. For the side door mirror bracket, install masking tape and apply a black Sika
joint around the bracket. Install the mirrors and connect the wires (see Figure 44).

Figure 44 - Install the Mirrors

1.47.

Install the red decal on the front of the bus, using the old front shell as reference (see Figure 45).

Red decal

Figure 45 - Install the Red Decal

PAGE 26 OF 29

SERVICE BULLETIN
1.48.

SAV.1E.2012MA

BS4040ER3

Install the door seal, apply black Sika behind the existing top seal and clamp the seal with a piece of wood in
order to apply uniform pressure. Apply black Sika behind the vertical seal and clamp with a piece of wood to
apply uniform pressure. Seal the joint between the horizontal and vertical seals with black Sika (see Figure 46).

vertical seal

Joint
Horizontal seal

Figure 46 - Install Door Seals

1.49.

Install reflectors, marker lights and signal lights (see Figure 47).

Figure 47 - Install Reflectors, Marker Lights and Signal Lights

PAGE 27 OF 29

SERVICE BULLETIN
1.50.

SAV.1E.2012MA

BS4040ER3

Install wiper arms while maintaining proper alignment, connect wiper hoses and install cover caps (see
Figure 48).

Figure 48 - Install the Windshield Wipers

1.51.

Install the license plate and the tow plugs (see Figure 49).

Figure 49 - Install the License Plate and Tow Plugs

1.52.

Install turn signals and headlights. Apply black Sika around the light housings to prevent water infiltration and
install the light bezels (see Figure 50).

Figure 50 - Install the Turn Signals and Headlights

PAGE 28 OF 29

SERVICE BULLETIN
1.53.

SAV.1E.2012MA

BS4040ER3

Install the bicycle rack (see Figure 51).

Figure 51 - Install the Bicycle Rack

1.54.

Place the battery disconnect switch in the battery compartment in the ON position and connect the negative
cable from the battery terminal.

1.55.

Return the bus to service. 

PAGE 29 OF 29