service bulletin - mckenzie tank lineshr.mckenzietank.com/maint/bulletins/41-sb214026.pdf ·...

SB-214-026 — of 25SERVICE PUBLICATIONS, ALLENTOWN, PA 18105 ©MACK TRUCKS, INC. 2004

SERVICE BULLETIN

NUMBER: SB-214-026DATE: 7/30/04

MODEL: ASET™ AC(Not applicable to Mack Trucks Australia)(Supersedes SB-214-026 dated 2/2/04)

EGR MASS FLOW SYSTEM CONVERSION KIT (FROM TWO-PIECE TUBE WITH BELLOWS-TYPE CONNECTIONS TO ONE-PIECE TUBE

WITH HOSE CONNECTIONS) — ASET™ AC ENGINES

The EGR mass flow system (MFS) consists of the EGR “cold” tube, which routes the cooledexhaust gases from the EGR cooler to the mixer tube located on the inlet manifold, the massflow sensors, electronic control module and the connecting harnesses. These componentsare calibrated as a unit, and when replacement is necessary, they must be replaced as acomplete system.

Prior to 12/17/03, the mass flow system used a two-piece upper and lower EGR cold tube.With this system, only the upper tube assembly was the part of the system that had to bereplaced as a unit. Effective 12/17/03, a revised mass flow system was implemented intoproduction beginning with engine serial No. 3Y1326. The revised mass flow system consistsof a single tube (rather than the two-piece upper and lower tubes) with a revised mountingsystem. The EGR cold tube now uses hose connections at both ends, eliminating thebellows sections as used with the two-piece tube arrangement.

Effective July 8, 2004 (beginning with engine serial No. 4N0478), the following changeswere made to the EGR mass flow system:

� The mass flow system module software has been revised to eliminate heater failures.

� Reflective sleeves were added to the sections of mass flow sensor harnesses thatpasses over the top of the engine. These sleeves protect the harnesses from heatradiated by the exhaust manifold.

� The retaining nut for the rear mass flow sensor is welded, just as it is on the frontsensor. Both sensor retaining nuts are welded to provide a measure of tamperresistance. Previously, only the front sensor nut was welded.

The components of the mass flow system (which includes themass flow tube, sensors, module and connecting harnesses) arecalibrated as a unit during manufacture. Whenever a mass flowsystem is replaced, the tube, sensors, harnesses and modulemust be replaced as a unit. DO NOT attempt to remove orreplace the mass flow sensors. Whether or not one or both of thesensor retaining nuts are welded, disturbing either sensor byattempting to remove the sensor retaining nuts can result in afailure of the mass flow system to perform properly. Doing so isconsidered tampering or abuse which would void the warrantyon the mass flow system components.

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The following part is required to repair a mass flow system on an engine already equippedwith a one-piece cold tube:

� 206MS58M — This is the only component needed. Do not order the conversion kit, oilline kit or EGR mixer tube.

Should any component of a two-piece cold tube mass flow system require replacement, itwill be necesary to convert from the two-piece cold tube system to the current one-piecedesign by using conversion kit part No. 57GC2248, together with certain additionalcomponents as described below and as given in the parts lists outlined in this bulletin.

It is imortant to order only the parts needed for the particularapplication. It is also imortant to note that the mass flow system(one-piece tube with sensors and module) is NOT INCLUDED inthe conversion kit.

The following parts are required for a non-brake or PowerLeash™-equipped engine havingthe two-piece (bellows connections) mass flow tube:

� 206MS58M — One-piece (hose connections) mass flow system

� 57GC2248 — Mass flow system conversion kit

� 682GC512M — EGR mixer tube

The following parts are required for a J-Tech™-equipped engine having the two-piece(bellows connections) mass flow tube:

� 206MS58M — One-piece (hose connections) mass flow system

� 57GC2248 — Mass flow system conversion kit

� 57GC2247 — Turbocharger and EGR valve oil line kit

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Figure 1 — EGR Mass Flow Tube Replacement

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The one-piece mass flow system must be ordered separately. Part number is as follows:

Depending upon engine configuration (MACK PowerLeash™ engine brake, J-Tech™ enginebrake or non-brake), the following additional parts will be required:

57GC2248 Mass Flow System Conversion Kit

Key Qty. Part No. Description

1 2 670GC2112 Adapter, EGR mass flow tube mounting flange

2 2 449GC237M Gasket, EGR mass flow tube flange

3 2 260GB214 V-band clamp, EGR mass flow tube flange

4 2 744GB261 Coupling hose, EGR mass flow tube connections

5 4 180GB330M47 Clamp, EGR mass flow tube coupling hoses

6 2 66AM19 Bolt, EGR mass flow tube mounting clamps at exhaust manifold

2 421GC318M Bolt, button-head, EGR mass flow tube mounting clamps at EGRvalve

7 4 158GB3581 Clamp, EGR mass flow tube mounting (upper and lower)

8 2 449GC236M Gasket, EGR hot tube flange

9 3 189AM3 Nut, EGR mass flow tube mounting bracket

10 3 271AM5009 Flat washer, EGR mounting bracket spacer studs

11 3 616GC278M Spacer stud, EGR mass flow tube mounting bracket

12 3 616GC228M3 Stud, EGR valve mounting (in exhaust manifold)

13 1 573GB323 Gasket, EGR valve mounting

14 1 158GB4814M Bracket, EGR mass flow tube mounting at EGR valve

15 1 83AX1046 Clamp, VTG actuator air line

16 2 66AM44 Bolt, VTG actuator air line and wire harness clamps

17 1 744GB356P4 Turbocharger oil feed line (from F-fitting-to-turbocharger)

18 1 744GB357 Oil drain line, EGR valve-to-turbocharger drain tube (NOTE: Someearlier ASET™ engines may utilize a 45 degree fitting at theturbocharger drain tube for the EGR valve oil drain line. If this is thecase, the 45 degree fitting must be replaced with a straight fitting (partNo. 497GB2124.)

19 1 66AM44 Bolt, wire harness clamp-to-EGR tube mounting bracket

20 1 83AX354 Clamp, wire harness to EGR tube mounting bracket at front of exhaustmanifold

21 1 158GB4815M Bracket, EGR mass flow tube mounting at front exhaust manifold

22 1 66AM6 Bolt, EGR tube mounting bracket-to-exhaust manifold


A 1 206MS58M Mass flow system, one-piece tube design


B 1 682GC512M EGR mixer tube required for MACK PowerLeash™-equipped andnon-brake engines.

C 1 57GC2247 Turbocharger and EGR valve oil line kit for engines equipped with J-Tech™ engine brakes (this kit replaces the F-fitting)

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The 57GC2247 Turbocharger and EGR Valve Oil Line Kit for engines equipped with the J-Tech™ engine brake includes the following:2

Figure 2 — Turbocharger and EGR Valve Oil Line Kit for Engines Equipped with J-Tech™ Engine Brakes

Installation of the EGR mass flow system conversion kit is as follows:

1. Disconnect the mass flow sensor harness connectors at the mass flow system modulemounted to the engine electronic control unit (EECU) cooling plate.


1 1 744GB356P10 Oil supply line from 4-way fitting to turbocharger.

2 1 83AX118 Clamp, oil line at EGR valve

3 2 83AX55 Clamp, EGR oil supply line

4 1 66AM44 Screw, EGR oil supply line-to-exhaust manifold clamp (included in57GC2248 kit)

5 1 796AX22 Convoluted tube (24″ [610 mm] length), EGR oil supply line

6 1 744GB356 Oil supply line to EGR valve from cylinder block

7 1 497GB2125 Fitting, EGR oil supply line at cylinder block

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To disconnect the sensor harness connectors from the module,slide the red secondary lock tab out, press down on the primarylock tab and then disconnect the connectors from the module.

3

Figure 3 — Mass Flow System Module

2. Remove the engine electronic control unit (EECU), and then remove the mass flowsensor module from the EECU cooling plate

1. Mass Flow Sensor Connectors

2. EECU Cooling Plate

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3. Loosen and remove the nuts securing the upper EGR tube support brackets to thestuds on the cylinder head cover capscrews.

4

Figure 4 — Upper EGR Tube Support Bracket

4. Loosen and remove the clamp that secures the upper tube to the EGR mixer port.5

Figure 5 — Removing EGR Upper Tube Clamp

1. Support Bracket, Rear2. Upper EGR Tube

3. Front Cylinder Head Cover

1. EGR Mixer 2. Upper EGR Tube

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5. Loosen and remove the clamp from the flange at the upper-to-lower EGR tubeconnection.

6

Figure 6 — Upper-to-Lower EGR Tube Connection

6. Remove the upper EGR tube with the sensors and sensor harness from the engine.7

Figure 7 — Removing Upper EGR Tube

1. Upper EGR Tube 2. Upper-to-Lower EGR Tube Clamp

1. EGR Mixer Tube 2. Upper EGR Tube

2. Lower EGR Tube

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7. Loosen and remove the bolts and brackets that secure the lower EGR tube to theexhaust manifold and the water pump housing.

8. Loosen and remove the clamp from the lower EGR tube at the EGR cooler flange, thenremove the tube from the engine.

8

Figure 8 — Removing Lower EGR Tube Clamp

9. On PowerLeash™-equipped and non-brake engines, the existing EGR mixer tube mustbe replaced with a new tube (part No. 682GC512M) as follows:

If the proper mixer tube is not installed, the connection from theEGR mass flow tube to the mixer tube will not align properly,which could result in failure of the EGR mass flow tube, couplinghose or both.

a. At the mixer tube, disconnect the harness connectors from the charge air cooleroutlet pressure and temperature sensors.

b. Remove the capscrew from the support bracket at the side of the EGR mixer tube.The bracket is secured between the mixer tube and the coolant manifold.

1. EGR Cooler 2. Lower EGR Tube

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c. Remove the capscrews that attach the mixer tube to the inlet manifold, thenremove the tube.

9

Figure 9 — EGR Mixer Tube

d. Clean and inspect the mixer tube mounting collar on the inlet manifold and place asmall amount of clean engine oil on the mixer tube O-ring.

1. Charge Air Pressure Sensor

2. Charge Air Temperature Sensor

3. Pressure Relief Valve4. EGR Mass Flow Tube5. Mixer Tube6. Capscrews

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e. Place the mixer tube in position on the inlet manifold and install the two mountingcapscrews. Tighten the capscrews to 40 lb-ft (55 N·m).

10

Figure 10 — Installing EGR Mixer Tube

f. Install the capscrew that secures the support bracket to the side of the mixer tube.Tighten the capscrew to 40 lb-ft (55 N·m).

g. Connect the harness connectors to the charge air cooler outlet pressure andtemperature sensors.

10. Disconnect the oil supply line from the turbocharger bearing housing. Temporarily capthe fitting to prevent the entry of dirt and debris. Cut the tie wraps that secure the line tothe VTG actuator air line. Disconnect the air line from the VTG actuator.

11

Figure 11 — Disconnect Turbocharger Oil Supply Line and VTG Air Line

1. Mixer Tube 2. Inlet Manifold

1. VTG Actuator Air Line2. Turbocharger Oil Supply

Line

3. F-Fitting

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11. Disconnect the oil return line at the EGR valve and at the turbocharger oil drain tube.Temporarily install plugs in the fittings to prevent the entry of dirt and debris.

12

Figure 12 — EGR Valve Oil Return Line

On some earlier ASET™ AC engines, the turbocharger draintube may have a 45 degree fitting at the EGR valve oil return lineconnection. The 45 degree fitting must be replaced with astraight fitting (part No. 497GB2124).

12. Disconnect the turbocharger oil supply line from the F-fitting, and then remove the linefrom the engine.

13. On J-Tech™-equipped engines, disconnect the oil supply line from the four-way fittinglocated on the left-hand side of the engine (between the front and rear cylinder headcovers) and from the F-fitting. Temporarily cap the four-way fitting to prevent the entryof dirt and debris.

1. EGR Valve2. Turbocharger Oil Drain

Tube

3. Oil Return Line

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Stainless steel braided hoses will crimp shut if not handled orinstalled correctly. If the steel braid has been kinked, it pinchesthe inner tube, and even if the steel braid is straightened, theinner tube will remain pinched. Caution must be used not tobend or twist the steel braided line to the point where it becomeskinked. If the line has been kinked, it must be replaced toeliminate turbocharger damage resulting from restricted oil flow.

14. Disconnect the oil supply line from the EGR valve. This line must be disconnected inorder to route the mass flow sensor harness wires. Install a plug in the fitting and in theopen end of the supply line to prevent the entry of dirt and debris.

On J-Tech™-equipped engines, the EGR oil supply line will bereplaced with a new line that is routed from the front of thecylinder block.

15. On J-Tech™-equipped engines, remove the F-fitting and mounting bracket.13

Figure 13 — Disconnect Oil Lines

1. EGR Valve Oil Supply Line2. Turbocharger Oil Supply

Line

3. Oil Line4. F-fitting (remove on

J-Tech™-equipped engines)

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16. Disconnect the harness connector from the EGR valve.

17. Loosen and remove the clamps from the hot tube at the EGR valve and at the EGRcooler. Remove the hot tube from the engine.

14

Figure 14 — EGR Hot Tube

18. Remove the four nuts that retain the EGR valve assembly to the exhaust manifold.Remove the EGR valve from the manifold, then remove and discard the metal gasket.

15

Figure 15 — Removing ERG Valve

1. EGR Hot Tube2. EGR Valve

3. EGR Cooler

1. EGR Valve 2. Exhaust Manifold

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19. Remove the two EGR valve mounting studs located on the outboard side of theexhaust manifold, and the one mounting stud located on the inboard side of themanifold facing the rear of the engine.

16

Figure 16 — Remove Three EGR Valve Mounting Studs

20. Install three new EGR valve mounting studs (part No. 616GC228M3) into the exhaustmanifold. These studs, which are longer than the original studs, are required so that theEGR mass flow tube mounting bracket spacer studs can be installed.

21. Install a new metal gasket (part No. 573GB323) on the EGR valve mounting surface ofthe exhaust manifold.

17

Figure 17 — Installing EGR Valve Gasket

1. EGR Valve Gasket 2. Exhaust Manifold

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22. Place the EGR valve in position on the exhaust manifold, then install the washers andretaining nuts and tighten to 40 lb-ft (55 N·m). (Reuse the existing washers and nuts.

23. Carefully clean and inspect the EGR hot tube mounting flanges.

Use care when cleaning EGR system components. Dirt anddebris entering the system can cause blockage inside the EGRcooler core or the EGR valve.

24. Position new wire-mesh gaskets (part No.449GC236M) in both flanges of the EGR hottube. Place the tube in position on the EGR valve and EGR cooler flanges and installthe clamps. Tighten the clamps to 110 lb-in (13 N·m).

Whenever the EGR hot-tube clamps are removed, the T-bolts(part No. 2529-4A920082) and nuts (part No. 2529-4A920030)should be replaced. The clamp assembly (part No. 260GB215)should be replaced only if damage is evident.

25. Install the three spacer studs (part No. 616GC278M) to the three longer EGR valvemounting studs that were previously installed. Tighten the spacer studs to 40 lb-ft(54 N·m).

18

Figure 18 — Installing Spacer Studs


1 3 616GC278M Spacer studs

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26. Place a flat washer (part No. 271AM5009) on the top of each spacer stud.19

Figure 19 — Place Flat Washer on Spacer Studs

27. Place the EGR tube upper mounting bracket (part No. 158GB4814M) on the spacerstuds. Secure the mounting bracket with three nuts (part No. 189AM3). Tighten thenuts to 40 lb-ft (54 N·m).

20

Figure 20 — EGR Tube Upper Mounting Bracket


1 3 271AM5009 Flat washers


1 3 189AM3 Nuts

2 1 158GB4814M Upper mounting bracket, EGR tube

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28. On J-Tech™ equipped engines, install and clamp the turbocharger oil supply line andthe VTG actuator air line as follows:

21

Figure 21 — Turbocharger and VTG Air Line Installation

a. Install the turbocharger oil supply line (part No. 744GB356P10) to the existingfour-way fitting.

b. Install the smaller clamp (part No. 83AX1046) over the VTG actuator air line andthe larger clamp (part No. 83AX118) over the turbocharger oil supply line.

c. Secure both clamps to the tang on the front of the EGR tube upper mountingbracket with a bolt (part No. 66AM44). Position the lines for optimum routing, andthen tighten the bolt.

29. On non-brake and PowerLeash™-equipped engines, clamp the VTG air line to theEGR mass flow tube mounting bracket tang, and connect the turbocharger oil supplyline (part No. 744GB356P4) to the F-fitting.


1 1 744GB356P10 Turbocharger oil supply line, J-Tech™-equipped engines only

2 1 83AX118 Clamp, turbocharger oil supply line

3 1 83AX1046 Clamp, VTG actuator air line

4 1 66AM44 Bolt, M8 x 1.25 x 16 mm

5 1 (existing) VTG actuator air line

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30. Install the EGR tube lower mounting bracket (part No. 158GB4815M) on the boss atthe top of the front exhaust manifold. and use the existing bolt to secure the bracket.Tighten the bolt to 40 lb-ft (54 N·m).

22

Figure 22 — EGR Tube Lower Mounting Bracket

31. Install a new EGR mass flow tube gasket (part No. 449GB237M) onto each of the EGRmass flow tube coupling adapters (part No. 670GC2112).

32. Install the coupling adapters to the EGR cooler and the EGR mixer flanges using bandclamps (part No. 260GB214). Tighten the band clamp nuts to 110 lb-in (13 N·m).

23

Figure 23 — EGR Tube Coupling Flange (Flange on EGR Cooler Shown)


1 1 158GB4815M Lower mounting bracket, EGR tube

2 1 66AM6 Bolt, lower mounting bracket


1 2 260GB214 Band clamp, EGR mass flow tube coupling flange

2 2 670GC2112 Coupling flange, EGR mass flow tube

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33. Slide a hose clamp (part No. 180GB330M47) onto each coupling flange (both at theEGR mixer and EGR cooler connections).

34. Slide a hose clamp (part No. 180GB330M47) and coupling hose (part No. 744GB261)over each end of the EGR mass flow tube assembly (part No. 206MS58M).

35. Position the new tube assembly on the engine between the mixer tube and EGR coolerconnections. Slide the coupling hoses onto the adapters and secure with the hoseclamps.

24

Figure 24 — EGR Mass Flow Tube Hose Connections (EGR Cooler Connection Shown)

36. Use clamps (part No. 158GB3581), along with the button-head bolts (part No.421GC318M) to secure the EGR tube to the previously installed mounting brackets atthe EGR valve and the front exhaust manifold. Tighten the bolts to 96 lb-in (11 N·m).

25

Figure 25 — EGR Mass Flow Tube Clamp


1 4 180GB330M47 Hose clamp, EGR coupling hose

2 2 744GB261 Coupling hose, EGR mass flow tube


1 2 66AM19 Bolts, EGR mass flow tube mounting clamp at exhaust manifold

2 421GC318M Bolts, button-head, EGR mass flow tube mounting clamp at EGR valve

2 4 158GB3581 Clamp (upper and lower halves), EGR mass flow tube mounting

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37. Route the turbocharger oil supply line and the VTG actuator air line over the top of theEGR mass flow tube, and then connect the oil line to the turbocharger and the air lineto the VTG actuator.

26

Figure 26 — Turbocharger Oil Supply and VTG Actuator Air Lines (J-Tech™-Equipped Shown)

38. Connect the EGR valve oil return line (part No. 744GB357) between the EGR valveand the turbocharger oil drain tube.

27

Figure 27 — EGR Valve Oil Drain Line

1. Turbocharger Oil Supply Line

3. VTG Actuator Air Line


1 1 744GB357 Oil drain line, EGR valve

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39. Secure the engine harness to the EGR tube mounting bracket at the front exhaustmanifold using a clamp (part No. 83AX354) and bolt (part No. 66AM44).

28

Figure 28 — Engine Harness Clamped to EGR Tube Mounting Bracket

40. On PowerLeash™ and non-brake engines, connect the oil supply line to the EGRcontrol valve.


1 1 83AX354 Clamp, engine harness-to-EGR tube mounting bracket

2 1 66AM44 Bolt, engine harness clamp

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41. On J-Tech™-equipped engines, install the EGR control valve oil supply line as follows:29

Figure 29 — EGR Control Valve Oil Supply Line (J-Tech™-Equipped Engines)

a. Remove the plug from the cylinder block oil supply port, then install the 90 degreeelbow fitting (part No. 497GB2125). Install with the fitting facing up.

b. Install a 24″ (610 mm) length of convoluted tubing (part No. 796AX22) over theEGR valve oil supply line (part No. 744GB356).

c. Route the oil line from the EGR valve location to the cylinder block fitting. The lineis to be routed inboard of the EGR cooler coolant supply pipe and inboard of theEGR valve and turbocharger harnesses.


1 1 744GB356 Oil supply line, EGR control valve

2 2 83AX55 Clamp, oil line-to-mass flow tube lower bracket, and oil line-to-timing gearcover

3 1 66AM44 Bolt, oil line clamp-to-mass flow tube lower bracket

4 1 796AX22 Convoluted tubing, 24″ (610 mm) length

5 1 497GB2125 Fitting, 90-degree elbow, EGR valve oil supply line at cylinder block

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d. Connect the EGR oil supply line to the cylinder block fitting.

e. Remove the bolt securing the engine harness clamp to the right-side of the timinggear cover.

f. Slide the convoluted tubing upward, then install a clamp (part No. 83AX55) overthe oil supply line. Using the existing bolt, secure both the engine position sensorharness clamp and the oil supply line clamp to the same location on the timinggear cover. Slide the convoluted tubing downward until it rests on top of the clamp.

g. Connect the oil supply line to the EGR control valve.

h. Secure the oil supply line to the EGR mass flow tube lower mounting bracket witha clamp (part No. 83AX55) and bolt (66AM44).

42. Install the new EGR mass flow sensor module to the EECU cooling plate, then connectthe mass flow sensor harness connectors to the module.

The mass flow sensor electronic module is part of the mass flowsystem assembly and must be installed along with the new tubeand sensor assembly.

43. Install the EECU.

The EECU cooling plate used on ASET™ AC engine from thebeginning of production through mid-May 2003 (cooling platepart No. 32GB460AM) has two 0.580″ diameter mounting holesat the two lower corners of the plate. The lower mountingisolators are installed through these holes, and each isolator isthen secured with two 0.188″ washers (part No. 35AX858) andone nut (part No. 189AM1).

Due to the tolerance stack-up between the thickness of thecooling plate and the dimensions of the isolators, some isolatorsmay not clamp onto the cooling plate when the nut is tightened.When this occurs, tightening the nut further will cause thewashers to rotate, which places force on the rubber portion ofthe isolator, resulting in tearing or breaking of the rubber. Toprevent this from occurring, it is recommended that anotherwasher (part No. 35AX1446X) be added between the two 0.188″washers. This should be done whenever the EECU or coolingplate is removed for any reason, or if torn or broken mountingisolators are encountered.

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The upper isolators are secured with flanged-nuts only; washers are not used. The upper mounting nuts must be tighten to 108 lb-in (12 N·m). The lower mounting isolators must be tightened to 180 lb-in (20 N·m).

Beginning May 15, 2003, the EECU cooling plate arrangement(part No. 32GB522M) was changed to include integral bushingsat the two lower mounting bolt holes. The inside diameter of theintegral bushings is 0.540″. The lower mounting isolators areinstalled through these bushings and secured by one 0.065″thick washer (part No. 26AM13) and one nut (part No. 189AM1).

The upper isolators are secured with flanged-nuts only; washersare not used. The upper mounting nuts must be tightened to108 lb-in (12 N·m), and the lower mounting nuts must betightened to 180 lb-in (20 N·m).

For warrantable repairs, the following labor code and maximum labor allowance apply:

Mack Trucks, Inc. engages in a continuous program of evaluation and testing to provide thebest possible product. While product enhancements are a natural result, Mack Trucks, Inc. isnot liable for or committed to updating existing chassis.

214 5A 23 80 3.1 hr. — Time allowed to replace two-piece EGRmass flow system with new one-piecedesign on an ASET™ AC engine, eitherPowerLeash™ -equipped or non-brake.Does not include “take-charge” time.

214 5B 23 80 2.5 hr. — Time allowed to replace two-piece EGRmass flow system with new one-piecedesign on an ASET™ AC engine equippedwith a J-Tech™ engine brake. Does notinclude “take-charge” time.

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