R22BX-NSB – Corrosion May Cause Fuel Line Leak – 2018-2023 Blue Bird Vision Transit Buses

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BLUE BIRD BODY COMPANY 3920 Arkwright Road, Suite 200, Macon, GA 31210 – (478) 825-2021 R22BX IMPORTANT SAFETY RECALL NOTICE (Interim Notice) NHTSA Campaign Number: 22V-579 (School Bus) NHTSA Campaign Number: 22V-578 (Non-School Bus) DATE: September 20, 2022 SUBJECT: R22BX: Roush Zinc Plated Return Line Fittings Dear Blue Bird Owner: This important safety recall notice applies to your bus(es) identified by both Blue Bird Body Number and Vehicle Identification Number (VIN) on the enclosed yellow cover sheet. If you no longer own the subject bus(es), please complete the appropriate section of the yellow cover sheet and return to Blue Bird in the enclosed pink postage prepaid envelope. This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Blue Bird Body Company is voluntarily recalling the following:  Certain model year 2017-2023 Blue Bird Vision School Buses o manufactured from June 11, 2016 through July 27, 2022  Certain model year 2018-2023 Blue Bird Vision Non-School Buses o manufactured from November 30, 2016 through July 6, 2022 On the subject buses, it has been determined a defect which relates to motor vehicle safety exists in certain Blue Bird Propane Vision School and Non-School Buses equipped with Ford 6.8L and 7.3L engines that have been modified by the addition of a ROUSH CleanTech (“ROUSH”) Gen 4 or Gen 5 LPG fuel system. The zinc plated carbon steel fitting on the fuel return line on some of these vehicles may corrode over time due to exposure to salt spray, particularly where impacts from road debris have damaged the protective coating that had been applied to the fitting. Such corrosion could lead to a failure of the fuel return line fitting, which would result in a leak of liquid propane fuel, increasing the risk of a fire with the affected units. The corrosion at issue occurs only in the presence of significant amounts of road salt. This notice applies only to vehicles originally or currently registered in the following states: Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, and Wisconsin. According to our records, an LPG system covered by this recall was installed on the referenced vehicle. Corrective Action: ROUSH will replace the fuel return line on the customer’s vehicle with a redesigned part(s) at no cost to the vehicle owner. However, despite ROUSH’s best efforts, replacement parts are not currently available. Parts for this recall are anticipated to be available on or before March 31, 2023. As soon as parts are available, Blue Bird Campaigns Administration will notify you again, when the parts are available. BLUE BIRD BODY COMPANY 3920 Arkwright Road, Suite 200, Macon, GA 31210 – (478) 825-2021 Blue Bird Body Company R22BX Page 2 Corrective Action: (continued) Once you have been notified by Blue Bird Campaigns Administration, please contact an authorized ROUSH CleanTech Service Center to schedule an appointment to bring your vehicle in for repair or your local Blue Bird Dealer to arrange to have the Recall performed. To locate an authorized dealer, search online at www.blue-bird.com/find-a-dealer For Generation 4 style vehicles the repair time for this recall is 1.5 hours. For Generation 5 style vehicles the repair time for this recall is 1.0 hour. What You Should Do: ROUSH and Blue Bird have not issued instructions to stop driving Your Vehicle under this safety recall. However, in the event that you detect a fuel leak, please stop driving Your Vehicle, park it outdoors in a well-ventilated area, and contact ROUSH immediately at 1-800-597-6874 to make arrangements for an interim remedy. 1. If you will be performing the repairs yourself, open a case with ROUSH CleanTech requesting parts for the repair. This can be done in two ways: a. After obtaining the customer’s vehicle information, log into the ROUSH CleanTech Service portal and open a warranty case (https://rctws.force.com/rct/s/technical-support) b. After obtaining the customer’s vehicle information, e-mail all details to support@ROUSHCleanTech.com 2. When replacement parts are available, please perform the procedure in the work instructions provided by Blue Bird and ROUSH CleanTech. For any questions or concerns regarding this recall, please contact ROUSH CleanTech via phone at 1-800-59-ROUSH (Option 2) or via e-mail at support@roushcleantech.com Return Line Part Numbers and Standard Labor Repair Times: Return Line Part Numbers: Generation Wheelbase Part Number Bluebird G5 169 P-10R430-AA-4826 Bluebird G5 189 P-10R430-AA-5334 Bluebird G5 217 P-10R430-AA-6045 Bluebird G5 238 P-10R430-AA-6579 Bluebird G5 252 P-10R430-AA-6934 Bluebird G5 273 P-10R430-AA-7467 Bluebird G5 280 P-10R430-AA-7645 Bluebird G4 169 P-10R400-B-4593 Bluebird G4 189 P-10R400-B-5101 Bluebird G4 217 P-10R400-B-5812 Bluebird G4 238 P-10R400-B-6345 Bluebird G4 252 P-10R400-B-6701 Bluebird G4 273 P-10R400-B-7234 Bluebird G4 280 P-10R400-B-7431 BLUE BIRD BODY COMPANY 3920 Arkwright Road, Suite 200, Macon, GA 31210 – (478) 825-2021 Blue Bird Body Company R22BX Page 3 Standard Labor Repair Times: Labor Code Wheelbase Approved Time RCTL22A Replace Return Line for Gen 4 1.5 hours RCTL22B Replace Return Line for Gen 5 1 hour Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. If the modifications directed by this notification were performed on your bus prior to the receipt of this recall notification, please follow the instructions outlined above in the section “What You Should Do” and open a case with ROUSH CleanTech. Reimbursements will be made in accordance with the requirements of the National Highway Transportation Safety Act, Title 49 Code of Federal Regulations, Parts 573 and 577. For any questions or concerns regarding this recall, please contact ROUSH CleanTech via phone at 1-800-59-ROUSH (Option 2) or via e-mail at support@roushcleantech.com If you believe that ROUSH or Blue Bird Body Company have failed or are unable to remedy the defect without charge within a reasonable time, please contact ROUSH at the telephone number shown above. You may also contact: ADMINISTRATOR NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION 1200 NEW JERSEY AVENUE, SE WASHINGTON, D.C. 20590 Or, 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.gov

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Return Line Service InstructionsBluebird Return Line Replacement Instructions ApplicableModel(s)/VINs: Gen4-5BlueBirdVisionPropaneBuses • Gen 4–MY 2016-2019 With 6.8L V10 Engine • Gen 5 –MY 2020-2022 With 7.3L V8 Engine Description: ProcedureforremovalandreplacementoftheReturnFuelLineonGen4andGen5BlueBirdVisionLPGbuses. Tools/PartsRequired: • WD-40orotherpenetrationfluid • Ratchet3/8drive • TorqueWrench3/8Drive • 3/8”DriveCrowsFootWrenches • 11/16” • 5/8” • BoltCutters • Wrenches • 9/16”Short • 5/8”Short • 11/16”Short • 10mm • 8mm • 6mmHexDrive(Allen) • Marine-gradeAnti-Seize • ZipTieCutterslarge(“Snips”) • ElectricalTape • FirTreeTool P-01B084-AA –Blue Bird Return Line Replacement For any questions or concerns regarding this procedure, please contact ROUSH CleanTechvia phone at 1-800-59-ROUSH (Option 2) or via e-mail at support@roushcleantech.com Blue Bird Return Fuel Line Replacement (R22BX) Gen 4 and 5 Blue Bird Vision -Return Fuel Line Removal and Replacement Instructions 1 NFPA 58 Guidelines Always follow all NFPA 58 guidelines. When working on the propane fuel system or refueling a vehicle, you must be in a well-ventilated area at least 35 ft away from heat, sparks, flames, static electricity, lighted smoking materials, or other sources of ignition. Failure to heed this danger may result in severe personal injury or death. Training Only technicians trained on the ROUSH Clean Tech fuel systems should complete this procedure or any other procedure on a ROUSH Clean Tech propane vehicle. Technicians working with or around any fuel system should be properly trained to always utilize extreme care and caution. Failure to exercise extreme caution and care may lead to serious accidents which can result in property damage, personal injury, and/or death. FRPCM The Fuel Rail Pressure Control Module (FRPCM) is brass. Use care when removing any components from the FRPCM. When installing new fuel line to the FRPCM, first, hand-tighten the line and then torque to the correct torque spec found in these instructions.Do not over torque the lines as this may damage the FRPCM and require replacement. Blue Bird Return Fuel Line Replacement (R22BX) Warnings and Advisories P-01B084-AA –Blue Bird Return Line Replacement FRPCM 2 Fuel Line “Quick Connect” Fittings This instruction manual covers the removal and replacement of the ReturnFuel Line on Gen 4and Gen 5Blue Bird Vision Propane Buses. For ease of removing the originalReturn Fuel Line, it is acceptable to disconnect this fuel line at the quick connect joints (see greenfitting in the image below). The procedure for disconnecting these “quick connect” fittings from the Return Fuel Line is covered in this manual. Only disconnect the Return Fuel line “quick connect” fittings after the fuel line has been de-pressurized(see next page for de-pressurization instructions). DO NOT attempt to disconnect any “quick connects” on the Supply Fuel Line at any time. Blue Bird Return Fuel Line Replacement (R22BX) Warnings and Advisories Continued P-01B084-AA –Blue Bird Return Line Replacement 3 Return Fuel Line “Quick Connect” Fitting. Supply Fuel Line “Quick Connect” Fitting. DO NOT DISCONNECT THESE FITTINGS. GEN 4 GEN 5 Tip: look at the top right corner of each page to verify if that page applies to the vehicle you are working on. Attheundersideofthefueltank,applyWD-40orotherpenetratingfluidtothefourfastenersthatretaintheFuelTankValveCoverPlate.Allowthepenetratingfluidtimetosoak. Movethevehicletoawell-ventilatedoutsideareaatleast35ftawayfromanypotentialignitionsource. 1.RemovethefourfastenersthatretaintheValveCoverPlatetothefueltank(seeimageontheright). a) Ifthefastenerthreadsaredamageduponremoval,seeAppendixAattheendofthisinstructiondocument.NOTE:SomevehiclesmayhaveavariantoftheValveCoverPlatewithoutcenteraccesscutout. 2.OntheSupplyValve,turntheManualShutoffValveclockwisetoshut.Turnthedialbyhandtoclose. P-01B084-AA –Blue Bird Return Line Replacement GEN 4 GEN 5 Blue Bird Return Fuel Line Replacement (R22BX) Fuel Line Depressurization Return Valve Supply Valve Manual Shutoff Valve Return Fuel Line Fitting at Return Valve Fuel Tank Valve Cover Plate 4 3. Topurgefuelinthelines,starttheengineandrununtilitstalls.Removekeysfromtheignitionandsetaside. 4. Disconnectthenegativebatteryterminal. 5. Wearingpropanesafeglovesandeyeprotection,slowlyloosentheReturnFuelLinefittingattheReturnValveusinga9/16”open-endwrench.Therewillbeahissingsoundwithodorfrompropaneescaping.Donotcompletelyunthreadthefittinguntilthehissingsoundcompletelystops.NOTE:Watchforliquidpropanedrippingascontactwithliquidpropanecancauseinjury. 6. Whenthehissingsoundstops,completelydisconnecttheReturnFuelLinefromtheReturnValve.NOTE:DoNotDisconnecttheSupplyFuelLinefromtheSupplyValve. 7. InspecttheO-ringmatingsurfaceontheReturnValvefordamage. P-01B084-AA –Blue Bird Return Line Replacement GEN 4 GEN 5 Blue Bird Return Fuel Line Replacement (R22BX) Fuel Line Depressurization Continued Return Valve Supply Valve Manual Shutoff Valve Return Fuel Line Fitting at Return Valve Fuel Tank Valve Cover Plate 5 1. Removeallretentionpieces(zipties,clips,andfasteners)thatretaintheoriginalReturnFuelLinetothevehicle.TheReturnFuelLineisthepurplefuellineinimagesbelow.Theretentionpiecesarecircledinred.NOTE:Becarefulwhenremovingretentionpiecesastonotdamageadjacentfuellinesorcomponents. 2. AfterallretentionpiecesaredisconnectedfromtheoriginalReturnFuelLine,begintoremoveitfromthevehicle. P-01B084-AA –Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Removal of the Original Return Fuel Line Original Return Fuel Line at Fuel Tank from vehicle underside: CONTINUED ON NEXT PAGE Carefully remove the original Return Fuel Line from this clip but keep the clip in place to retain the existing Supply Fuel Line. Disconnect the original Return Fuel Line at front of Fuel Tank. Press plastic tab on the quick disconnect fitting and pull the fuel line sections apart from each other. It may be necessary to snip the Fuel Line to the right of Quick Disconnect fitting if line separation is not possible due to corrosion. DO NOT USE ANY CUTTING TOOLS THAT EMIT SPARKS Remove the Fuel Tank Return Fuel Line from the rear of the vehicle. Quick Disconnect Fitting 6 GEN 4 GEN 5 P-01B084-AA –Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Removal of the Original Return Fuel Line Continued In front of the fuel tank (on the driver’s side frame rail), carefully cut the zip ties that retain the original Return Fuel Line. Return Fuel Line at Front of Fuel Tank At the driver’s side frame rail, carefully cut the zip ties that retain the original Return Fuel Line near all frame crossmembers. 1. Removeallretentionpieces(zipties,clips,andfasteners)thatretaintheoriginalReturnFuelLinetothevehicle.TheReturnFuelLineisthepurplefuellineinimagesbelow.Theretentionpiecesarecircledinred.NOTE:Becarefulwhenremovingretentionpiecesastonotdamageadjacentfuellinesorcomponents. 2. AfterallretentionpiecesaredisconnectedfromtheoriginalReturnFuelLine,begintoremoveitfromthevehicle. Return Fuel Line at Driver’s Side Frame Rail (near crossmembers) Behind the engine, disconnect the two “quick disconnect” fittings (OPTIONAL) from the Return Fuel Line Tube, and remove this tube from the clips that retain it to the vehicle. Skip to Page #10 to see removal of original Gen 4 Return Fuel Line from the FRPCM on top of the engine. Return Fuel Line Tube (Purple) Quick Disconnect Fitting Original Return Fuel Line 7 GEN 4 Return Fuel Line Along “Center Spine” (Gen 5) P-01B084-AA –Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Removal of the Original Return Fuel Line CONTINUED ON NEXT PAGE Remove zip ties from saddles that retain the original Return Fuel Line. In front of the fuel tank (on the driver’s side frame rail), carefully cut the zip ties that retain the original Return Fuel Line. 1. Removeallretentionpieces(zipties,clips,andfasteners)thatretaintheoriginalReturnFuelLinetothevehicle.TheReturnFuelLineisthepurplefuellineinimagesbelow.Theretentionpiecesarecircledinred.NOTE:Becarefulwhenremovingretentionpiecesastonotdamageadjacentfuellinesorcomponents. 2. AfterallretentionpiecesaredisconnectedfromtheoriginalReturnFuelLine,begintoremoveitfromthevehicle. Return Fuel Line at Front of Fuel Tank 8 GEN 5 This page applies to ONLY Gen 5 vehicles. Return Fuel Line at Top of Engine P-01B084-AA –Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Removal of the Original Return Fuel Line Continued Return Fuel Line Behind Engine 1. Removeallretentionpieces(zipties,clips,andfasteners)thatretaintheoriginalReturnFuelLinetothevehicle.TheReturnFuelLineisthepurplefuellineinimagesbelow.Theretentionpiecesarecircledinred.NOTE:Becarefulwhenremovingretentionpiecesastonotdamageadjacentfuellinesorcomponents. 2. AfterallretentionpiecesaredisconnectedfromtheoriginalReturnFuelLine,begintoremoveitfromthevehicle. Save these green parts for re-use later. Remove the Plampand Doublelipsthat retain the original Return Fuel Line on the top of the engine. Save these parts and hardware for later use. Skip to page #11 for instructions to disconnect the Gen 5 Return Fuel Line at the FRPCM on top of the engine. Behind the engine, disconnect the two “quick disconnect” fittings (OPTIONAL) from the Return Fuel Line Tube, and remove this tube from the clips that retain it to the vehicle. Quick Disconnect Fitting Carefully remove the original Return Fuel Line from these clips but keep the clips in place to retain the existing Supply Fuel Line. Return Fuel Line Tube (Purple) 9 GEN 5 RemovalofOriginalReturnFuelLineatFRPCM(topofengine) 1. LoosentheFRPCMmountingbolts(red)usinga10mmwrench,butdonotremovecompletely.ThisistopreventtheFRPCMfrombeingdamagedduringtheremovalandinstallationoftheReturnFuelLines.Ifissuesarisewithaccessibilitytotheindicatedcomponents,itisacceptabletocompletelyremovetheFRPCMmountingboltstobettermanipulatetheFRPCM. 2. RemovetheEVAPhosefromtheBleedPortbypressingthelockingtabontheconnector(lightblue)andcarefullypulling.ThenremovetheBleedPort(yellow)fromtheFRPCMusinga5/8”wrench. 3. RemovetheReturnFuelLine(purple)fromtheFRPCMusinga9/16”wrench. InstallationofNewReturnFuelLineatFRPCM(topofengine).Readpages#12and#14beforeperformingthisprocedure. 1. Ensurethatthenewreturnfuellineisroutedproperlyontopofengine.SeePage#16toverifyrouting. 2. AttachnewReturnFuelLineattheFRPCM(purple).SlowlyhandtightentonotdamagetheFRPCM. 3. TorquethenewReturnFuelLinetotheFRPCMto19Nm±2Nmusingan11/16”crows’footandtorquewrench. 4. Re-installtheBleedport(yellow)andtorqueto19±2Nmusinga5/8”crows’footandtorquewrench,ora5/8”deep-wellsocketandtorquewrench. 5. ThenpushtheEVAPhose(lightblue)backontotheBleedPortandlistenforanaudible“click”sound.GivetheconnectoralightpulltoverifythatithasproperlyengagedwiththeBleedPortFitting. 6. TorquetheFRPCMmountingbolts(red)to8-12Nm. Description Torque Fuel Vapor Outlet (Bleed Port-Yellow) 19 ±2Nm Fuel Rail Return Outlet (Purple) 19 ±2Nm FRPCM Mounting Bolts (Red) 8-12 Nm Blue Bird Return Fuel Line Replacement (R22BX) Removal and Installation of the Original and New Return Fuel Line at the FRPCM P-01B084-AA –Blue Bird Return Line Replacement 10 TQ 19 ±2 Nm TQ 8-12 Nm TQ 19 ±2 Nm TQ 8-12 Nm GEN 4 RemovalofOriginalReturnFuelLineatFRPCM(topofengine) 1. LoosentheFRPCMmountingbolts(red)usinga10mmwrench,butdonotremovecompletely.ThisistopreventtheFRPCMfrombeingdamagedduringtheremovalandinstallationoftheReturnFuelLines.Ifissuesarisewithaccessibilitytotheindicatedcomponents,itisacceptabletocompletelyremovetheFRPCMmountingboltstobettermanipulatetheFRPCM. 2. RemovetheEVAPhosefromtheBleedPortbypressingthelockingtabontheconnector(lightblue)andcarefullypulling.ThenremovetheBleedPort(yellow)fromtheFRPCMusinga5/8”wrench. 3. RemovetheReturnFuelLine(purple)fromtheFRPCMusinga9/16”wrench. InstallationofNewReturnFuelLineatFRPCM(topofengine).Readpages#13and#14beforeperformingthisprocedure. 1. Ensurethatthenewreturnfuellineisroutedproperlyontopofengine.SeePage#18toverifyrouting. 2. AttachnewReturnFuelLineattheFRPCM(purple).SlowlyhandtightentonotdamagetheFRPCM. 3. TorquethenewReturnFuelLinetotheFRPCMto19±2Nmusingan11/16”crows’footandtorquewrench. 4. Re-installtheBleedport(yellow)andtorqueto19±2Nmusinga5/8”crows’footandtorquewrench,ora5/8”deep-wellsocketandtorquewrench. 5. ThenpushtheEVAPhose(lightblue)backontotheBleedPortandlistenforanaudible“click”sound.GivetheconnectoralightpulltoverifythatithasproperlyengagedwiththeBleedPortFitting. 6. TorquetheFRPCMmountingbolts(red)to5±0.5Nm. Description Torque Fuel Vapor Outlet (Bleed Port-Yellow) 19 ±2Nm Fuel Rail Return Outlet (Purple) 19 ±2Nm FRPCM Mounting Bolts (Red) 5 ±0.5 Nm Blue Bird Return Fuel Line Replacement (R22BX) Removal and Installation of the Original and New Return Fuel Line at the FRPCM P-01B084-AA –Blue Bird Return Line Replacement 11 TQ 19 ±2 Nm TQ 19 ±2 Nm TQ 5 ±0.5 Nm TQ 5 ±0.5 Nm GEN 5 1. VerifythatthenewReturnFuelLineappearsasshownintheimagebelow(Gen4only). 2. Donotremovetheplasticcoveringsfromtheendfittingsuntilthetimecomestoinstallthesefittingsintotheirdesignatedlocationsonthevehicle(asdescribedinthismanual).Thesecoveringsprotectthefuellinefrominternalcontaminationduringtheinstallationprocess. 3. Pre-installprovided4’LongConvolute(P/NPLS-34-100-B-1219)tothefuellineattheindicatedlocation.Retaintheendsofitinplacewithelectricaltape.Thetapewillensurethattheconvolutestaysinpositionduringfuellineinstallation. Blue Bird Return Fuel Line Replacement (R22BX) Preparing New Return Fuel Line for Installation P-01B084-AA –Blue Bird Return Line Replacement 12 Look for white label that says “Tank Side” Install the provided 4’ section of convolute here (to the immediate left of the red tag as shown). Tape the ends of the convolute to the fuel line using electrical tape. Look for white label that says “Engine Side” Verify that 4’ Long convolute starts to the immediate left of this red tag Fuel Tank Side Engine Side GEN 4 1. VerifythatthenewReturnFuelLineappearsasshownintheimagebelow(Gen5only). 2. Donotremovetheplasticcoveringsfromtheendfittingsuntilthetimecomestoinstallthesefittingsintotheirdesignatedlocationsonthevehicle(asdescribedinthismanual).Thesecoveringsprotectthefuellinefrominternalcontaminationduringtheinstallationprocess. 3. Pre-installprovided4’LongConvolute(P/NPLS-34-100-B-1219)tothefuellineattheindicatedlocation.Retaintheendsofitinplacewithelectricaltape.Thetapewillensurethattheconvolutestaysinpositionduringfuellineinstallation. Blue Bird Return Fuel Line Replacement (R22BX) Preparing New Return Fuel Line for Installation P-01B084-AA –Blue Bird Return Line Replacement 13 Pre-Installed Heat Wrap Install the provided 4’ section of convolute here (to the immediate left of the red tag as shown). Tape the ends of the convolute to the fuel line using electrical tape. Verify that 4’ Long convolute starts to the immediate left of this red tag Fuel Tank Side Engine Side GEN 5 1. RoutethenewReturnFuellineunderthevehicleanduptowardstheengine(samegeneralroutingastheoldReturnFuelLine). 2. TorquethenewReturnFuellineontotheFRPCMperinstructionsonpages10(Gen4)&11(Gen5). Blue Bird Return Fuel Line Replacement (R22BX) NewReturn Fuel Line Routing P-01B084-AA –Blue Bird Return Line Replacement 14 GEN 4 GEN 5 1. BeginroutingthenewReturnFuelLinefromthefrontofthevehicle(engine)totheback(fueltank).ThegeneralroutinglocationswillbethesameastheoriginalReturnFuelLine.SeeupcomingpagesformoreinformationregardingtheexactretentionandroutingrequirementsforthenewReturnFuelLine. Blue Bird Return Fuel Line Replacement (R22BX) NewReturn Fuel Line Routing P-01B084-AA –Blue Bird Return Line Replacement GEN 4 GEN 5 15 1. VerifythatthenewReturnFuelLineisroutedontopoftheengineaspictured: Blue Bird Return Fuel Line Replacement (R22BX) Installation of the New Return Fuel Line at the Engine P-01B084-AA –Blue Bird Return Line Replacement 16 New Return Fuel Line New Return Fuel Line See next page for instructions to retain new Return Fuel Line behind engine. GEN 4 Blue Bird Return Fuel Line Replacement (R22BX) Installation of the New Return Fuel Line at the Engine 1.Behind the engine, remove Snail Clip and original Return Fuel Line tube (yellow). 2.Install Dual Clamp Zip Tie and secure the new Return Fuel Line together with the Supply Fuel Line. Ensure that the 6mm Aluminum spacer is installed as pictured. NOTE: A red tag on the new Return Fuel Line will indicate the proper location to clamp the new fuel line in place. 3.Install a Double Clip 5 inches below the Dual Clamp Zip Tie. # P/N Description QTY Torque (Nm) 1 20-403-0004 Dual Clamp Zip Tie 1 N/A 2 11-357-0315 Bolt -M6 X 1.0 X 40 mm (Allen) 1 10 +/-2 Nm 3 11-278-0274 M6 X 1.0 Nut 1 N/A 4 W713776-S300 Double Clip 1 N/A 5 11-373-0014 6mm Aluminum Spacer 1 N/A 4 P-01B084-AA –Blue Bird Return Line Replacement 17 GEN 4 2 1 TQ 10 ±2 Nm 3 5 1. Ontopoftheengine,re-usethesamePlampthatheldtheoriginalreturnfuellineinplace.NOTE:AredtagonthenewReturnFuelLinewillindicatetheproperlocationtoclampthenewfuellineinplacewiththePlamppicturedbelow. 2. SecurethenewReturnFuelLinetotheexistingsupplyfuellineusingDoublelips.Referencetheimageontheright. 3. Installtheprovided4”pieceofconvolute(Item#2)totheimmediateleftoftheDoubleCliponthenewreturnhose. Blue Bird Return Fuel Line Replacement (R22BX) Installation of the New Return Fuel Line at the Engine P-01B084-AA –Blue Bird Return Line Replacement New Return Fuel Line Re-Use Plampand Hardware on new return fuel line. Torque bolt to 10 +/-2 Nm. 18 1 Re-Use from original Return Fuel Line New Return Fuel Line 2 1 1 GEN 5 # P/N Description QTY 1 W713776-S300 Double Clip 3 2 PLS-34-100-B-100 4” Long Convolute 1 Justbehindtheengine,removetheexistingsnailclipandusetwoPlampstoretaintheexistingSupplyFuelLineandthenewReturnFuelLine.Aredtagonthereturnfuellinewillindicatetheproperlocationtoclampthenewfuellineinplace. # P/N Description QTY Torque (Nm) 1 11-056-0048 Plamp 2 N/A 2 W500215-S439 Bolt M6 X 1.0 X 25mm 1 10 +/-2 Nm 3 11-278-0274 M6 X 1.0 Nut 1 N/A Blue Bird Return Fuel Line Replacement (R22BX) Installation of the Return Fuel Line at the Engine P-01B084-AA –Blue Bird Return Line Replacement BEFORE NEW RETURN FUEL LINE AFTER NEW RETURN FUEL LINE GEN 5 19 Snail Clip Remove the original snail clip that was positioned here. Mount Plampsto the engine lifting bracket using the indicated hole. 2 3 1 1 Route the new Return Fuel Line and the existing Supply Fuel Line through the two supplied Plamps. Keep this Snail Clip TQ 10 ±2 Nm GEN 4 Near the top of the transmission, secure the flex hose (of new Return Fuel Line) to Supply Fuel Line with Double Clip. NOTE: install the Double Clip immediately forward of the bend in the Supply Fuel Line Tube # P/N Description QTY 1 W713776-S300 Double Clip 1 1 GEN 5 Blue Bird Return Fuel Line Replacement (R22BX) Installation of the Return Line Near the Transmission P-01B084-AA –Blue Bird Return Line Replacement 20 1 Install Double Clip forward of bend in Supply Fuel Line tube. Install Double Clip forward of bend in Supply Fuel Line tube. Double Clip GEN 4 GEN 5 2.Secure both the existing Supply Fuel Line and new Return Fuel line with two Plampsadjacent to each other at the transmission mounting point. Use an edge clip cable tie on the left side of the bracket to secure the new return fuel line. A red tag on the new return fuel line will indicate the proper location to clamp the new fuel line in place with the Plamp. 4 1.On top of the transmission, remove the snail clip (yellow) from the pictured bracket and discard. # P/N Description QTY Torque (Nm) 1 11-278-0274 M6 Nut 1 N/A 2 W500215-S439 Bolt -M6 X 1.0 X 25mm 1 10 +/-2 Nm 3 11-056-0048 Plamp 2 N/A 4 20-403-0015 Edge Clip Cable Tie (Side Mount) 1 N/A Blue Bird Return Fuel Line Replacement (R22BX) Installation of the Return Line Near the Transmission P-01B084-AA –Blue Bird Return Line Replacement GEN 4 GEN 5 21 3 3 1&2 Item #4 TQ 10 ±2 Nm Towards the transmission, where the fuel line is routed away from the frame rail, the fuel lines are secured to the pictured crossmember saddle using a large zip tie. Two Double Clips should be used as pictured to separate the supply and return fuel lines just before the transmission bracket: # P/N Description QTY 1 11-469-0003 ZIP TIE 9mm x 15IN LONG TBD 2 W713776-S300 Double Clip 2 1 2 2 GEN 4 Blue Bird Return Fuel Line Replacement (R22BX) Installation of the Return Line Near the Transmission P-01B084-AA –Blue Bird Return Line Replacement 22 GEN 4 1. Towards the rearof the transmission, where the fuel line is routed away from the center spine, the fuel lines are secured to the pictured crossmember saddle using a large zip tie. NOTE: Two Double Clips should be used as pictured to separate the supply and return fuel lines just before the transmission bracket. # P/N Description QTY 1 11-403-0029 ZIP TIE XL20.3 INCH LONG 1 2 W713776-S300 Double Clip 2 2 1 2 GEN 5 GEN 5 Blue Bird Return Fuel Line Replacement (R22BX) Installation of the Return Line Near the Transmission P-01B084-AA –Blue Bird Return Line Replacement 23 2 2 GEN 5 Blue Bird Return Fuel Line Replacement (R22BX) Installation of Return Line –Along Frame Rail and Center 1. Route the Return Fuel Line down the mid-section of the vehicle as shown below. a) *For Gen 4 vehicles, the provided 12” sections of convolute will need to be placed on the new return line at everycrossmember location (see circle below). Re-use original convolute on the Supply Line only. # P/N Description QTY 1 PLS-34-100-B-305 Convolute-12” 5 (there may be extras depending on wheelbase) 2 11-469-0003 ZIP TIE 9mm x 15IN LONG Varies by Wheelbase 3 11-469-0001 ZIP TIE -8 INCH LONG -BLACK Varies by Wheelbase 1 2 3 GEN 4 GEN 5 P-01B084-AA –Blue Bird Return Line Replacement 24 3 GEN 4 GEN 5 Nearthefrontofthefueltank,ensurethatthenewReturnFuelLineisrouteduptotheframerailandissecuredtotheretentiontabindicatedusingafirtreecabletie.SecurethenewReturnFuelLinetotheexistingSupplyFuelLineandwiringharnessjustbeforetheshockusingalargecabletie.AnadditionalDualClampZipTie(Item#2)willbesuppliedincasetheexistingonewasremovedduringremovaloforiginalfuelline.Placeseconddualclampziptieontheoppositesideoftheshock(notpictured). # P/N Description QTY 1 157-00052 Fir Tree Zip Tie 1 2 20-403-0004 Dual Clamp Zip Tie 2 3 11-403-0029 ZIP TIE XL20.3 INCH LONG 1 1 2 3 1 GEN 4 Blue Bird Return Fuel Line Replacement (R22BX) Installation of the Return Line Near the Rear Axle P-01B084-AA –Blue Bird Return Line Replacement 25 Secure Item #1 to the crossmember tab as shown. GEN 4 # P/N Description QTY 1 11- ZIP TIE XL20.3 INCH LONG 3 2 20-403-0004 Dual Clamp Zip Tie 1 1 1 1 2 1. Onthedriver’ssideframerailneartherearaxle,retainthesupplyandreturnfuellinestotheexistingsaddlesusingsupplied20”ZipTies(Item#1). 2. Forwardoftherearaxle,thefuellinesdepartfromtheframerailandareroutedtowardsthecenter“spine”sectionofthebus.Atthisfinalframemountinglocation,securethefuellinesusingadualclampziptie(Item#2)asshown.Verifythatthisdoublesaddleziptieretainsthesamehosesandwiringharnessesasitdidoriginally. 3. Ensurethatthereis2″minimumofclearancebetweenthefuellinesandallelectronicmodulesneartherearofthevehicle. Blue Bird Return Fuel Line Replacement (R22BX) Installation of the Return Line Near the Rear Axle P-01B084-AA –Blue Bird Return Line Replacement 26 Front of vehicle GEN 5 Return Fuel Line Retention at Fuel Tank (R22BX) Extended Range Fuel Tank # P/N Description QTY 1 156-00537 Edge Clip Zip Tie 7 2 15-003824 Fir Tree Clip 1 3 W713776-S300 Double Clip 1 1 1 2 1 1 1 1 Use a Double Clip (Item #3) to maintain clearance between new Return Fuel Line and Supply Fuel Line tube. If the supply fuel line was originally retained at this location, retain it to the same tab using the provided Fir Tree Clip (Item #2). 3 1 See page 30 for retention instructions in this area. Item #1 1 Use Edge Clip Zip Ties (Item #1) on the underside of fuel tank at indicated areas. Secure edge clip to the fuel tank and secure the zip tie firmly around the new Return Fuel Line. Bottom view of fuel tank 27 GEN 4 With Extended Range Fuel Tank GEN 5 With Extended Range Fuel Tank Blue Bird Return Fuel Line Replacement 2 1 1 1 3 # P/N Description QTY 1 156-00537 Edge Clip Zip Tie 3 2 15-003824 Fir Tree Clip 1 3 W713776-S300 Double Clip 1 Item #1 1 Use Edge Clip Zip Ties (Item #1) on the underside of fuel tank at indicated areas. Secure edge clip to the fuel tank and secure the zip tie firmly around the new Return Fuel Line. Use a Double Clip (Item #3) to maintain clearance between new Return Fuel Line and Supply Fuel Line tube. See page 30 for retention instructions in this area. If the supply fuel line was originally retained at this location, retain it to the same tab using the provided Fir Tree Clip (Item #2). Return Fuel Line Retention at Fuel Tank (R22BX) Standard Range Fuel Tank Bottom view of fuel tank 28 GEN 4 With Standard Range Fuel Tank GEN 5 With Standard Range Fuel Tank Blue Bird Return Fuel Line Replacement 5/17/2023 2 1 1 # P/N Description QTY 1 156-00537 Edge Clip Zip Tie 2 2 15-003824 Fir Tree Clip 1 If the supply fuel line was originally retained at this location, retain it to the same tab using the provided Fir Tree Clip (Item #2). Item #1 1 Use Edge Clip Zip Ties (Item #1) on the underside of fuel tank at indicated areas. Secure edge clip to the fuel tank and secure the zip tie firmly around the new Return Fuel Line. See page 30 for retention instructions in this area. Return Fuel Line Retention at Fuel Tank (R22BX) 53 Inch Range Fuel Tank Bottom view of fuel tank 29 GEN 4 With 53 Inch Fuel Tank GEN 5 With 53 Inch Fuel Tank Blue Bird Return Fuel Line Replacement # P/N Description QTY 1 156-00537 Edge Clip Zip Tie 1 2 20-403-0004 Dual Clamp Zip Tie 2 3 157-00052 Circular Fir Tree Cable Tie 2 3 2 Ensure that the convoluted Return Fuel Line and original Supply Fuel Line are routed up towards the frame rail as shown. Use two fir tree cable ties (Item #1) to secure the supply and return fuel lines to the indicated retention tab. Then secure both the Supply and Return Fuel Line to the frame edge as shown using Item #1. 3 Return Fuel Line Retention Under Fuel Tank (Near Front) (R22BX) All Fuel Tank Variants Retain the Return Fuel Line to the pressure relief valve hose using two Dual Clamp Zip Ties as pictured. Maintain a minimum of 2” of clearance between the fuel line and clamp used on the pressure relief valve hose. The red tape on the Return Fuel Line indicates the proper retention locations. 2 2 3 Bottom view of fuel tank Front of vehicle Maintain 2” of clearance between the new Return Fuel Line and the clamp used on the pressure relief hose. If necessary, compress the clamp and rotate the tabs away from the new Return Fuel Line. 1 Item #1 30 GEN 4 –All Fuel Tank Variants GEN 5 -All Fuel Tank Variants Blue Bird Return Fuel Line Replacement 1. Carefully reonnectthe Return Fuel Line to the return valve. Begin threading the fitting into the return valve by hand, and then torque the fuel line to 19 ±2 Nm using an 11/16” crow’s foot and torque wrench. 2. On the Supply Valve, turn the Manual Shutoff Valve counterlockwiseto open. Turn the dial by hand to open. 3. Inspect the new Return Fuel Line and verify that it is not in contact with any sharp objects anywhere on the vehicle. 4. After confirming that the new Return Fuel Line is routed and retained per the requirements in this manual, start the vehicle’s engine and inspect for any leaks (propane vapor) throughout the entire length of the new fuel line. 5. Apply marine-grade anti-seize and re-attach the fasteners that hold the tank cover plate. Torque the fasteners to 10Nm. a) If the fastener threads aredamaged upon removal, see Appendix A at the end of this instruction document Start vehicle to ensure normal operation before returning to service. For any questions or concerns regarding this procedure, please contact ROUSH CleanTech via phone at 1-800-59-ROUSH (Option 2) or via e-mail at support@roushcleantech.com Return Fuel Line Replacement (R22BX) Installation of the Return Fuel Line and Returning the Vehicle to Service P-01B084-AA –Blue Bird Return Line Replacement 31 Return Valve Supply Valve Manual Shutoff Valve Return Fuel Line Fitting at Return Valve TQ 10 ±2 Nm GEN 4 GEN 5 APPENDIX A(R22BX) G4 Bluebird Fuel Tank Valve Guard–Thumb Screw Service Procedure P-01B084-AA –Blue Bird Return Line Replacement 32 GEN 4 GEN 5 Issue Description When removing the four thumb screws that retain the valve guard on Gen 4 Bluebird busses, it is possible for the thumb screws(circled in the picturebelow) to shear if they are corroded and seized onto the fuel tank. This procedure provides a corrective action if this happens. Tools Required: • Electric drill •¼” drill bit •Center punch •Hammer •Acetone •White automotive paint •Pliers •Anti-Seize •Vernier calipers or other measuring tool •Rags APPENDIX A(R22BX) G4 Bluebird Fuel Tank Valve Guard–Thumb Screw Service Procedure P-01B084-AA –Blue Bird Return Line Replacement 33 GEN 4 GEN 5 Corrective Action 1.Remove the four thumb screws that retain the fuel tank valve guard. It may be necessary to use pliers and firmly grip the thumb screws whileloosening them. The screws may shear off inside the weld nut. 2.Remove the valve guard from the fuel tank. Step #1 Step #2 APPENDIX A(R22BX) G4 Bluebird Fuel Tank Valve Guard–Thumb Screw Service Procedure P-01B084-AA –Blue Bird Return Line Replacement 34 GEN 4 GEN 5 Old valve guard fastener hole. Drill new ¼” hole here. Old valve guard fastener hole. Drill new ¼” hole here. 10 mm 14 mm Roush Part Number:N623331-S2 Corrective Action 3.With a ¼” drill bit, drill four holes in the pictured vertical brackets before installing the pictured Jlips(green). Before drilling, use a center punch todimple the metal where you intend to drill. While drilling, be careful not to damage any fuel lines, wiring, etc..DoNOTdrill into any curved and/orcylindrical shaped pieces of metal. 4.Before installing the Jlips,add white automotive paint to all bare metal on the newly drilled holes to prevent future corrosion. Thoroughly clean thebare metal with acetone before paining. 5.Add four M5 Jlips(Roush part number N623331-S2) to the locations shown. 14 mm 10 mm APPENDIX A(R22BX) G4 Bluebird Fuel Tank Valve Guard–Thumb Screw Service Procedure P-01B084-AA –Blue Bird Return Line Replacement 35 Corrective Action 6. Re-install the fuel tank valve guard plate and secure it to firmly to the fuel tank using new thumb screws and anti-seizeon the threads. NOTE: Failure to apply anti-seize each time the thumb screws are removed and re-installed may lead to the thumb screws breaking in the future. GEN 4 GEN 5

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el Line ReepIlnacsetmreunct t(Rio22nBsX nd Repla Applicable Model(s)/VINs: Gen 4-5 Blue Bird Vision Propane Buses • Gen 4 – MY 2016-2019 With 6.8L V10 Engine • Gen 5 – MY 2020-2022 With 7.3L V8 Engine Description: Procedure for removal and replacement of the Return Fuel Line on Gen 4 and Gen 5 Blue Bird Vision LPG buses. Tools/Parts Required: • WD- 40 or other penetration fluid • Ratchet 3/8 drive • Torque Wrench 3/8 Drive • 3/8” Drive Crows Foot Wrenches • 11/16” • 5/8” • Bolt Cutters • Wrenches • 9/16” Short • 5/8” Short • 11/16” Short • 10mm • 8mm • 6mm Hex Drive (Allen) • Marine-grade Anti-Seize • Zip Tie Cutters large (“Snips”) • Electrical Tape • Fir Tree Tool rns r h via phone at 59-ROUSH (Option 2) or P-01B084-AA – Blue Bird Return Line Replacement procedure, please contact support@roushcleantech.com t Instructions 1 Blue Bird Return Fuel Line Replacement (R22BX) Warnings and Advisories NFPA 58 Guidelines Always follow all NFPA 58 guidelines. When working on the propane fuel system or refueling a vehicle, you must be in a well- ventilated area at least 35 ft away from heat, sparks, flames, static electricity, lighted smoking materials, or other sources of ignition. Failure to heed this danger may result in severe personal injury or death. Training Only technicians trained on the ROUSH Clean Tech fuel systems should complete this procedure or any other procedure on a ROUSH Clean Tech propane vehicle. Technicians working with or around any fuel system should be properly trained to always utilize extreme care and caution. Failure to exercise extreme caution and care may lead to serious accidents which can result in property damage, personal injury, and/or death. FRPCM The Fuel Rail Pressure Control Module (FRPCM) is brass. Use care when removing any components from the FRPCM. When installing new fuel line to the FRPCM, first, hand-tighten the line and then torque to the correct torque spec found in these instructions. Do not over torque the lines as this may damage the FRPCM and require replacement. 2 FRPCM P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Warnings and Advisories Continued GEN 4 GEN 5 Fuel Line “Quick Connect” Fittings Tip: look at the top right corner of each page to verify if that page applies to the vehicle you are working on. This instruction manual covers the removal and replacement of the Return Fuel Line on Gen 4 and Gen 5 Blue Bird Vision Propane Buses. For ease of removing the original Return Fuel Line, it is acceptable to disconnect this fuel line at the quick connect joints (see green fitting in the image below). The procedure for disconnecting these “quick connect” fittings from the Return Fuel Line is covered in this manual. Only disconnect the Return Fuel line “quick connect” fittings after the fuel line has been de-pressurized (see next page for de-pressurization instructions). DO NOT attempt to disconnect any “quick connects” on the Supply Fuel Line at any time. Return Fuel Line “Quick Connect” Fitting. Supply Fuel Line “Quick Connect” Fitting. DO NOT DISCONNECT THESE FITTINGS. 3 P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Fuel Line Depressurization GEN 4 GEN 5 At the underside of the fuel tank, apply WD-40 or other penetrating fluid to the four fasteners that retain the Fuel Tank Valve Cover Plate. Allow the penetrating fluid time to soak. Fuel Tank Valve Cover Plate Move the vehicle to a well-ventilated outside area at least 35ft away from any potential ignition source. 1. Remove the four fasteners that retain the Valve Cover Plate to the fuel tank (see image on the right). a) If the fastener threads are damaged upon removal, see Appendix A at the end of this instruction document. NOTE: Some vehicles may have a variant of the Valve Cover Plate without center access cutout. 2. On the Supply Valve, turn the Manual Shutoff Valve clockwise to shut. Turn the dial by hand to close. Return Valve Manual Shutoff Valve Supply Valve Return Fuel Line Fitting at Return Valve 4 P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Fuel Line Depressurization Continued GEN 4 GEN 5 3. To purge fuel in the lines, start the engine and run until it stalls. Remove keys from the ignition and set aside. 4. Disconnect the negative battery terminal. 5. Wearing propane safe gloves and eye protection, slowly loosen the Return Fuel Line fitting at the Return Valve using a 9/16” open-end wrench. There will be a hissing sound with odor from propane escaping. Do not completely unthread the fitting until the hissing sound completely stops. NOTE: Watch for liquid propane dripping as contact with liquid propane can cause injury. 6. When the hissing sound stops, completely disconnect the Return Fuel Line from the Return Valve. NOTE: Do Not Disconnect the Supply Fuel Line from the Supply Valve. 7. Inspect the O-ring mating surface on the Return Valve for damage. Return Valve Fuel Tank Valve Cover Plate Manual Shutoff Valve Supply Valve Return Fuel Line Fitting at Return Valve 5 P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Removal of the Original Return Fuel Line GEN 4 GEN 5 1. Remove all retention pieces (zip ties, clips, and fasteners) that retain the original Return Fuel Line to the vehicle. The Return Fuel Line is the purple fuel line in images below. The retention pieces are circled in red. NOTE: Be careful when removing retention pieces as to not damage adjacent fuel lines or components. 2. After all retention pieces are disconnected from the original Return Fuel Line, begin to remove it from the vehicle. Original Return Fuel Line at Fuel Tank from vehicle underside: Remove the Fuel Tank Return Fuel Line from the rear of the vehicle. Quick Disconnect Fitting Carefully remove the original Return Fuel Line from this clip but keep the clip in place to retain the existing Supply Fuel Line. Disconnect the original Return Fuel Line at front of Fuel Tank. Press plastic tab on the quick disconnect fitting and pull the fuel line sections apart from each other. It may be necessary to snip the Fuel Line to the right of Quick Disconnect fitting if line separation is not possible due to corrosion. DO NOT USE ANY CUTTING TOOLS THAT EMIT SPARKS 6 CONTINUED ON NEXT PAGE P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Removal of the Original Return Fuel Line Continued GEN 4 1. Remove all retention pieces (zip ties, clips, and fasteners) that retain the original Return Fuel Line to the vehicle. The Return Fuel Line is the purple fuel line in images below. The retention pieces are circled in red. NOTE: Be careful when removing retention pieces as to not damage adjacent fuel lines or components. 2. After all retention pieces are disconnected from the original Return Fuel Line, begin to remove it from the vehicle. Return Fuel Line at Front of Fuel Tank Return Fuel Line at Driver’s Side Frame Rail (near crossmembers) Quick Disconnect Fitting Original Return Fuel Line Return Fuel Line Tube (Purple) In front of the fuel tank (on the driver’s side frame rail), carefully cut the zip ties that retain the original Return Fuel Line. At the driver’s side frame rail, carefully cut the zip ties that retain the original Return Fuel Line near all frame crossmembers. Behind the engine, disconnect the two “quick disconnect” fittings (OPTIONAL) from the Return Fuel Line Tube, and remove this tube from the clips that retain it to the vehicle. Skip to Page #10 to see removal of original Gen 4 Return Fuel Line from the FRPCM on top of the engine. 7 P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Removal of the Original Return Fuel Line This page applies to ONLY Gen 5 vehicles. GEN 5 1. Remove all retention pieces (zip ties, clips, and fasteners) that retain the original Return Fuel Line to the vehicle. The Return Fuel Line is the purple fuel line in images below. The retention pieces are circled in red. NOTE: Be careful when removing retention pieces as to not damage adjacent fuel lines or components. 2. After all retention pieces are disconnected from the original Return Fuel Line, begin to remove it from the vehicle. Return Fuel Line at Front of Fuel Tank Return Fuel Line Along “Center Spine” (Gen 5) In front of the fuel tank (on the driver’s side frame rail), carefully cut the zip ties that retain the original Return Fuel Line. Remove zip ties from saddles that retain the original Return Fuel Line. 8 CONTINUED ON NEXT PAGE P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Removal of the Original Return Fuel Line Continued GEN 5 1. Remove all retention pieces (zip ties, clips, and fasteners) that retain the original Return Fuel Line to the vehicle. The Return Fuel Line is the purple fuel line in images below. The retention pieces are circled in red. NOTE: Be careful when removing retention pieces as to not damage adjacent fuel lines or components. 2. After all retention pieces are disconnected from the original Return Fuel Line, begin to remove it from the vehicle. Return Fuel Line Behind Engine Behind the engine, disconnect the two “quick disconnect” fittings (OPTIONAL) from the Return Fuel Line Tube, and remove this tube from the clips that retain it to the vehicle. Quick Disconnect Fitting Return Fuel Line at Top of Engine Remove the Plamp and Doublelips that retain the original Return Fuel Line on the top of the engine. Save these parts and hardware for later use. Skip to page #11 for instructions to disconnect the Gen 5 Return Fuel Line at the FRPCM on top of the engine. Return Fuel Line Tube (Purple) Carefully remove the original Return Fuel Line from these clips but keep the clips in 9 place to retain the existing Supply Fuel Line. Save these green parts for re-use later. P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Removal and Installation of the Original and New Return Fuel Line at the FRPCM GEN 4 Removal of Original Return Fuel Line at FRPCM (top of engine) 1. Loosen the FRPCM mounting bolts (red) using a 10mm wrench, but do not remove completely. This is to prevent the FRPCM from being damaged during the removal and installation of the Return Fuel Lines. If issues arise with accessibility to the indicated components, it is acceptable to completely remove the FRPCM mounting bolts to better manipulate the FRPCM. 2. Remove the EVAP hose from the Bleed Port by pressing the locking tab on the connector (light blue) and carefully pulling. Then remove the Bleed Port (yellow) from the FRPCM using a 5/8” wrench. 3. Remove the Return Fuel Line (purple) from the FRPCM using a 9/16” wrench. TQ 8-12 Nm TQ 8-12 Nm Installation of New Return Fuel Line at FRPCM (top of engine). Read pages #12 and #14 before performing this procedure. 1. Ensure that the new return fuel line is routed properly on top of engine. See Page #16 to verify routing. 2. Attach new Return Fuel Line at the FRPCM (purple). Slowly hand tighten to not damage the FRPCM. 3. Torque the new Return Fuel Line to the FRPCM to 19Nm ± 2Nm using an 11/16” crows’ foot and torque TQ 19 ± 2 Nm Description TQ 19 ± 2 Nm Torque wrench. 4. Re-install the Bleed port (yellow) and torque to 19 ± 2Nm using a 5/8” crows’ foot and torque wrench, or a 5/8” deep-well socket and torque wrench. 5. Then push the EVAP hose (light blue) back onto the Bleed Port and listen for an audible “click” sound. Give the connector a light pull to verify that it has properly engaged with the Bleed Port Fitting. 6. Torque the FRPCM mounting bolts (red) to 8-12 Nm. Fuel Vapor Outlet (Bleed Port-Yellow) Fuel Rail Return Outlet (Purple) FRPCM Mounting Bolts (Red) 19 ± 2Nm 19 ± 2Nm 8-12 Nm 10 P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Removal and Installation of the Original and New Return Fuel Line at the FRPCM GEN 5 Removal of Original Return Fuel Line at FRPCM (top of engine) 1. Loosen the FRPCM mounting bolts (red) using a 10mm wrench, but do not remove completely. This is to prevent the FRPCM from being damaged during the removal and installation of the Return Fuel Lines. If issues arise with accessibility to the indicated components, it is acceptable to completely remove the FRPCM mounting bolts to better manipulate the FRPCM. 2. Remove the EVAP hose from the Bleed Port by pressing the locking tab on the connector (light blue) and carefully pulling. Then remove the Bleed Port (yellow) from the FRPCM using a 5/8” wrench. TQ 5 ± 0.5 Nm 3. Remove the Return Fuel Line (purple) from the FRPCM using a 9/16” wrench. TQ 5 ± 0.5 Nm TQ 19 ± 2 Nm Installation of New Return Fuel Line at FRPCM (top of engine). Read pages #13 and #14 before performing this procedure. 1. Ensure that the new return fuel line is routed properly on top of engine. See Page #18 to verify routing. 2. Attach new Return Fuel Line at the FRPCM (purple). Slowly hand tighten to not damage the FRPCM. 3. Torque the new Return Fuel Line to the FRPCM to 19 ± 2Nm using an 11/16” crows’ foot and torque wrench. 4. Re-install the Bleed port (yellow) and torque to 19 ± 2Nm using a 5/8” crows’ foot and torque wrench, or a 5/8” deep-well socket and torque wrench. 5. Then push the EVAP hose (light blue) back onto the Bleed Port and listen for an audible “click” sound. Give Description TQ 19 ± 2 Nm Torque the connector a light pull to verify that it has properly engaged with the Bleed Port Fitting. 6. Torque the FRPCM mounting bolts (red) to 5 ± 0.5 Nm. Fuel Vapor Outlet (Bleed Port-Yellow) Fuel Rail Return Outlet (Purple) FRPCM Mounting Bolts (Red) 19 ± 2Nm 19 ± 2Nm 5 ± 0.5 Nm 11 P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Preparing New Return Fuel Line for Installation GEN 4 1. Verify that the new Return Fuel Line appears as shown in the image below (Gen 4 only). 2. Do not remove the plastic coverings from the end fittings until the time comes to install these fittings into their designated locations on the vehicle (as described in this manual). These coverings protect the fuel line from internal contamination during the installation process. 3. Pre-install provided 4’ Long Convolute (P/N PLS-34-100-B-1219) to the fuel line at the indicated location. Retain the ends of it in place with electrical tape. The tape will ensure that the convolute stays in position during fuel line installation. Look for white label that says “Engine Side” Install the provided 4’ section of convolute here (to the immediate left of the red tag as shown). Tape the ends of the convolute to the fuel line using electrical tape. Fuel Tank Side Engine Side Verify that 4’ Long convolute starts to the immediate left of this red tag Look for white label that says “Tank Side” 12 P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Preparing New Return Fuel Line for Installation GEN 5 1. Verify that the new Return Fuel Line appears as shown in the image below (Gen 5 only). 2. Do not remove the plastic coverings from the end fittings until the time comes to install these fittings into their designated locations on the vehicle (as described in this manual). These coverings protect the fuel line from internal contamination during the installation process. 3. Pre-install provided 4’ Long Convolute (P/N PLS-34-100-B-1219) to the fuel line at the indicated location. Retain the ends of it in place with electrical tape. The tape will ensure that the convolute stays in position during fuel line installation. Install the provided 4’ section of convolute here (to the immediate left of the red tag as shown). Tape the ends of the convolute to the fuel line using electrical tape. Engine Side Pre-Installed Heat Wrap Verify that 4’ Long convolute starts to the immediate left of this red tag Fuel Tank Side 13 P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) New Return Fuel Line Routing GEN 4 GEN 5 1. Route the new Return Fuel line under the vehicle and up towards the engine (same general routing as the old Return Fuel Line). 2. Torque the new Return Fuel line onto the FRPCM per instructions on pages 10 (Gen 4) & 11 (Gen 5). 14 P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) New Return Fuel Line Routing GEN 4 GEN 5 1. Begin routing the new Return Fuel Line from the front of the vehicle (engine) to the back (fuel tank). The general routing locations will be the same as the original Return Fuel Line. See upcoming pages for more information regarding the exact retention and routing requirements for the new Return Fuel Line. 15 P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Installation of the New Return Fuel Line at the Engine GEN 4 1. Verify that the new Return Fuel Line is routed on top of the engine as pictured: See next page for instructions to retain new Return Fuel Line behind engine. New Return Fuel Line New Return Fuel Line 16 P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Installation of the New Return Fuel Line at the Engine GEN 4 # P/N 1 20-403-0004 2 11-357-0315 3 11-278-0274 4 W713776-S300 5 11-373-0014 Description Dual Clamp Zip Tie Bolt – M6 X 1.0 X 40 mm (Allen) M6 X 1.0 Nut Double Clip 6mm Aluminum Spacer QTY 1 1 1 1 1 Torque (Nm) N/A 10 +/- 2 Nm N/A N/A N/A TQ 10 ± 2 Nm 1 5 2 3 4 1. Behind the engine, remove Snail Clip and original Return Fuel Line tube (yellow). 17 2. Install Dual Clamp Zip Tie and secure the new Return Fuel Line together with the Supply Fuel Line. Ensure that the 6mm Aluminum spacer is installed as pictured. NOTE: A red tag on the new Return Fuel Line will indicate the proper location to clamp the new fuel line in place. 3. Install a Double Clip 5 inches below the Dual Clamp Zip Tie. P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Installation of the New Return Fuel Line at the Engine 1. On top of the engine, re-use the same Plamp that held the original return fuel line in place. NOTE: A red tag on the new Return Fuel Line will indicate the proper location to clamp the new fuel line in place with the Plamp pictured below. 2. Secure the new Return Fuel Line to the existing supply fuel line using Doublelips. Reference the image on the right. 3. Install the provided 4” piece of convolute (Item #2) to the immediate left of the Double Clip on the new return hose. GEN 5 Re-Use Plamp and Hardware on new return fuel line. Torque bolt to 10 +/- 2 Nm. New Return Fuel Line New Return Fuel Line 2 1 1 1 Re-Use from original Return Fuel Line # P/N 1 W713776-S300 2 PLS-34-100-B-100 Description Double Clip 4” Long Convolute QTY 3 1 18 P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) GEN 5 Installation of the Return Fuel Line at the Engine BEFORE NEW RETURN FUEL LINE AFTER NEW RETURN FUEL LINE Route the new Return Fuel Line and the existing Supply Fuel Line through the two supplied Plamps. 2 1 1 3 TQ 10 ± 2 Nm Keep this Snail Clip Remove the original snail clip that was positioned here. Mount Plamps to the engine lifting bracket using the indicated hole. # P/N 1 11-056-0048 Plamp Description QTY 2 Torque (Nm) N/A Just behind the engine, remove the existing snail clip and use two Plamps to retain the existing 2 W500215-S439 3 11-278-0274 Bolt M6 X 1.0 X 25mm M6 X 1.0 Nut 1 10 +/- 2 Nm 1 N/A Supply Fuel Line and the new Return Fuel Line. A red tag on the return fuel line will indicate the proper location to clamp the new fuel line in place. Snail Clip 19 P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Installation of the Return Line Near the Transmission GEN 4 GEN 5 # P/N 1 W713776-S300 GEN 4 Description Double Clip QTY 1 GEN 5 Double Clip 1 1 Install Double Clip forward of bend in Supply Fuel Line tube. Install Double Clip forward of bend in Supply Fuel Line tube. Near the top of the transmission, secure the flex hose (of new Return Fuel Line) to Supply Fuel Line with Double Clip. NOTE: install the Double Clip immediately forward of the bend in the Supply Fuel Line Tube 20 P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Installation of the Return Line Near the Transmission GEN 4 GEN 5 # P/N 1 11-278-0274 2 W500215-S439 3 11-056-0048 4 20-403-0015 Description M6 Nut Bolt – M6 X 1.0 X 25mm Plamp Edge Clip Cable Tie (Side Mount) QTY 1 1 2 1 Torque (Nm) N/A 10 +/- 2 Nm N/A N/A Item #4 3 4 TQ 10 ± 2 Nm 1&2 3 1. On top of the transmission, remove the snail clip (yellow) from the pictured bracket and discard. 21 2. Secure both the existing Supply Fuel Line and new Return Fuel line with two Plamps adjacent to each other at the transmission mounting point. Use an edge clip cable tie on the left side of the bracket to secure the new return fuel line. A red tag on the new return fuel line will indicate the proper location to clamp the new fuel line in place with the Plamp. P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Installation of the Return Line Near the Transmission GEN 4 Towards the transmission, where the fuel line is routed away from the frame rail, the fuel lines are secured to the pictured crossmember saddle using a large zip tie. Two Double Clips should be used as pictured to separate the supply and return fuel lines just before the transmission bracket: GEN 4 1 2 2 # 1 22 2 P/N 11-469-0003 W713776-S300 Description ZIP TIE 9mm x 15IN LONG Double Clip QTY TBD 2 P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Installation of the Return Line Near the Transmission 1. Towards the rear of the transmission, where the fuel line is routed away from the center spine, the fuel lines are secured to the pictured crossmember saddle using a large zip tie. NOTE: Two Double Clips should be used as pictured to separate the supply and return fuel lines just before the transmission bracket. GEN 5 # P/N 1 11-403-0029 Description ZIP TIE XL 20.3 INCH LONG QTY 1 GEN 5 2 W713776-S300 Double Clip 2 GEN 5 1 2 2 2 2 23 P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Installation of Return Line – Along Frame Rail and Center 1. Route the Return Fuel Line down the mid-section of the vehicle as shown below. GEN 4 GEN 5 a) *For Gen 4 vehicles, the provided 12” sections of convolute will need to be placed on the new return line at every crossmember location (see circle below). Re-use original convolute on the Supply Line only. GEN 4 GEN 5 3 1 2 3 # P/N 1 PLS-34-100-B-305 2 11-469-0003 3 11-469-0001 24 Description Convolute- 12” ZIP TIE 9mm x 15IN LONG ZIP TIE – 8 INCH LONG – BLACK QTY 5 (there may be extras depending on wheelbase) Varies by Wheelbase Varies by Wheelbase P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Installation of the Return Line Near the Rear Axle GEN 4 # P/N 1 157-00052 1 2 20-403-0004 3 11-403-0029 Description Fir Tree Zip Tie Dual Clamp Zip Tie ZIP TIE XL 20.3 INCH LONG QTY 1 2 1 GEN 4 Secure Item #1 to the 1 crossmember tab as shown. 2 3 Near the front of the fuel tank, ensure that the new Return Fuel Line is routed up to the frame rail and is secured to the retention tab indicated using a fir tree cable tie. Secure the new Return Fuel Line to the existing Supply Fuel Line and wiring harness just before the shock using a large cable tie. An additional Dual Clamp Zip Tie (Item #2) will be supplied in case the existing one was removed during removal of original fuel line. Place second dual clamp zip tie on the opposite side of the shock (not pictured). 25 P-01B084-AA – Blue Bird Return Line Replacement Blue Bird Return Fuel Line Replacement (R22BX) Installation of the Return Line Near the Rear Axle Front of vehicle GEN 5 # P/N Description QTY 2 1 11- 2 20-403-0004 ZIP TIE XL 20.3 INCH LONG 3 Dual Clamp Zip Tie 1 1 1 1 1. On the driver’s side frame rail near the rear axle, retain the supply and return fuel lines to the existing saddles using supplied 20” Zip Ties (Item #1). 2. Forward of the rear axle, the fuel lines depart from the frame rail and are routed towards the center “spine” section of the bus. At this final frame mounting location, secure the fuel lines using a dual clamp zip tie (Item #2) as shown. Verify that this double saddle zip tie retains the same hoses and wiring harnesses as it did originally. 3. Ensure that there is 2″ minimum of clearance between the fuel lines and all electronic modules near the rear of the vehicle. 26 P-01B084-AA – Blue Bird Return Line Replacement Return Fuel Line Retention at Fuel Tank (R22BX) Extended Range Fuel Tank If the supply fuel line was originally retained at GEN 4 With Extended Range Fuel Tank # P/N 1 156-00537 2 15-003824 3 W713776-S300 Description Edge Clip Zip Tie Fir Tree Clip Double Clip QTY 7 1 1 this location, retain it to the same tab using the provided Fir Tree Clip (Item #2). GEN 5 With Extended Range Fuel Tank Bottom view of fuel tank 2 1 1 1 1 1 3 1 1 Item #1 1 See page 30 for retention instructions in this area. Use Edge Clip Zip Ties (Item #1) on the underside of fuel tank at indicated areas. Secure edge clip to the fuel tank and secure the zip tie firmly around the 27 new Return Fuel Line. Use a Double Clip (Item #3) to maintain clearance between new Return Fuel Line and Supply Fuel Line tube. Blue Bird Return Fuel Line Replacement Return Fuel Line Retention at Fuel Tank (R22BX) Standard Range Fuel Tank # P/N Description QTY 1 156-00537 Edge Clip Zip Tie 3 2 15-003824 Fir Tree Clip 1 3 W713776-S300 Double Clip 1 GEN 4 With Standard Range Fuel Tank GEN 5 With Standard Range Fuel Tank If the supply fuel line was originally retained at this location, retain it to the same tab using the provided Fir Tree Clip (Item #2). 2 Bottom view of fuel tank 1 1 1 3 Item #1 1 See page 30 for retention instructions in this area. Use Edge Clip Zip Ties (Item #1) on the underside of fuel tank at indicated areas. Secure edge clip to the fuel tank and secure the zip tie firmly around the 28 new Return Fuel Line. Use a Double Clip (Item #3) to maintain clearance between new Return Fuel Line and Supply Fuel Line tube. Blue Bird Return Fuel Line Replacement Return Fuel Line Retention at Fuel Tank (R22BX) 53 Inch Range Fuel Tank # P/N Description QTY 1 156-00537 Edge Clip Zip Tie 2 GEN 4 With 53 Inch Fuel Tank GEN 5 With 53 Inch Fuel Tank 2 15-003824 Fir Tree Clip 1 Bottom view of fuel tank 2 If the supply fuel line was originally retained at this location, retain it to the same tab using the provided Fir Tree Clip (Item #2). 1 1 Item #1 1 See page 30 for retention instructions in this area. 29 5/17/2023 Use Edge Clip Zip Ties (Item #1) on the underside of fuel tank at indicated areas. Secure edge clip to the fuel tank and secure the zip tie firmly around the new Return Fuel Line. Blue Bird Return Fuel Line Replacement Return Fuel Line Retention Under Fuel Tank (Near Front) (R22BX) All Fuel Tank Variants GEN 4 – All Fuel Tank Variants # P/N 1 156-00537 2 20-403-0004 3 157-00052 Description Edge Clip Zip Tie Dual Clamp Zip Tie Circular Fir Tree Cable Tie QTY 1 2 2 Maintain 2” of clearance between the new Return Fuel Line and the clamp used on the pressure relief hose. If necessary, compress the clamp and rotate the tabs away from the new Return Fuel Line. GEN 5 – All Fuel Tank Variants Item #1 2 Bottom view of fuel tank 1 3 Retain the Return Fuel Line to the pressure relief valve hose using two Dual Clamp Zip Ties as pictured. Maintain a minimum of 2” of clearance between the fuel line and clamp used on the pressure relief valve 2 hose. The red tape on the Return Fuel Line indicates the proper retention locations. 2 3 3 Front of vehicle 30 Ensure that the convoluted Return Fuel Line and original Supply Fuel Line are routed up towards the frame rail as shown. Use two fir tree cable ties (Item #1) to secure the supply and return fuel lines to the indicated retention tab. Then secure both the Supply and Return Fuel Line to the frame edge as shown using Item #1. Blue Bird Return Fuel Line Replacement Return Fuel Line Replacement (R22BX) Installation of the Return Fuel Line and Returning the Vehicle to Service GEN 4 GEN 5 1. Carefully reonnect the Return Fuel Line to the return valve. Begin threading the fitting into the return valve by hand, and then torque the fuel line to 19 ± 2 Nm using an 11/16” crow’s foot and torque wrench. 2. On the Supply Valve, turn the Manual Shutoff Valve counterlockwise to open. Turn the dial by hand to open. 3. Inspect the new Return Fuel Line and verify that it is not in contact with any sharp objects anywhere on the vehicle. 4. After confirming that the new Return Fuel Line is routed and retained per the requirements in this manual, start the vehicle’s engine and inspect for any leaks (propane vapor) throughout the entire length of the new fuel line. 5. Apply marine-grade anti-seize and re-attach the fasteners that hold the tank cover plate. Torque the fasteners to 10Nm. a) If the fastener threads are damaged upon removal, see Appendix A at the end Return Valve Manual Shutoff Valve of this instruction document Start vehicle to ensure normal operation before returning to service. For any questions or concerns regarding this procedure, please contact ROUSH CleanTech via phone at 1-800-59-ROUSH (Option 2) or via e-mail at support@roushcleantech.com TQ 10 ± 2 Nm Return Fuel Line Fitting at Return Valve Supply Valve 31 P-01B084-AA – Blue Bird Return Line Replacement APPENDIX A (R22BX) G4 Bluebird Fuel Tank Valve Guard– Thumb Screw Service Procedure GEN 4 GEN 5 Issue Description When removing the four thumb screws that retain the valve guard on Gen 4 Bluebird busses, it is possible for the thumb screws (circled in the picture below) to shear if they are corroded and seized onto the fuel tank. This procedure provides a corrective action if this happens. Tools Required: • Electric drill • ¼” drill bit • Center punch • Hammer • Acetone • White automotive paint • Pliers • Anti-Seize • Vernier calipers or other measuring tool • Rags 32 P-01B084-AA – Blue Bird Return Line Replacement APPENDIX A (R22BX) G4 Bluebird Fuel Tank Valve Guard– Thumb Screw Service Procedure GEN 4 GEN 5 Corrective Action 1. Remove the four thumb screws that retain the fuel tank valve guard. It may be necessary to use pliers and firmly grip the thumb screws while loosening them. The screws may shear off inside the weld nut. 2. Remove the valve guard from the fuel tank. Step #1 Step #2 33 P-01B084-AA – Blue Bird Return Line Replacement Corrective Action APPENDIX A (R22BX) G4 Bluebird Fuel Tank Valve Guard– Thumb Screw Service Procedure GEN 4 GEN 5 3. With a ¼” drill bit, drill four holes in the pictured vertical brackets before installing the pictured Jlips (green). Before drilling, use a center punch to dimple the metal where you intend to drill. While drilling, be careful not to damage any fuel lines, wiring, etc.. Do NOT drill into any curved and/or cylindrical shaped pieces of metal. 4. Before installing the Jlips, add white automotive paint to all bare metal on the newly drilled holes to prevent future corrosion. Thoroughly clean the bare metal with acetone before paining. 5. Add four M5 Jlips (Roush part number N623331-S2) to the locations shown . Old valve guard fastener hole. Drill new ¼” hole here. Drill new ¼” hole here. Old valve guard fastener hole. 14 mm 14 mm Roush Part Number: N623331-S2 34 P-01B084-AA – Blue Bird Return Line Replacement APPENDIX A (R22BX) G4 Bluebird Fuel Tank Valve Guard– Thumb Screw Service Procedure P-01B084-AA – Blue Bird Return Line Replacement 35 Corrective Action 6. Re-install the fuel tank valve guard plate and secure it to firmly to the fuel tank using new thumb screws and anti-seize on the threads. NOTE: Failure to apply anti-seize each time the thumb screws are removed and re-installed may lead to the thumb screws breaking in the future. GEN 4 GEN 5

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BLUE BIRD BODY COMPANY 3920 Arkwright Road, Suite 200, Macon, GA 31210 – (478) 825-2021 R22BX IMPORTANT SAFETY RECALL NOTICE (Interim Notice) NHTSA Campaign Number: 22V-579 (School Bus) NHTSA Campaign Number: 22V-578 (Non-School Bus) DATE: September 20, 2022 TO: U.S. DEALERS SUBJECT: R22BX: Roush Zinc Plated Return Line Fittings This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. This important safety recall notice applies to your buses identified by both Blue Bird Body Number and Vehicle Identification Number (VIN) on the attached yellow cover sheet. Blue Bird Body Company is voluntarily recalling the following:  Certain model year 2017-2023 Blue Bird Vision School Buses o manufactured from June 11, 2016 through July 27, 2022  Certain model year 2018-2023 Blue Bird Vision Non-School Buses o manufactured from November 30, 2016 through July 6, 2022 On the subject buses, it has been determined a defect which relates to motor vehicle safety exists in certain Blue Bird Propane Vision School and Non-School Buses equipped with Ford 6.8L and 7.3L engines that have been modified by the addition of a ROUSH CleanTech (“ROUSH”) Gen 4 or Gen 5 LPG fuel system. The zinc plated carbon steel fitting on the fuel return line on some of these vehicles may corrode over time due to exposure to salt spray, particularly where impacts from road debris have damaged the protective coating that had been applied to the fitting. Such corrosion could lead to a failure of the fuel return line fitting, which would result in a leak of liquid propane fuel, increasing the risk of a fire with the affected units. The corrosion at issue occurs only in the presence of significant amounts of road salt. This notice applies only to vehicles originally or currently registered in the following states: Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, and Wisconsin. According to our records, an LPG system covered by this recall was installed on the referenced vehicle. Corrective Action: ROUSH will replace the fuel return line on the customer’s vehicle with a redesigned part(s) at no cost to the Dealer or the vehicle owner. However, despite ROUSH’s best efforts, replacement parts are not currently available. Parts for this recall are anticipated to be available on or before March 31, 2023. As soon as parts are available, Blue Bird Campaigns Administration will notify you again, when the parts are available. BLUE BIRD BODY COMPANY 3920 Arkwright Road, Suite 200, Macon, GA 31210 – (478) 825-2021 Blue Bird Body Company R22BX Page 2 What You Should Do: 1. Once you have been notified by Blue Bird Campaigns Administration, obtain the customer’s vehicle information and open a case with ROUSH CleanTech requesting parts for the repair. This can be done in two ways: a. After obtaining the customer’s vehicle information, log into the ROUSH CleanTech Service portal and open a warranty case (https://rctws.force.com/rct/s/technical-support) b. After obtaining the customer’s vehicle information, e-mail all details to support@ROUSHCleanTech.com 2. When replacement parts are available, please perform the procedure in the work instructions provided by Blue Bird and ROUSH CleanTech. For any questions or concerns regarding this recall, please contact ROUSH CleanTech via phone at 1-800-59-ROUSH (Option 2) or via e-mail at support@roushcleantech.com Return Line Part Numbers and Standard Labor Repair Times: Return Line Part Numbers: Generation Wheelbase Part Number Bluebird G5 169 P-10R430-AA-4826 Bluebird G5 189 P-10R430-AA-5334 Bluebird G5 217 P-10R430-AA-6045 Bluebird G5 238 P-10R430-AA-6579 Bluebird G5 252 P-10R430-AA-6934 Bluebird G5 273 P-10R430-AA-7467 Bluebird G5 280 P-10R430-AA-7645 Bluebird G4 169 P-10R400-B-4593 Bluebird G4 189 P-10R400-B-5101 Bluebird G4 217 P-10R400-B-5812 Bluebird G4 238 P-10R400-B-6345 Bluebird G4 252 P-10R400-B-6701 Bluebird G4 273 P-10R400-B-7234 Bluebird G4 280 P-10R400-B-7431 Standard Labor Repair Times: Labor Code Wheelbase Approved Time RCTL22A Replace Return Line for Gen 4 1.5 hours RCTL22B Replace Return Line for Gen 5 1 hour If Blue Bird’s records indicate bus(es) subject to this recall were delivered in your service area, a list of affected bus(es) will be enclosed. The bus(es) will be identified by Blue Bird Body Number and Vehicle Identification Number (VIN) on the enclosed yellow cover sheet. Dealers should verify correct owners and assure that complete mailing and shipping addresses are provided for each listed owner. BLUE BIRD BODY COMPANY 3920 Arkwright Road, Suite 200, Macon, GA 31210 – (478) 825-2021 Blue Bird Body Company R22BX Page 3 It is the dealer’s responsibility to verify that the correct owner name, address, and telephone number is provided for each listed vehicle. Any corrections or updates should be made in ClaimsCenter. Addresses that cannot be updated should be forwarded to the Recall Administrator. Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Dealers are reminded of their responsibilities under Section 154 of The National Traffic and Motor Vehicle Safety Act of 1991. Dealers are required to complete modifications on units in their inventory before delivering to the final owner. Reference Blue Bird Body Company Distributor Memo No. 42-92. If you have in your possession or have sold a bus that was purchased from another dealer, that may be affected by this recall, please notify Lisa Hancock at 478-822-2242 or lisa.hancock@blue-bird.com Sincerely, Lisa Hancock Corporate Recall Administrator Blue Bird Corporation 402 Blue Bird Blvd, Fort Valley, Georgia 31030 Phone 478.822.2242 lisa.hancock@blue-bird.com

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BLUE BIRD BODY COMPANY 3920 Arkwright Road, Suite 200, Macon, GA 31210 – (478) 825-2021 R22BX IMPORTANT SAFETY RECALL NHTSA Recall Number: 22V-579 (School Bus) NHTSA Recall Number: 22V-578 (Non-School Bus) DATE: May 24, 2023 TO: U.S. DEALERS SUBJECT: R22BX: Roush Zinc Plated Return Line Fittings This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. This notice applies to your buses identified by both Blue Bird Body Number and Vehicle Identification Number (VIN) on the attached yellow cover sheet. Blue Bird Body Company has decided that a defect, which relates to motor vehicle safety, exists in certain: • Certain model year 2017-2023 Blue Bird Vision School Buses o manufactured from June 11, 2016 through July 27, 2022 • Certain model year 2018-2023 Blue Bird Vision Non-School Buses o manufactured from November 30, 2016 through July 6, 2022 Per the Blue Bird’s Interim Notification letter issued September 20, 2022, parts are now available in limited quantities. Due to continued material availability issues, ROUSH CleanTech continues to receive parts shipment to fulfill the requests. As soon as those parts are available for your customers, ROUSH CleanTech will contact the Dealers so that repairs can be scheduled with your customers/owners. Certain Blue Bird Propane Vision School and Non-School Buses equipped with Ford 6.8L and 7.3L engines have been modified by the addition of a ROUSH CleanTech (“ROUSH”) Gen 4 or Gen 5 LPG fuel system. The zinc plated carbon steel fitting on the fuel return line on some of these vehicles may corrode over time due to exposure to salt spray, particularly where impacts from road debris have damaged the protective coating that had been applied to the fitting. Such corrosion could lead to a failure of the fuel return line fitting, which would result in a leak of liquid propane fuel, increasing the risk of a fire with the affected units. The corrosion at issue occurs only in the presence of significant amounts of road salt. This notice applies only to vehicles registered in the following states: Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, BLUE BIRD BODY COMPANY 3920 Arkwright Road, Suite 200, Macon, GA 31210 – (478) 825-2021 Blue Bird Body Company R22BX Page 2 New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, and Wisconsin. According to our records, an LPG system covered by this recall was installed on the referenced vehicle. Corrective Action: ROUSH will provide the redesigned fuel line for the customer’s vehicle at no cost to the Dealer or the vehicle owner. ROUSH will reimburse labor per the stated SLT. What You Should Do: Blue Bird Dealer, Authorized ROUSH CleanTech Service Center or Owner authorized to complete their own ROUSH CleanTech repairs: Using the vehicle information, open a case with ROUSH CleanTech requesting parts for the repair. This can be done in two ways: 1. After obtaining the customer’s vehicle information, log into the ROUSH CleanTech Service portal and open a warranty case (https://rctws.force.com/rct/s/technical-support). This will need to include the VIN and mileage for each vehicle and will allow ROUSH CleanTech to schedule a remedy for your concerns. a. For customers with multiple vehicles, please include a complete list of the vehicle VINs and mileage in the case. 2. Perform the procedure in the work instructions provided by Blue Bird and ROUSH CleanTech. a. When the repairs are complete, upload a copy of your labor invoice to the case. Non Blue Bird Dealer, Authorized ROUSH CleanTech Service Center or Owner authorized to complete their own ROUSH CleanTech repairs: 1. Contact your local Blue Bird Dealer or Authorized ROUSH CleanTech Service Center. For any questions or concerns with this recall, please contact ROUSH CleanTech via phone at 1-800-59-ROUSH (Option 2) or via email at support@roushcleantech.com To access the instructions for the recall repair please visit the ROUSH CleanTech portal at https://rctws.force.com/rct/s/article/Recall-Gen-4-and-5-Blue-Bird-Vision Return Line Kit Numbers – Gen 4 Return Line Kit Numbers: Wheelbase Kit Number Standard Range P22BB-RLSTDKIT-AA BB G4 STD RANGE RLINE KIT (169WB) P22BB-RLSTDKIT-BA BB G4 STD RANGE RLINE KIT (189WB) P22BB-RLSTDKIT-CA BB G4 STD RANGE RLINE KIT (217WB) P22BB-RLSTDKIT-DA BB G4 STD RANGE RLINE KIT (238WB) P22BB-RLSTDKIT-EA BB G4 STD RANGE RLINE KIT (252WB) P22BB-RLSTDKIT-FA BB G4 STD RANGE RLINE KIT (273WB) P22BB-RLSTDKIT-GA BB G4 STD RANGE RLINE KIT (280WB) BLUE BIRD BODY COMPANY 3920 Arkwright Road, Suite 200, Macon, GA 31210 – (478) 825-2021 Blue Bird Body Company R22BX Page 3 Return Line Kit Numbers – Gen 4 Return Line Kit Numbers: (continued) Wheelbase Kit Number Extended Range P22BB-RLEXTKIT-AA BB G4 EXT RANGE RLINE KIT (169WB) P22BB-RLEXTKIT-BA BB G4 EXT RANGE RLINE KIT (189WB) P22BB-RLEXTKIT-CA BB G4 EXT RANGE RLINE KIT (217WB) P22BB-RLEXTKIT-DA BB G4 EXT RANGE RLINE KIT (238WB) P22BB-RLEXTKIT-EA BB G4 EXT RANGE RLINE KIT (252WB) P22BB-RLEXTKIT-FA BB G4 EXT RANGE RLINE KIT (273WB) P22BB-RLEXTKIT-GA BB G4 EXT RANGE RLINE KIT (280WB) 53” Tank P22BB-RL53KIT-AA BB G4 53IN TANK RLINE KIT (169WB) P22BB-RL53KIT-BA BB G4 53IN TANK RLINE KIT (189WB) P22BB-RL53KIT-CA BB G4 53IN TANK RLINE KIT (217WB) P22BB-RL53KIT-DA BB G4 53IN TANK RLINE KIT (238WB) P22BB-RL53KIT-EA BB G4 53IN TANK RLINE KIT (252WB) P22BB-RL53KIT-FA BB G4 53IN TANK RLINE KIT (273WB) P22BB-RL53KIT-GA BB G4 53IN TANK RLINE KIT (280WB) Gen 5 Return Line Part Numbers: Wheelbase Kit Number Standard Range P22BK-RLSTDKIT-AA BB G5 STD RANGE RLINE KIT (169WB) P22BK-RLSTDKIT-BA BB G5 STD RANGE RLINE KIT (189WB) P22BK-RLSTDKIT-CA BB G5 STD RANGE RLINE KIT (217WB) P22BK-RLSTDKIT-DA BB G5 STD RANGE RLINE KIT (238WB) P22BK-RLSTDKIT-EA BB G5 STD RANGE RLINE KIT (252WB) P22BK-RLSTDKIT-FA BB G5 STD RANGE RLINE KIT (273WB) P22BK-RLSTDKIT-GA BB G5 STD RANGE RLINE KIT (280WB) Extended Range P22BK-RLEXTKIT-AA BB G5 EXT RANGE RLINE KIT (169WB) P22BK-RLEXTKIT-BA BB G5 EXT RANGE RLINE KIT (189WB) P22BK-RLEXTKIT-CA BB G5 EXT RANGE RLINE KIT (217WB) P22BK-RLEXTKIT-DA BB G5 EXT RANGE RLINE KIT (238WB) P22BK-RLEXTKIT-EA BB G5 EXT RANGE RLINE KIT (252WB) P22BK-RLEXTKIT-FA BB G5 EXT RANGE RLINE KIT (273WB) P22BK-RLEXTKIT-GA BB G5 EXT RANGE RLINE KIT (280WB) BLUE BIRD BODY COMPANY 3920 Arkwright Road, Suite 200, Macon, GA 31210 – (478) 825-2021 Blue Bird Body Company R22BX Page 4 Gen 5 Return Line Part Numbers: (continued) Wheelbase Kit Number 53” Tank P22BK-RL53KIT-AA BB G5 53IN RANGE RLINE KIT (169WB) P22BK-RL53KIT-BA BB G5 53IN RANGE RLINE KIT (189WB) P22BK-RL53KIT-CA BB G5 53IN RANGE RLINE KIT (217WB) P22BK-RL53KIT-DA BB G5 53IN RANGE RLINE KIT (238WB) P22BK-RL53KIT-EA BB G5 53IN RANGE RLINE KIT (252WB) P22BK-RL53KIT-FA BB G5 53IN RANGE RLINE KIT (273WB) P22BK-RL53KIT-GA BB G5 53IN RANGE RLINE KIT (280WB) Standard Labor Times: Labor Code Wheelbase Approved Time RCTL22A Replace Return Line for Gen 4 1.5 hours RCTL22B Replace Return Line for Gen 5 1 hour If Blue Bird’s records indicate bus(es) subject to this recall were delivered in your service area, a list of affected bus(es) will be enclosed. The bus(es) will be identified by Blue Bird Body Number and Vehicle Identification Number (VIN) on the enclosed yellow cover sheet. Dealers should verify correct owners and assure that complete mailing and shipping addresses are provided for each listed owner. It is the dealer’s responsibility to verify the correct owner name, address, and telephone number is provided for each listed vehicle. Any corrections or updates should be made in ClaimsCenter. Addresses that cannot be updated should be forwarded to the Recall Administrator. Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Dealers are reminded of their responsibilities under Section 154 of The National Traffic and Motor Vehicle Safety Act of 1991. Dealers are required to complete modifications on units in their inventory before delivering to the final owner. Reference Blue Bird Body Company Distributor Memo No. 42-92. If you have in your possession or have sold a bus that was purchased from another dealer that may be affected by this recall, please notify Lisa Hancock at 478-822-2242 or lisa.hancock@blue-bird.com Sincerely, Lisa Hancock Corporate Recall Administrator Blue Bird Corporation 402 Blue Bird Blvd, Fort Valley, Georgia 31030 Phone 478.822.2242 lisa.hancock@blue-bird.com

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-578 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Blue Bird Body Company Submission Date : AUG 04, 2022 NHTSA Recall No. : 22V-578 Manufacturer Recall No. : R22BX-NSB Manufacturer Information : Manufacturer Name : Blue Bird Body Company Address : P.O. Box 937 402 Blue Bird Boulevard Fort Valley GA 31030 Company phone : 478-822-2242 Population : Number of potentially involved : 49 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2018-2023 Blue Bird Vision Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : CNG/LPG Descriptive Information : The population of items of original equipment covered by this report does not include LPG systems manufactured prior to July, 2015 because that date is when Roush began to use zincplated fittings on the return lines in its LPG conversion kits. The population does not include LPG systems shipped after June 30, 2022 because LPG systems shipped after that date had fuel return lines with additional protection that prevents the corrosion at issue here. Because the corrosion at issue here occurs only in the presence of significant amounts of road salt, this notice applies only to the fuel return lines in LPG conversion kits installed in vehicles originally or currently registered in the following states: Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, and Wisconsin (which are referred to in this Report as the “Salt Belt States”). Roush’s conclusion that this report does not apply to fuel return lines that were installed in vehicles that were not operated in the Salt Belt states is based primarily on the following: (1) all of the 19 warranty claims that reported corrosion of a fuel return line fitting came from vehicles in the Salt Belt states. (2) Roush’s inspection of 166 vehicles from various regions of the United States (the results of which are described in the “Describe the Cause” section of this report) demonstrated that there has been extremely little, if any, corrosion of fittings on vehicles outside of the Salt Belt states. Production Dates : NOV 30, 2016 – JUL 06, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 22V-578 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Defect : Description of the Defect : Some zinc-plated carbon steel fuel return line fittings on Gen 4 and Gen 5 Roush Cleantech LPG fuel conversion kits installed on vehicles operated in the Salt Belt states have exhibited galvanic-reaction-caused corrosion where the stainless-steel crimp collar on the fuel return line contacts the zinc-plated carbon steel fitting, if the zinc-plating has been compromised by road debris pecking. If this occurs, there is a risk that the fuel line fitting could corrode to the point where LPG fuel will leak. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : If the fuel return line leaks, it could increase the risk of a fire. Description of the Cause : Roush believes that a galvanic reaction can occur under certain road conditions (i.e., a combination of road debris pecking on the zinc-plated carbon steel fitting, and road salt and moisture from snow/ice/water). This galvanic reaction can create the potential for compromised zinc plating to corrode the carbon steel LPG fuel return line fittings where the stainless-steel crimp collar contacts the fitting. Roush has concluded that this problem is limited to vehicle operated in the Salt Belt States. Roush inspected (and rated for degree of corrosion on a scale of 1 (like new) to 6 (leaking)) the fittings on 166 representative vehicles (altered Ford E/F Series vehicles and Blue Bird School buses) in multiple regions of the country. Of the 70 vehicles inspected and rated in the non-Salt Belt States, 55 were rated #1 (still looking new with the zinc plating intact), and the remaining 15 were rated #2 (little to no rust showing on the fittings). Conversely, of the 96 vehicles inspected in the Salt Belt States, only 8 received a #1 rating, 45 were rated #2, and 43 were rated either #3 (red rust greater than/equal to 50% of the inspected parts) or higher. Identification of Any Warning that can Occur : It may be possible to observe a significant amount of red rust on the fuel return line connector fitting prior to any fuel leak. Involved Components : Component Name 1 : ¼” fuel return line (Roush) Component Description : Fuel return line assembly that includes a zinc-plated carbon steel fitting and stainless-steel crimp collar (Roush). Component Part Number : See MFR Comments to NHTSA (Roush 22E049) and Manufacturer Comments to NHTSA Staff below Supplier Identification : Part 573 Safety Recall Report 22V-578 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Component Manufacturer Name : Roush CleanTech Address : 12170 Globe Street Livonia Michigan 48051 Country : United States Chronology : October, 2020: Roush was informed that two Blue Bird school buses in Pennsylvania had experienced apparent corrosion-caused fuel return line fitting failures about three weeks apart. Roush started to investigate service history, engineering, and supplier quality. Several additional similar warranty claims were reported in 2021. Spring 2022, Roush had received a total of 19 corrosion warranty claims, with no fires. These claims arose solely in Salt Belt states and involved vehicles with various mileage and manufacturing dates. Roush began its Salt Belt and non-Salt Belt geographic field and laboratory investigation in 2021. In total, Roush inspected (and rated for degree of corrosion) the fittings on more than 166 representative vehicles as described in the “Describe the Cause” section above. The inspections identified the vehicle make, model, part number, part location, orientation, mileage, alteration date, geographic location, and route characteristics. Some non-leaking fittings observed with exterior corrosion were dissected to ascertain the extent of any internal compromised metal. Roush also conducted two types of laboratory salt spray testing. The ASTM B117 salt spray testing varied the orientation of the fittings in the salt test chamber (parallel to ground, perpendicular, 45 degrees, reversed male tube directions). Roush’s modified salt spray testing included a road debris pecking simulation. Roush then tested fittings equipped with additional spiral wrap protection, with braided loom protection, and with a combination of the two protections. Based on the results of its investigation, in late May 2022, Roush decided to submit a 573. August 1, 2022: Blue Bird Corporation was notified by Roush of the Safety Recall Campaign for return line fittings. Description of Remedy : Description of Remedy Program : Roush will work with Blue Bird and the Blue Bird Dealers to replace the fuel return lines in the recalled vehicles. Roush initially corrected the “Recall Condition” for most of its equipment items sold to independent alterers in late November, 2021, by using a new 5″ spiral wrap covered with a 9″ braded loom zip tied at each end of the spiral wrap (the “Wrap and Loom protection”). However, Roush anticipates that the purchasers will utilize a newly-designed fuel return line as the recall remedy for inuse vehicles. All parts and material will be supplied by Roush. Applicable servicers will be reimbursed by Roush for all associated labor costs. How Remedy Component Differs The corrective action for vehicles in the field will involve replacing the Part 573 Safety Recall Report 22V-578 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 from Recalled Component : return lines with a flexible return line that runs from the FRPCM to the tank return valve. Identify How/When Recall Condition was Corrected in Production : Roush initially corrected the “Recall Condition” for most of its equipment items sold to independent alterers in late November, 2021, by using a new 5″ spiral wrap covered with a 9″ braded loom zip tied at each end of the spiral wrap (the “Wrap and Loom protection”). However, Roush anticipates that the purchasers will utilize a newly-designed fuel return line, as the recall remedy. Recall Schedule : Description of Recall Schedule : Interim Dealer and Owner Notifications are to be issued on or before September 28, 2022. Parts are unavailable at this time. Roush will reimburse the labor cost of the repair related to this recall at no cost to the Dealer or to the vehicle owner. Planned Dealer Notification Date : SEP 28, 2022 – SEP 28, 2022 Planned Owner Notification Date : SEP 28, 2022 – SEP 28, 2022 * NR – Not Reported

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-578 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Blue Bird Body Company Submission Date : AUG 12, 2022 NHTSA Recall No. : 22V-578 Manufacturer Recall No. : R22BX-NSB Manufacturer Information : Manufacturer Name : Blue Bird Body Company Address : P.O. Box 937 402 Blue Bird Boulevard Fort Valley GA 31030 Company phone : 478-822-2242 Population : Number of potentially involved : 49 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2018-2023 Blue Bird Vision Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : CNG/LPG Descriptive Information : The population of items of original equipment covered by this report does not include LPG systems manufactured prior to July, 2015 because that date is when Roush began to use zincplated fittings on the return lines in its LPG conversion kits. The population does not include LPG systems shipped after June 30, 2022 because LPG systems shipped after that date had fuel return lines with additional protection that prevents the corrosion at issue here. Because the corrosion at issue here occurs only in the presence of significant amounts of road salt, this notice applies only to the fuel return lines in LPG conversion kits installed in vehicles originally or currently registered in the following states: Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, and Wisconsin (which are referred to in this Report as the “Salt Belt States”). Roush’s conclusion that this report does not apply to fuel return lines that were installed in vehicles that were not operated in the Salt Belt states is based primarily on the following: (1) all of the 19 warranty claims that reported corrosion of a fuel return line fitting came from vehicles in the Salt Belt states. (2) Roush’s inspection of 166 vehicles from various regions of the United States (the results of which are described in the “Describe the Cause” section of this report) demonstrated that there has been extremely little, if any, corrosion of fittings on vehicles outside of the Salt Belt states. Production Dates : NOV 30, 2016 – JUL 06, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 22V-578 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Defect : Description of the Defect : Some zinc-plated carbon steel fuel return line fittings on Gen 4 and Gen 5 Roush Cleantech LPG fuel conversion kits installed on vehicles operated in the Salt Belt states have exhibited galvanic-reaction-caused corrosion where the stainless-steel crimp collar on the fuel return line contacts the zinc-plated carbon steel fitting, if the zinc-plating has been compromised by road debris pecking. If this occurs, there is a risk that the fuel line fitting could corrode to the point where LPG fuel will leak. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : If the fuel return line leaks, it could increase the risk of a fire. Description of the Cause : Roush believes that a galvanic reaction can occur under certain road conditions (i.e., a combination of road debris pecking on the zinc-plated carbon steel fitting, and road salt and moisture from snow/ice/water). This galvanic reaction can create the potential for compromised zinc plating to corrode the carbon steel LPG fuel return line fittings where the stainless-steel crimp collar contacts the fitting. Roush has concluded that this problem is limited to vehicle operated in the Salt Belt States. Roush inspected (and rated for degree of corrosion on a scale of 1 (like new) to 6 (leaking)) the fittings on 166 representative vehicles (altered Ford E/F Series vehicles and Blue Bird School buses) in multiple regions of the country. Of the 70 vehicles inspected and rated in the non-Salt Belt States, 55 were rated #1 (still looking new with the zinc plating intact), and the remaining 15 were rated #2 (little to no rust showing on the fittings). Conversely, of the 96 vehicles inspected in the Salt Belt States, only 8 received a #1 rating, 45 were rated #2, and 43 were rated either #3 (red rust greater than/equal to 50% of the inspected parts) or higher. Identification of Any Warning that can Occur : It may be possible to observe a significant amount of red rust on the fuel return line connector fitting prior to any fuel leak. Involved Components : Component Name 1 : ¼” fuel return line (Roush) Component Description : Fuel return line assembly that includes a zinc-plated carbon steel fitting and stainless-steel crimp collar (Roush). Component Part Number : See MFR Comments to NHTSA (Roush 22E049) and Manufacturer Comments to NHTSA Staff below Supplier Identification : Part 573 Safety Recall Report 22V-578 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Component Manufacturer Name : Roush CleanTech Address : 12170 Globe Street Livonia Michigan 48051 Country : United States Chronology : October, 2020: Roush was informed that two Blue Bird school buses in Pennsylvania had experienced apparent corrosion-caused fuel return line fitting failures about three weeks apart. Roush started to investigate service history, engineering, and supplier quality. Several additional similar warranty claims were reported in 2021. Spring 2022, Roush had received a total of 19 corrosion warranty claims, with no fires. These claims arose solely in Salt Belt states and involved vehicles with various mileage and manufacturing dates. Roush began its Salt Belt and non-Salt Belt geographic field and laboratory investigation in 2021. In total, Roush inspected (and rated for degree of corrosion) the fittings on more than 166 representative vehicles as described in the “Describe the Cause” section above. The inspections identified the vehicle make, model, part number, part location, orientation, mileage, alteration date, geographic location, and route characteristics. Some non-leaking fittings observed with exterior corrosion were dissected to ascertain the extent of any internal compromised metal. Roush also conducted two types of laboratory salt spray testing. The ASTM B117 salt spray testing varied the orientation of the fittings in the salt test chamber (parallel to ground, perpendicular, 45 degrees, reversed male tube directions). Roush’s modified salt spray testing included a road debris pecking simulation. Roush then tested fittings equipped with additional spiral wrap protection, with braided loom protection, and with a combination of the two protections. Based on the results of its investigation, in late May 2022, Roush decided to submit a 573. August 1, 2022: Blue Bird Corporation was notified by Roush of the Safety Recall Campaign for return line fittings. Part 573 Safety Recall Report 22V-578 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : Roush will work with Blue Bird and the Blue Bird Dealers to replace the fuel return lines in the recalled vehicles. Roush initially corrected the “Recall Condition” for most of its equipment items sold to independent alterers in late November, 2021, by using a new 5″ spiral wrap covered with a 9″ braded loom zip tied at each end of the spiral wrap (the “Wrap and Loom protection”). However, Roush anticipates that the purchasers will utilize a newly-designed fuel return line as the recall remedy for inuse vehicles. All parts and material will be supplied by Roush. Applicable servicers will be reimbursed by Roush for all associated labor costs. If the modifications directed by this notification were performed on your bus prior to the receipt of this recall notification, provide a copy of the invoice to Roush CleanTech. Roush CleanTech details will be provide in the recall communication. How Remedy Component Differs from Recalled Component : The corrective action for vehicles in the field will involve replacing the return lines with a flexible return line that runs from the FRPCM to the tank return valve. Identify How/When Recall Condition was Corrected in Production : Roush initially corrected the “Recall Condition” for most of its equipment items sold to independent alterers in late November, 2021, by using a new 5″ spiral wrap covered with a 9″ braded loom zip tied at each end of the spiral wrap (the “Wrap and Loom protection”). However, Roush anticipates that the purchasers will utilize a newly-designed fuel return line, as the recall remedy. Recall Schedule : Description of Recall Schedule : Interim Dealer and Owner Notifications are to be issued on or before September 28, 2022. Parts are unavailable at this time. Roush will reimburse the labor cost of the repair related to this recall at no cost to the Dealer or to the vehicle owner. Planned Dealer Notification Date : SEP 28, 2022 – SEP 28, 2022 Planned Owner Notification Date : SEP 28, 2022 – SEP 28, 2022 * NR – Not Reported

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