Description

NAVISTAR BE 200 BUS FRONT END SERVICE MANUAL

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NAVISTAR BE 200 BUS FRONT END SERVICE MANUAL contains high quality images, diagrams, instructions to help you to operate, maintenance, diagnostic, and repair your machine. This document is printable, without restrictions, contains searchable text and bookmarks for easy navigation.

NAVISTAR BE 200 BUS FRONT END SERVICE MANUAL includes:

• Numbered table of contents easy to use so that you can find the information you need fast.
• Detailed sub-steps expand on repair procedure information.
• Numbered instructions guide you through every repair procedure step by step.
• Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
• Notes, cautions and warnings throughout each chapter pinpoint critical information.
• Bold figure number help you quickly match illustrations with instructions.
• Detailed illustrations, drawings and photos guide you through every procedure.
• Enlarged inset helps you identify and examine parts in detail.

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TABLE OF CONTENT OF THE NAVISTAR BE 200 BUS FRONT END SERVICE MANUAL

1. DESCRIPTION…………………………………………………………………………………………….1
2. IDENTIFICATION………………………………………………………………………………………….1
2.1. VEHICLE CERTIFICATION PLATE……………………………………………………………..1
2.2. BODY SERIAL NUMBER……………………………………………………………………….3
3. DESCRIPTION…………………………………………………………………………………………….4
3.1. VEHICLE EXTERIOR …………………………………………………………………………..4
3.2. REPORTING SAFETY DEFECTS………………………………………………………………4
3.3. FRONT END…………………………………………………………………………………….5
Bumper……………………………………………………………………………………..5
Hood………………………………………………………………………………………..6
Grille………………………………………………………………………………………..7
Splash Panels………………………………………………………………………………7
Fenders……………………………………………………………………………………..8
Air Intakes…………………………………………………………………………………..9
Fender Extensions………………………………………………………………………..10
Fender Valance Panels……………………………………………………………………11
Mud Guards……………………………………………………………………………….11
Headlight Assemblies…………………………………………………………………….12
Hood Seal………………………………………………………………………………….12
Engine Cowl……………………………………………………………………………….13
Hood Latch………………………………………………………………………………..14
Windshield Washer Fluid Reservoir……………………………………………………..15
Safety Gate………………………………………………………………………………..15
Lollipop Style Fender Mounter Directional Lights (Optional).. … … … … … … … … … …16
Cross-View Fender Mounted Mirrors…………………………………………………….17
Hood Stop Assembly……………………………………………………………………..17
3.4. BUS BODY — EXTERIOR…………………………………………………………………….18
Windshield, and Windshield Wipers……………………………………………………..18
Rear View Mirrors…………………………………………………………………………19
Passenger Entry Door…………………………………………………………………….20
Vandal Lock……………………………………………………………………………….22
Front Warning Lights……………………………………………………………………..23
D.O.T. Lights and Reflectors……………………………………………………………..23
Assist Steps……………………………………………………………………………….24
Fuel Fill…………………………………………………………………………………….25
Emergency Exit Doors…………………………………………………………………….26
Emergency Exit Windows…………………………………………………………………27
Passenger Windows………………………………………………………………………27
Roof Mounted Escape Hatch……………………………………………………………..28
Rear Bumper Assembly…………………………………………………………………..29
Rear Body Exterior Lights………………………………………………………………..30
Side Traffic Stop Arm……………………………………………………………………..30
Electrical Compartment…………………………………………………………………..33
Battery Compartment……………………………………………………………………..34
Radio Antenna…………………………………………………………………………….35

Chair Lift Door and Chair Lift…………………………………………………………….36
Roof Mounted Strobe Light (Optional)…………………………………………………..38
Transition Panels………………………………………………………………………….39
End Caps…………………………………………………………………………………..39
Windshield- 3 Piece……………………………………………………………………….40
Driver Side Window……………………………………………………………………….41
Driver Side Storm Glass Windows……………………………………………………….42
Static Roof Vents………………………………………………………………………….42
Mud Guards……………………………………………………………………………….42
Rear Wheel Rubber Fenderettes …………………………………………………………42
Body Tie Down Bolts and Assemblies…………………………………………………..42
3.5. BUS BODY— INTERIOR……………………………………………………………………..43
Step Well…………………………………………………………………………………..43
Assist Rails………………………………………………………………………………..44
Step Well Heater…………………………………………………………………………..45
Crash Barriers…………………………………………………………………………….45
Fire Extinguisher………………………………………………………………………….46
Driver Controls / Instrument Panel……………………………………………………….47
Steering Column…………………………………………………………………………..50
Accelerator Pedal Assembly……………………………………………………………..51
Driver Side Sliding Window………………………………………………………………51
Driver Side Storm Window Assembly (Optional)………………………………………..51
Driver Seat…………………………………………………………………………………51
Heater and Defroster………………………………………………………………………53
Light Bars………………………………………………………………………………….54
Flooring……………………………………………………………………………………57
Seats and Seating…………………………………………………………………………58
Windows…………………………………………………………………………………..61
Emergency Exit Door Lower Glass Protection Screen………………………………….63
Emergency Exit Latches and Alarms…………………………………………………….64
Exterior Light Monitor (Optional)…………………………………………………………65
Safety Equipment- Reflective Road Triangles……………………………………………66
Seat Tracks………………………………………………………………………………..66
Wheelchair Access Door and Chair Lift………………………………………………….68
Wheelchair Access Door Assembly…………………………………………………….. 73
Fuel Sender Access Panel………………………………………………………………..76
Miscellaneous Options……………………………………………………………………77
First Aid Kit………………………………………………………………………………..77
Body Fluid Clean-up Kit (Optional)……………………………………………………….77
Windshield Defroster Fan (Optional)……………………………………………………..78
Driver Side Interior Rear View Mirror and Sun Visor…………………………………….79
Manual Door Opener………………………………………………………………………79
4. REMOVE…………………………………………………………………………………………………81
4.1. FRONT END COMPONENT- REMOVE………………………………………………………..81
Bumper…………………………………………………………………………………….81
Hood……………………………………………………………………………………….82
Grille……………………………………………………………………………………….91
Splash Panels……………………………………………………………………………..92
Fenders……………………………………………………………………………………93
Air Intakes…………………………………………………………………………………94
Fender Extensions………………………………………………………………………..94
Valance Panels…………………………………………………………………………….96

Head Lamp Replacement……………………………………………………………….. 99
Directional Bulb Remove and Replace………………………………………………….101
Fog Lights (Optional)…………………………………………………………………….105
Hood Latches…………………………………………………………………………….107
Hood Seal………………………………………………………………………………..109
Windshield Washer Fluid Reservoir…………………………………………………….110
Fender Mounted Cross View Mirrors……………………………………………………115
Safety Gate……………………………………………………………………………….117
External Block Heater Connection………………………………………………………121
4.2. EXTERIOR BODY COMPONENT — REMOVE………………………………………………122
Windshield Wiper Drive Arm Removal………………………………………………….122
Windshield Removal…………………………………………………………………….124
Rear View Mirror- Driver Side……………………………………………………………127
Rear View Mirror- Passenger Side………………………………………………………128
Front Warning Lights…………………………………………………………………….129
Destination Sign Lighted (Optional)…………………………………………………….130
D.O.T. Lights and Reflectors…………………………………………………………….131
Vandal Lock………………………………………………………………………………131
Assist Steps……………………………………………………………………………..133
Passenger Entry Door……………………………………………………………………134
Fuel Fill…………………………………………………………………………………..135
Passenger Windows and Emergency Exit Windows………………… ………………..136
Emergency Exit Doors ………………………………………………………………….136
Roof Mounted Escape Hatch……………………………………………………………138
Wheelchair Access Door………………………………………………………………..140
Rear Bumper Assembly…………………………………………………………………141
Rear Body Exterior Lights and Warning Lights………………… ……………………..143
Street Side Stop Signs…………………………………………………………………..144
Rubber Fenderettes……………………………………………………………………..146
Electrical Compartment………………………………………………………………….146
Battery Compartment……………………………………………………………………147
Radio Antenna……………………………………………………………………………148
Transition Panels………………………………………………………………………..148
End Caps…………………………………………………………………………………149
Optional Warning Lights…………………………………………………………………150
Body Attachment………………………………………………………………………..150
Static Roof Vents…………………………………………………………………………155
Mud Guards………………………………………………………………………………156
4.3. INTERIOR BODY COMPONENTS — REMOVE……………………………………………..156
Step Well Tread Plates…………………………………………………………………..156
Step Well Assembly-Removal…………………………………………………………..157
Assist Handrails………………………………………………………………………….158
Defroster Fans (Optional)……………………………………………………………….159
Sun Visor…………………………………………………………………………………159
Destination Board Lights (Optional)…………………………………………………….160
Interior Rear View Mirror………………………………………………………………..161
Dash Board Panels, Cluster and Switch Panels………………………………………..162
Steering Wheel and Clock Spring Removal…………………………………………….167
Front and Side Cover…………………………………………………………………….167
Locking Clip……………………………………………………………………………..169
Steering Wheel…………………………………………………………………………..170
Clock Spring……………………………………………………………………………..171

Steering Column…………………………………………………………………………173
Accelerator Pedal………………………………………………………………………..174
Brake Pedal………………………………………………………………………………175
Driver Side Sliding Window Assembly………………………………………………….176
Driver Seat……………………………………………………………………………….178
Driver Seat Belts…………………………………………………………………………179
Fire Extinguisher…………………………………………………………………………181
Driver Seat Bulkhead / Passenger Crash Barrier.. ……. …… ……. ……. ……. ……. ..181
Passenger Door Control Panel— Electric………………………………………………182
Passenger Door Removal……………………………………………………………….184
Bus Interior Light Bars…………………………………………………………………..185
Seats and Seating Removal……………………………………………………………..186
Seat Tracks (Optional)…………………………………………………………………..189
Seat Belts— Two Point (Optional)………………………………………………………190
Passenger Windows……………………………………………………………………..191
Emergency Window Exits……………………………………………………………….192
Stationary Glass Removal……………………………………………………………….192
Emergency Window Exit Alarms ……………………………………………………….193
Emergency Exit Doors, Buzzers and Latches………………………………………….194
Wheelchair Lift (Optional)……………………………………………………………….197
Wheelchair Floor Plates…………………………………………………………………198
Wheelchair Seat Belts and Shoulder Harness………………………………………….198
Rear Door Glass Protection Screen…………………………………………………….199
Safety Equipment — Required………………………………………………………….199
Safety Equipment — Optional…………………………………………………………..200
Exterior Light Monitor……………………………………………………………………200
Fuel Sender Access Hatch ……………………………………………………………..201
Flooring…………………………………………………………………………………..202
Plywood Sub-Flooring…………………………………………………………………..202
5. INSTALL………………………………………………………………………………………………..203
5.1. EXTERIOR BODY COMPONENTS…………………………………………………………..203
Bumper Assembly……………………………………………………………………….203
Hood………………………………………………………………………………………204
Grille / Shroud……………………………………………………………………………207
Splash Panels……………………………………………………………………………208
Fender Extensions……………………………………………………………………….209
Headlight Assemblies……………………………………………………………………211
Head Lamp……………………………………………………………………………….212
Fog Lights………………………………………………………………………………..213
Hood Latches…………………………………………………………………………….213
Hood Seal………………………………………………………………………………..214
Windshield Washer Fluid Reservoir…………………………………………………….214
Fender Mounted Cross-View Mirrors……………………………………………………215
Safety Gate……………………………………………………………………………….216
Windshield Wiper Install…………………………………………………………………216
Windshield Install………………………………………………………………………..218
Driver Side Rear View Mirror…………………………………………………………….224
Passenger Side Rear View Mirror……………………………………………………….224
Front Warning Lights…………………………………………………………………….225
Destination Sign…………………………………………………………………………225

Assist Steps……………………………………………………………………………..227
Passenger Entry Door……………………………………………………………………228
Fuel Fill Door…………………………………………………………………………….228
Passenger Windows……………………………………………………………………..228
Emergency Exit Windows……………………………………………………………….228
Emergency Exit Doors and Latches…………………………………………………….228
Roof Mounted Escape Hatch……………………………………………………………229
Wheelchair Access Door………………………………………………………………..230
Rear Bumper Assembly…………………………………………………………………231
Rear Body Exterior Lights and Warning Lights………………… ……………………..232
Street Side Body Stop Signs…………………………………………………………….232
Rubber Fenderettes……………………………………………………………………..232
Under Body Compartments (Optional)………………………………………………….233
Electrical Compartment Door……………………………………………………………233
Battery Compartment ……………………………………………………………………234
Radio Antenna……………………………………………………………………………235
Driver Side Sliding Window……………………………………………………………..235
Driver Side Storm Window (Optional)…………………………………………………..235
Transition Panels………………………………………………………………………..235
End Caps…………………………………………………………………………………236
Static Roof Vents…………………………………………………………………………237
Optional Roof Mounted Warning Lights………………………………………………..237
Body Attachments or Tie Downs………………………………………………………..238
5.2. INTERIOR INSTALL………………………………………………………………………….238
Step Well…………………………………………………………………………………238
Assist Handrails………………………………………………………………………….239
Defroster Fans (Optional)……………………………………………………………….240
Sun Visor…………………………………………………………………………………240
Destination Sign Lights (Optional)………………………………………………………240
Interior Rear View Mirror………………………………………………………………..240
Dash Board Panels, Cluster and Switch Panels………………………………………..241
Driver Side Storage Compartment………………………………………………………241
Heater and Environmental Controls…………………………………………………….241
Driver Left Side Switch Panel……………………………………………………………241
Cluster Assembly………………………………………………………………………..241
Cluster Cover Panel……………………………………………………………………..242
Clock Spring……………………………………………………………………………..242
Steering Wheel / Clock Spring…………………………………………………………..243
Steering Column…………………………………………………………………………243
Accelerator Pedal………………………………………………………………………..244
Brake Pedal………………………………………………………………………………244
Right Wing Switch Panel and Cluster Bezel……………………………………………245
Step Well Panel…………………………………………………………………………..246
Driver Seat……………………………………………………………………………….246
Driver Seat Belts (3–Pt Belt Install)……………………………………………………..246
Driver Crash Barrier (Rail Mounted)…………………………………………………….247
Fire Extinguisher…………………………………………………………………………249
First Aid Kit………………………………………………………………………………250
Body Fluid Clean-up Kit (Optional)……………………………………………………..251
Passenger Door Control Mechanism……………………………………………………251
Bus Interior Light Bars…………………………………………………………………..253
Seats……………………………………………………………………………………..254

Seat Back…………………………………………………………………………………256
Seat Tracks (Optional)…………………………………………………………………..257
Seat Belt— 2 Point With Seat Track (Optional)…………………………………………258
Passenger Window Installation…………………………………………………………258
Stationary Glass Install………………………………………………………………….259
Emergency Exit Window Installation……………………………………………………260
Emergency Exit Doors and Latches…………………………………………………….260
Emergency Roof Hatch Exit Install……………………………………………………..261
Wheelchair Access Door (Optional)…………………………………………………….261
Wheelchair Lift…………………………………………………………………………..262
Wheelchair Floor Plates…………………………………………………………………262
Wheelchair Seat Belts and Shoulder Harness………………………………………….262
Emergency Door Glass Protection Screen (Optional)………………………………….262
Emergency Door and Wheelchair Access Door Glass Install………………………….262
Safety Equipment (Required)……………………………………………………………263
Exterior Light Monitor (Optional)……………………………………………………….264
Fuel Sender Access Panel………………………………………………………………265
Flooring…………………………………………………………………………………..266
6. MAINTENANCE…………………………………………………………………………………………267
6.1. HEATERS AND ACCESSORIES……………………………………………………………..267
Driver Side Heater……………………………………………………………………….267
Step Well Heater (Optional)……………………………………………………………..268
Under Seat Heaters………………………………………………………………………269
Rear Body Heaters (Optional)…………………………………………………………..270
Maintenance……………………………………………………………………………..270
Heaters and Accessories………………………………………………………………..270
Troubleshooting………………………………………………………………………….271
Heater / Defroster and Blower Motor Access Procedures……………………………..272
Access Main Front Heater / Defroster Blower Motors and Resistors Assembly. . . . . . . .272
Auxiliary / Midship Heater Motor Access……………………………………………….273
Optional Step Well Heater Assembly……………………………………………………274
Troubleshooting Chart…………………………………………………………………..277
Fluid Capacity……………………………………………………………………………278
Upholstery Care and Cleaning Recommendations…………………………………….278
7. ADJUSTMENTS………………………………………………………………………………………..279
7.1. HOOD ADJUSTMENT AND ALIGNMENT……………………………………………………279
7.2. HOOD STOP ADJUSTMENT…………………………………………………………………279
7.3. HEADLIGHT ADJUSTMENT…………………………………………………………………280
8. EXTERIOR BODY REPAIR …………………………………………………………………………….281
8.1. REMOVE……………………………………………………………………………………..281
Fasteners…………………………………………………………………………………281
Body Panel Remove……………………………………………………………………..282
End Cap Remove…………………………………………………………………………282
8.2. INSTALL……………………………………………………………………………………..282
Rivet Replacement……………………………………………………………………….282
Body Panel — Install…………………………………………………………………….282
End Cap Replacement…………………………………………………………………..283
9. WINDSHIELD WIPER DRIVE SYSTEM…………………………………………………………………284

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• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle.
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Find our other Navistar products.

Model: BE 200
S47006
09/16/2005