INSTRUCTION TO SERVICE
ITS: 61283

March 4, 2025

SECTION:

219-Exhaust System

WRITTEN BY:

New Flyer Service Engineering

SUBJECT:

Replace existing turbo outlet exhaust elbow with redesigned elbow and gasket

ISSUE:

Exhaust leak present at the turbo outlet and exhaust elbow joint

SUMMARY:

The existing elbows will be replaced with a redesigned elbow that has a gasket
implemented in the joint to ensure no exhaust leak is present.

ITS61283
Ref. NHTSA Recall No.
Not Applicable

Ref. Transport Canada Recall No.
Not Applicable

THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERRED TO FOR FUTURE MAINTENANCE UNTIL
THE NEW FLYER PARTS AND/OR SERVICE MANUAL IS UPDATED TO REFLECT WORK DONE AS A
RESULT OF THIS DOCUMENT. ENSURE THAT THIS DOCUMENT IS AVAILABLE FOR PARTS AND
MAINTENANCE STAFF GOING FORWARD.
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 unauthorized disclosure,
reproduction or other distribution of this document or information 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.

INSTRUCTION TO SERVICE
ITS61283

PROCEDURE:
1. Set park brake and chock wheels.
2. Turn the main battery disconnect switch to the “OFF” position.
3. In the engine compartment of the bus, locate and remove and retain the existing turbo outlet exhaust elbow
and clamps.
4. Inspect the existing gasket on the exhaust tube side of the elbow for gasket integrity. If any damage is found
replace with a new gasket (NF PN 395859).
5. Insert the new gasket into the turbo outlet end of the exhaust elbow and install the redesigned exhaust elbow
(NF PN 1115025).
6. Ensure the turbo exhaust elbow is aligned with both the turbo outlet and the exhaust tube. Torque the existing
clamps as shown in Figure 1.

Figure 1: Align Turbo Exhaust Elbow and Torque Clamps
7. Tap lightly around the perimeter of the clamps with a rubber mallet to ensure the elbow and gaskets have
properly seated, then recheck the torque on the clamps. Repat as required until the torque value is
consistently maintained.
8. Return the removed turbo exhaust elbow to your New Flyer Regional Product Support Manager.
9. Clean up all tools and debris and return the bus to service condition.
10. Turn the main battery disconnect switch to the “ON” position.

ITS61283

Page 2 of 3

March 4, 2025

INSTRUCTION TO SERVICE
ITS61283

LABOUR ESTIMATE
Operation
1

Replace existing turbo outlet exhaust elbow with

Number of
Technician(s)
1

Hours
1.5

Labor Time
T X HR
1.5

redesigned elbow and gasket

PARTS REQUIRED

Item

Part Number

1

395859

GASKET-MARMON 3.5" STD

2

1115025

TUBE-EXHAUST TURBO OUT L9

ITS61283

Description

Page 3 of 3

Qty.
per
Coach
2

Units

1

EA

EA

Notes
If Required

March 4, 2025