R16YT IMPORTANT SAFETY RECALL NOTICE NHTSA Recall
R16YTIMPORTANT SAFETY RECALL NOTICENHTSA Recall Number: 16V-542 School BusNHTSTA Recall Number: 16V-543 Non-School BusAugust 15, 2016Dear Blue Bird Owner:Subject:RECALL R16YT, Propane Fuel Line RoutingThis important safety recall notice applies to your bus(es) identified by both Blue Bird Body Number andVehicle Identification Number (VIN) on the enclosed yellow cover sheet.This notice is sent to you in accordance with the requirements of the National Traffic and Motor VehicleSafety Act.Blue Bird Body Company is recalling certain model year 2015-2017 Vision Propane School Busesmanufactured from July 3, 2014, through June 24, 2016, and certain model year 2016-2017 Vision PropaneNon-School Buses manufactured from September 24, 2015, through May 21, 2016. Certain buses equippedwith Ford 6.8L Propane Engines could have incorrect fuel line routing. If operated under this condition, thiscould cause the fuel lines to rub against each other which could lead to a propane fuel leak. A propane fuelleak in the presence of an ignition source could result in a fire causing injury and/or damage to property.Buses should be corrected immediately according to the enclosed instructions for Recall R16YT. Ownersshould have the bus(es) inspected and re-route the fuel lines to prevent future damage. Fuel line(s) should bereplaced if damage is found. Parts are currently available in limited quantities at no cost to you.Your Blue Bird bus(es) affected by this recall are identified by both the Blue Bird Body Number(s) andVehicle Identification Number(s) (VIN) on the enclosed yellow reply sheet. If you no longer own the subjectbus(es), please complete the appropriate section of the yellow reply sheet and return to Blue Bird in theenclosed pink postage prepaid envelope.Blue Bird recommends that you contact your local or nearest Blue Bird Dealer to arrange for this recallto be performed. The Dealer can perform the repairs, or arrange for repairs to be performed by a servicerepair facility authorized by the Dealer. However, you may elect to perform this recall yourself or pay anotherindependent repair facility to perform this recall. A qualified technician should perform this recall.If you elect to perform this recall yourself or pay another independent repair facility to perform this recall,complete and submit the Pink Owner’s Recall Reply Sheet provided. The Reply Sheet includes a section forthe owner to request reimbursement of the owner’s labor or to request reimbursement for a labor invoice paidby the owner to an independent repair facility.BLUE BIRD BODY COMPANYP.O. Box 937 – 402 Blue Bird Blvd – Fort Valley, Georgia – (478) 825-2021
Blue Bird Body CompanyPage 2R16YTSteps and allowable labor times for this campaign:Step A: Inspect, Add Ties, and Reroute Lines:o 0.5 hour (30 minutes)Step B: If necessary, purging the system to disconnect line(s) for rerouting (no lines replaced) for additional:o 0.5 hour (30 minutes)Step C: If necessary, purging the system to disconnect line(s) for rerouting and replace one line for additional:o 1 hour (60 minutes)Step C : If necessary, purging the system to disconnect line(s) for rerouting and replace additional line foradditional:o 0.5 hours (30 minutes) for eachWhen preparing the Pink Reply Sheet for each bus: Select “A” or Select “A” and “B” or Select “A” and enter the number of lines replaced in “C”Of course, if your Blue Bird Dealer performs the recall or arranged for repairs to be performed by a servicefacility authorized by the Dealer, the Blue Bird Dealer will notify Blue Bird about the completion of the recall.Parts to complete Recall R16YT must be obtained from Blue Bird Recall Administration via e-mail atcampaignparts@blue-bird.com or return the yellow coversheet to Blue Bird in the pink, self-addressed,postage prepaid envelope to receive parts at no charge. Be sure to provide a valid shipping address asUPS does not deliver to post office boxes. You should retain a copy of the reply sheet for your records.Parts are currently available in limited quantities.If the modifications directed by this notification were performed on your bus prior to the receipt of this recallnotification, attach a copy of the work order/invoice. Mail the documents in the pink self-addressed postageprepaid envelope included with the pink reply coversheet to Blue Bird for warranty consideration.Reimbursements will be made in accordance with the requirements of the National Highway TransportationSafety Act, Title 49 Code of Federal Regulations, Parts 573 and 577.Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of thisnotice to the lessee within ten days.
Blue Bird Body CompanyPage 3R16YTIf Blue Bird Body Company should fail to or is unable to remedy this condition without charge to you, youmay contact:ADMINISTRATORNATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION1200 NEW JERSEY AVENUE, SEWASHINGTON, D.C. 20590Or, you may call The National Highway Traffic Safety Administration toll free at:1-888-327-4236 TTY 1-800-424-9153 or go to: http:/www.safercar.govQuestions regarding this recall campaign should be directed to me at (478) 822-2242 or lisa.hancock@bluebird.com.Sincerely,Lisa HancockLisa HancockCorporate Recall AdministratorBlue Bird Body Company
Propane Fuel Line RoutingRECALLISSUECORRECTIVE ACTION ----Propane fuel lines may be crossed and/orrubbing. Crossed and/or rubbing fuel lines maybecome damaged from movement and developa leak.Inspect fuel lines and if necessary reroutepropane fuel lines to ensure the lines aresecured parallel and are not rubbing.Replace any damaged fuel line(s).INSPECTIONwheels.2. Disconnect batteries.3. Open hood and locate propane fuel lines from Fuel Rail Pressure Control Module(FRPCM) to the rear of the engine.FRPCM--1. Park bus on level surface, apply parking brake, turn off ignition, remove key, and chock--R E C A L LWARNING: Always follow all Federal, State, Local and Shop safety standards and use propersafety equipment, and thoroughly read and understand all instructions before performing theseprocedures.C A M P A I G N ---R 1 6 Y T---Models Affected: Certain 2015 through 2017 Model Year Vision BusesEquipped with Propane EnginesPage 1 of 11
Propane Fuel Line RoutingRECALLFRPCMThrottle body andair intake tube4. Inspect for clearance between the fuel lines and the air intake tube.5. If the fuel lines are contacting the air intake tube, inspect for damage to the fuel lines andfollow reroute instructions.NOTE: If any lines need replacing, obtain replacement parts before rerouting lines.--R E C A L LFuel line damagedfrom contact withair intake tubeC A M P A I G N ---R 1 6 Y T---INSPECT FUEL LINE ROUTING BELOW FRPCM--6. See Page 6 for help in identifying a good or damaged fuel line. If any fuel lines aredamaged, follow replacement instructions.Page 2 of 11
Propane Fuel Line RoutingRECALL7. Fuel lines may have been installed where they contact each other. If the lines are rubbingor crossed, then the fuel lines may become damaged. Remove the cable ties from bothheavy duty cable mounts and inspect the fuel lines for any damage. If the fuel line hasbeen damaged, follow fuel line replacement instructions.NOTE: If any lines need replacing, obtain replacement parts before rerouting lines.--These are examples of fuel linesrouting where the fuel lines may becrossed and/or rubbing. These linesmust be rerouted, per instructions onPage 4. Remove existing cable tiesfrom both heavy duty cable mounts.Note:Do not remove heavy duty cablemounts just the cable ties.--R E C A L LCable tie and heavy duty cablemountsC A M P A I G N ---R 1 6 Y T---INSPECT FOR CROSSED AND RUBBING FUEL LINESPage 3 of 11
Propane Fuel Line RoutingRECALLCAUTION: Allow engine and components to cool prior to performing these procedures toprevent risk of severe burns.WARNING: Technicians working with, or around, fuel systems should be properly trained toutilize extreme care and caution at all times. Failure to exercise extreme caution and care maylead to serious accidents which can result in property damage, personal injury and/or death.WARNING: LPG is under pressure, wear adequate eye protection. When LPG is discharged intothe atmosphere the rapid change in pressure can cause a refrigerant condition in the fuel (quickcooling) and can harm your skin or cause serious burns much like frostbite. Always wear gloves.WARNING: Liquid propane is cold. The temperature of propane in its liquid state is -44o F(-42o C). Wear eye and ear protection during venting and repair operations. Keep moisture awayfrom the valves. Failure to heed this warning can result in personal injury.1. Park bus on level surface, apply parking brake, turn off ignition, remove key, and chockwheels.2. Disconnect batteries.3. Open hood and locate propane fuel lines from FRPCM to the rear of the engine.4. NOTE 1: Cable ties on both sides of the bracket were cut and removed during theinspection process.NOTE 2: If any line needs replacing, obtain replacement parts before rerouting lines.NOTE 3: If the heavy duty cable mounts are missing during the inspection, please contactBlue Bird Recall Administration at campaignparts@blue-bird.com for parts. Parts shownbelow will be needed before lines can be rerouted because these support the dual clampties. 00024168 Mount, Heavy Duty CABLE, .25 hole size (2 required)01247709 Washer, Flat, 17/64 ID X 5/8 (1 required)01667773 Capscrew, Hex HD, ¼ - 20 X 1 , Gr 5 (1 required)01339639 Nut, Hex HD, ¼-20, PRVLG Torque, Flange (1 required)--R E C A L LWARNING: Always follow all Federal, State, Local, and Shop safety standards and use propersafety equipment, and thoroughly read and understand all instructions before performing theseprocedures.C A M P A I G N ---R 1 6 Y T---REROUTE PROCEDUREPage 4 of 11
Propane Fuel Line RoutingRECALL5. Using Photo’s 1, 2, 3, and 4 in the Proper Routing and Clamping Section as yourguide, reroute the four fuel lines to be parallel with each other. Install two or threedual clamp ties Part Number 00024043 to maintain separation.a. NOTE: It may be necessary to loosen the fuel lines on the bottom of the FRPCMto reroute these fuel lines. Please follow Roush CLEANTECHDepressurization Procedure at the end of the document for depressurizationprocedure (purging) a system prior to loosening fuel lines. If lines need to bedisconnected from the FRPCM for rerouting, replace Jiffy Tite Fittings. Roush’sdescription and part numbers for the 1/4 inch fitting is 25031 (2 per FRPCM, aswell as, 4 in the fuel lines) and for the 3/8 inch fitting part is 85672 (2 perFRPCM). Please contact ROUSH CLEANTECH at Phone Number:800.59.ROUSH or e-mail ROUSHcleantech.com with any questions regardingRoush’s procedures.b. Be sure to follow ALL of the Warnings and Cautions in the propane section ofBlue Bird Service Manual.6. Maintain 1/2 inch minimum clearance between the throttle body/air intake tube andthe bottom of the fuel lines (See Photo 1).7. If any fuel line has been damaged, replace fuel line(s) by following RoushCLEANTECH Instructions at the end of this document. See Page 6 on how toidentify a good or damaged fuel line. Please contact ROUSH CLEANTECH atPhone Number: 800.59.ROUSH or e-mail ROUSHcleantech.com with anyquestions regarding Roush’s procedures.--8. After all fuel lines have been rerouted, repaired and/or replaced, check for leaks, checkall the surrounding components to be sure nothing has been displaced with thisrework. Place the bus back into service.--R E C A L LC A M P A I G N ---R 1 6 Y T---REROUTE PROCEDUREPage 5 of 11
Propane Fuel Line RoutingRECALLVisible fiberglass damage shown onRoush Fuel Line. If the heat sleeve isworn through to the point that thefiberglass is visible like shown, then it isrecommended that it be replaced. Aslong as the line underneath shows nodamage to the braid then a replacementsleeve can be installed over the line.Please contact ROUSH CLEANTECHat Phone Number: 800.59.ROUSH or email ROUSHcleantech.com with anyquestions regarding Roush’s procedures.--Witness mark only, Do Not Replace.--R E C A L LSteel braid has been damaged,fuel line MUST be replaced.C A M P A I G N ---R 1 6 Y T---HOW TO IDENTFY A GOOD OR DAMAGED FUEL LINE/HOSEPage 6 of 11
RECALLPropane Fuel Line Routing10020944 HoseAssy., (fuel returnline from engine)10022860 Hose Assy.,(fuel line from tank)½ Inch minimum clearance10022862 Hose Assy., (fuelline return to tank)Throttle bodyHousingPhoto 1(Viewed from front of engine)--00024043 Tie,Clamp, Dual10020943 Hose Assy.,(fuel supply line toengine)--R E C A L LFRPCMC A M P A I G N ---R 1 6 Y T---PROPER ROUTING AND CLAMPING CPage 7 of 11
Propane Fuel Line RoutingRECALL00024043 Tie, Clamp, DualExisting supportbracket and twoheavy duty cablemounts10022860 Hose Assy.,(fuel line from tank)00024043 Tie,Clamp, Dual10020943 Hose Assy., (fuelsupply line to engine)Photo 2(Viewed looking down on top of engine with air brakes)--10020944 Hose Assy.,(fuel return line fromengine)10022862 Hose Assy.,(fuel line return totank)--R E C A L LNote: Ensure there is aminimum of ½ inchclearance between hoses.C A M P A I G N ---R 1 6 Y T---PROPER ROUTING AND CLAMPINGPage 8 of 11
Propane Fuel Line RoutingRECALL00024043 Tie,Clamp, Dual10022862 Hose Assy.,(fuel line return to tank)10020944 Hose Assy., (fuelreturn line from engine)Photo 3(Viewed from rear of engine looking forward with air brakes)--10022860 Hose Assy.,(fuel line from tank)Existing support bracket and twoheavy duty cable mounts--R E C A L L10020943 Hose Assy., (fuelsupply line to engine)C A M P A I G N ---R 1 6 Y T---PROPER ROUTING AND CLAMPINGPage 9 of 11
Propane Fuel Line RoutingRECALLExisting support bracketand two heavy dutycable mounts10022860 Hose Assy.,(fuel line from tank)10020943 Hose Assy.,(fuel supply line toengine)Photo 4(Viewed looking down on top of engine with hydraulic brakes)--10020944 Hose Assy.,(fuel return line fromengine)00024043 Tie, Clamp, Dual--R E C A L L10022862 Hose Assy.,(fuel line return to tank)C A M P A I G N ---R 1 6 Y T---PROPER ROUTING AND CLAMPINGPage 10 of 11
1002286200024168012477090166777301339639TIE, CLAMP, DUALHOSE ASSY, SUPPLY, FUEL RAIL,ROUSH PROPANEHOSE ASSY, SUPPLY, FUEL RAIL,ROUSH PROPANEHOSE ASSY, PROPANE, FRWD FUEL LINE , FEED,ROUSH ,CVHOSE ASSY, PROPANE, FRWD FUEL LINE , FEED,ROUSH ,CVMOUNT, HEAVY DUTY, .25 HOLE SIZEWASHER, FLAT, 17/64 ID X 5/8CAPSCREW, HEX HD, ¼ - 20 X 1 , Gr 5NUT, HEX HD, ¼-20, PRVLG TORQUE, FLANGEQUANTITY3As RequiredAs RequiredAs RequiredAs RequiredAs RequiredAs RequiredAs RequiredAs Required--10022860DESCRIPTIONC A M P A I G N ---R 1 6 Y T---PARTNUMBER000240431002094310020944RECALL--R E C A L LPropane Fuel Line RoutingPage 11 of 11
IMPORTANT SAFETY RECALL NOTICE NHTSA Recall Number: 16V-542 School Bus NHTSTA Recall Number: 16V-543 Non-School Bus August 15, 2016 Dear Blue Bird Owner: Subject: RECALL R16YT, Propane Fuel Line Routing This important safety recall notice applies to your bus(es) identified by both Blue Bird Body Number and
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