EGR MASS FLOW SYSTEM CONVERSION KIT (FROM TWO-PIECE TUBE WITH BELLOWS-TYPE CONNECTIONS TO ONE-PIECE TUBE WITH HOSE CONNECTIONS) ASET AC ENGINES

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1 SERVICE BULLETIN REV (Not applicable to Mack Trucks Australia) (Supersedes SB dated 2/2/04) NUMBER: SB DATE: 7/30/04 MODEL: ASET AC 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 cooled exhaust gases from the EGR cooler to the mixer tube located on the inlet manifold, the mass flow sensors, electronic control module and the connecting harnesses. These components are calibrated as a unit, and when replacement is necessary, they must be replaced as a complete 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 be replaced as a unit. Effective 12/17/03, a revised mass flow system was implemented into production beginning with engine serial No. 3Y1326. The revised mass flow system consists of a single tube (rather than the two-piece upper and lower tubes) with a revised mounting system. The EGR cold tube now uses hose connections at both ends, eliminating the bellows sections as used with the two-piece tube arrangement. Effective July 8, 2004 (beginning with engine serial No. 4N0478), the following changes were 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 that passes over the top of the engine. These sleeves protect the harnesses from heat radiated by the exhaust manifold. The retaining nut for the rear mass flow sensor is welded, just as it is on the front sensor. Both sensor retaining nuts are welded to provide a measure of tamper resistance. Previously, only the front sensor nut was welded. The components of the mass flow system (which includes the mass flow tube, sensors, module and connecting harnesses) are calibrated as a unit during manufacture. Whenever a mass flow system is replaced, the tube, sensors, harnesses and module must be replaced as a unit. DO NOT attempt to remove or replace the mass flow sensors. Whether or not one or both of the sensor retaining nuts are welded, disturbing either sensor by attempting to remove the sensor retaining nuts can result in a failure of the mass flow system to perform properly. Doing so is considered tampering or abuse which would void the warranty on the mass flow system components. SB Page 1 of 25 SERVICE PUBLICATIONS, ALLENTOWN, PA MACK TRUCKS, INC. 2004

2 REV The following part is required to repair a mass flow system on an engine already equipped with a one-piece cold tube: 206MS58M This is the only component needed. Do not order the conversion kit, oil line kit or EGR mixer tube. Should any component of a two-piece cold tube mass flow system require replacement, it will be necesary to convert from the two-piece cold tube system to the current one-piece design by using conversion kit part No. 57GC2248, together with certain additional components 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 particular application. It is also imortant to note that the mass flow system (one-piece tube with sensors and module) is NOT INCLUDED in the conversion kit. The following parts are required for a non-brake or PowerLeash -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 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 SB Page 2 of 25

3 REV 1 Figure 1 EGR Mass Flow Tube Replacement SB Page 3 of 25

4 REV 57GC2248 Mass Flow System Conversion Kit GC2112 Adapter, EGR mass flow tube mounting flange GC237M Gasket, EGR mass flow tube flange GB214 V-band clamp, EGR mass flow tube flange GB261 Coupling hose, EGR mass flow tube connections GB330M47 Clamp, EGR mass flow tube coupling hoses AM19 Bolt, EGR mass flow tube mounting clamps at exhaust manifold 2 421GC318M Bolt, button-head, EGR mass flow tube mounting clamps at EGR valve GB3581 Clamp, EGR mass flow tube mounting (upper and lower) GC236M Gasket, EGR hot tube flange AM3 Nut, EGR mass flow tube mounting bracket AM5009 Flat washer, EGR mounting bracket spacer studs GC278M Spacer stud, EGR mass flow tube mounting bracket GC228M3 Stud, EGR valve mounting (in exhaust manifold) GB323 Gasket, EGR valve mounting GB4814M Bracket, EGR mass flow tube mounting at EGR valve AX1046 Clamp, VTG actuator air line AM44 Bolt, VTG actuator air line and wire harness clamps GB356P4 Turbocharger oil feed line (from F-fitting-to-turbocharger) GB357 Oil drain line, EGR valve-to-turbocharger drain tube (NOTE: Some earlier ASET engines may utilize a 45 degree fitting at the turbocharger drain tube for the EGR valve oil drain line. If this is the case, the 45 degree fitting must be replaced with a straight fitting (part No. 497GB2124.) AM44 Bolt, wire harness clamp-to-egr tube mounting bracket AX354 Clamp, wire harness to EGR tube mounting bracket at front of exhaust manifold GB4815M Bracket, EGR mass flow tube mounting at front exhaust manifold AM6 Bolt, EGR tube mounting bracket-to-exhaust manifold The one-piece mass flow system must be ordered separately. Part number is as follows: REV A 1 206MS58M Mass flow system, one-piece tube design Depending upon engine configuration (MACK PowerLeash engine brake, J-Tech engine brake or non-brake), the following additional parts will be required: REV B 1 682GC512M EGR mixer tube required for MACK PowerLeash -equipped and non-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) SB Page 4 of 25

5 REV 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 GB356P10 Oil supply line from 4-way fitting to turbocharger AX118 Clamp, oil line at EGR valve AX55 Clamp, EGR oil supply line AM44 Screw, EGR oil supply line-to-exhaust manifold clamp (included in 57GC2248 kit) AX22 Convoluted tube (24 [610 mm] length), EGR oil supply line GB356 Oil supply line to EGR valve from cylinder block GB2125 Fitting, EGR oil supply line at cylinder block 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 module mounted to the engine electronic control unit (EECU) cooling plate. SB Page 5 of 25

6 To disconnect the sensor harness connectors from the module, slide the red secondary lock tab out, press down on the primary lock tab and then disconnect the connectors from the module. 3 Figure 3 Mass Flow System Module 1. Mass Flow Sensor Connectors 2. EECU Cooling Plate 2. Remove the engine electronic control unit (EECU), and then remove the mass flow sensor module from the EECU cooling plate SB Page 6 of 25

7 3. Loosen and remove the nuts securing the upper EGR tube support brackets to the studs on the cylinder head cover capscrews. 4 Figure 4 Upper EGR Tube Support Bracket 1. Support Bracket, Rear 2. Upper EGR Tube 3. Front Cylinder Head Cover 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. EGR Mixer 2. Upper EGR Tube SB Page 7 of 25

8 5. Loosen and remove the clamp from the flange at the upper-to-lower EGR tube connection. 6 Figure 6 Upper-to-Lower EGR Tube Connection 1. Upper EGR Tube 2. Upper-to-Lower EGR Tube Clamp 6. Remove the upper EGR tube with the sensors and sensor harness from the engine. 7 Figure 7 Removing Upper EGR Tube 1. EGR Mixer Tube 2. Upper EGR Tube 2. Lower EGR Tube SB Page 8 of 25

9 7. Loosen and remove the bolts and brackets that secure the lower EGR tube to the exhaust manifold and the water pump housing. 8. Loosen and remove the clamp from the lower EGR tube at the EGR cooler flange, then remove the tube from the engine. 8 Figure 8 Removing Lower EGR Tube Clamp 1. EGR Cooler 2. Lower EGR Tube 9. On PowerLeash -equipped and non-brake engines, the existing EGR mixer tube must be replaced with a new tube (part No. 682GC512M) as follows: If the proper mixer tube is not installed, the connection from the EGR mass flow tube to the mixer tube will not align properly, which could result in failure of the EGR mass flow tube, coupling hose or both. a. At the mixer tube, disconnect the harness connectors from the charge air cooler outlet 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. SB Page 9 of 25

10 9 c. Remove the capscrews that attach the mixer tube to the inlet manifold, then remove the tube. Figure 9 EGR Mixer Tube 1. Charge Air Pressure Sensor 2. Charge Air Temperature Sensor 3. Pressure Relief Valve 4. EGR Mass Flow Tube 5. Mixer Tube 6. Capscrews d. Clean and inspect the mixer tube mounting collar on the inlet manifold and place a small amount of clean engine oil on the mixer tube O-ring. SB Page 10 of 25

11 10 e. Place the mixer tube in position on the inlet manifold and install the two mounting capscrews. Tighten the capscrews to 40 lb-ft (55 N m). Figure 10 Installing EGR Mixer Tube 1. Mixer Tube 2. Inlet Manifold 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 and temperature sensors. 10. Disconnect the oil supply line from the turbocharger bearing housing. Temporarily cap the fitting to prevent the entry of dirt and debris. Cut the tie wraps that secure the line to the 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. VTG Actuator Air Line 2. Turbocharger Oil Supply Line 3. F-Fitting SB Page 11 of 25

12 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 1. EGR Valve 2. Turbocharger Oil Drain Tube 3. Oil Return Line REV On some earlier ASET AC engines, the turbocharger drain tube may have a 45 degree fitting at the EGR valve oil return line connection. The 45 degree fitting must be replaced with a straight fitting (part No. 497GB2124). 12. Disconnect the turbocharger oil supply line from the F-fitting, and then remove the line from the engine. 13. On J-Tech -equipped engines, disconnect the oil supply line from the four-way fitting located on the left-hand side of the engine (between the front and rear cylinder head covers) and from the F-fitting. Temporarily cap the four-way fitting to prevent the entry of dirt and debris. SB Page 12 of 25

13 REV Stainless steel braided hoses will crimp shut if not handled or installed correctly. If the steel braid has been kinked, it pinches the inner tube, and even if the steel braid is straightened, the inner tube will remain pinched. Caution must be used not to bend or twist the steel braided line to the point where it becomes kinked. If the line has been kinked, it must be replaced to eliminate turbocharger damage resulting from restricted oil flow. 14. Disconnect the oil supply line from the EGR valve. This line must be disconnected in order to route the mass flow sensor harness wires. Install a plug in the fitting and in the open end of the supply line to prevent the entry of dirt and debris. REV On J-Tech -equipped engines, the EGR oil supply line will be replaced with a new line that is routed from the front of the cylinder block. REV 15. On J-Tech -equipped engines, remove the F-fitting and mounting bracket. 13 Figure 13 Disconnect Oil Lines 1. EGR Valve Oil Supply Line 2. Turbocharger Oil Supply Line 3. Oil Line 4. F-fitting (remove on J-Tech -equipped engines) SB Page 13 of 25

14 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 EGR cooler. Remove the hot tube from the engine. 14 Figure 14 EGR Hot Tube 1. EGR Hot Tube 2. EGR Valve 3. EGR Cooler 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 Valve 2. Exhaust Manifold SB Page 14 of 25

15 19. Remove the two EGR valve mounting studs located on the outboard side of the exhaust manifold, and the one mounting stud located on the inboard side of the manifold 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 exhaust manifold. These studs, which are longer than the original studs, are required so that the EGR 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 of the exhaust manifold. 17 Figure 17 Installing EGR Valve Gasket 1. EGR Valve Gasket 2. Exhaust Manifold SB Page 15 of 25

16 22. Place the EGR valve in position on the exhaust manifold, then install the washers and retaining 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 and debris entering the system can cause blockage inside the EGR cooler core or the EGR valve. 24. Position new wire-mesh gaskets (part No.449GC236M) in both flanges of the EGR hot tube. Place the tube in position on the EGR valve and EGR cooler flanges and install the clamps. Tighten the clamps to 110 lb-in (13 N m). REV Whenever the EGR hot-tube clamps are removed, the T-bolts (part No A920082) and nuts (part No A920030) 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 valve mounting studs that were previously installed. Tighten the spacer studs to 40 lb-ft (54 N m). 18 Figure 18 Installing Spacer Studs GC278M Spacer studs SB Page 16 of 25

17 26. Place a flat washer (part No. 271AM5009) on the top of each spacer stud. 19 Figure 19 Place Flat Washer on Spacer Studs AM5009 Flat washers 27. Place the EGR tube upper mounting bracket (part No. 158GB4814M) on the spacer studs. Secure the mounting bracket with three nuts (part No. 189AM3). Tighten the nuts to 40 lb-ft (54 N m). 20 Figure 20 EGR Tube Upper Mounting Bracket AM3 Nuts GB4814M Upper mounting bracket, EGR tube SB Page 17 of 25

18 REV 28. On J-Tech equipped engines, install and clamp the turbocharger oil supply line and the VTG actuator air line as follows: 21 Figure 21 Turbocharger and VTG Air Line Installation GB356P10 Turbocharger oil supply line, J-Tech -equipped engines only AX118 Clamp, turbocharger oil supply line AX1046 Clamp, VTG actuator air line AM44 Bolt, M8 x 1.25 x 16 mm 5 1 (existing) VTG actuator air line REV a. Install the turbocharger oil supply line (part No. 744GB356P10) to the existing four-way fitting. b. Install the smaller clamp (part No. 83AX1046) over the VTG actuator air line and the 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 mounting bracket with a bolt (part No. 66AM44). Position the lines for optimum routing, and then tighten the bolt. 29. On non-brake and PowerLeash -equipped engines, clamp the VTG air line to the EGR mass flow tube mounting bracket tang, and connect the turbocharger oil supply line (part No. 744GB356P4) to the F-fitting. SB Page 18 of 25

19 30. Install the EGR tube lower mounting bracket (part No. 158GB4815M) on the boss at the 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 GB4815M Lower mounting bracket, EGR tube AM6 Bolt, lower mounting bracket 31. Install a new EGR mass flow tube gasket (part No. 449GB237M) onto each of the EGR mass flow tube coupling adapters (part No. 670GC2112). 32. Install the coupling adapters to the EGR cooler and the EGR mixer flanges using band clamps (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) GB214 Band clamp, EGR mass flow tube coupling flange GC2112 Coupling flange, EGR mass flow tube SB Page 19 of 25

20 33. Slide a hose clamp (part No. 180GB330M47) onto each coupling flange (both at the EGR 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 cooler connections. Slide the coupling hoses onto the adapters and secure with the hose clamps. 24 Figure 24 EGR Mass Flow Tube Hose Connections (EGR Cooler Connection Shown) GB330M47 Hose clamp, EGR coupling hose GB261 Coupling hose, EGR mass flow tube REV 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 at the 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 AM19 Bolts, EGR mass flow tube mounting clamp at exhaust manifold 2 421GC318M Bolts, button-head, EGR mass flow tube mounting clamp at EGR valve GB3581 Clamp (upper and lower halves), EGR mass flow tube mounting SB Page 20 of 25

21 37. Route the turbocharger oil supply line and the VTG actuator air line over the top of the EGR mass flow tube, and then connect the oil line to the turbocharger and the air line to the VTG actuator. 26 Figure 26 Turbocharger Oil Supply and VTG Actuator Air Lines (J-Tech -Equipped Shown) 1. Turbocharger Oil Supply Line 3. VTG Actuator Air Line 38. Connect the EGR valve oil return line (part No. 744GB357) between the EGR valve and the turbocharger oil drain tube. 27 Figure 27 EGR Valve Oil Drain Line GB357 Oil drain line, EGR valve SB Page 21 of 25

22 39. Secure the engine harness to the EGR tube mounting bracket at the front exhaust manifold using a clamp (part No. 83AX354) and bolt (part No. 66AM44). 28 Figure 28 Engine Harness Clamped to EGR Tube Mounting Bracket AX354 Clamp, engine harness-to-egr tube mounting bracket AM44 Bolt, engine harness clamp 40. On PowerLeash and non-brake engines, connect the oil supply line to the EGR control valve. SB Page 22 of 25

23 REV 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) GB356 Oil supply line, EGR control valve AX55 Clamp, oil line-to-mass flow tube lower bracket, and oil line-to-timing gear cover AM44 Bolt, oil line clamp-to-mass flow tube lower bracket AX22 Convoluted tubing, 24 (610 mm) length GB2125 Fitting, 90-degree elbow, EGR valve oil supply line at cylinder block a. Remove the plug from the cylinder block oil supply port, then install the 90 degree elbow fitting (part No. 497GB2125). Install with the fitting facing up. b. Install a 24 (610 mm) length of convoluted tubing (part No. 796AX22) over the EGR valve oil supply line (part No. 744GB356). c. Route the oil line from the EGR valve location to the cylinder block fitting. The line is to be routed inboard of the EGR cooler coolant supply pipe and inboard of the EGR valve and turbocharger harnesses. SB Page 23 of 25

24 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 timing gear cover. f. Slide the convoluted tubing upward, then install a clamp (part No. 83AX55) over the oil supply line. Using the existing bolt, secure both the engine position sensor harness clamp and the oil supply line clamp to the same location on the timing gear 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 with a clamp (part No. 83AX55) and bolt (66AM44). 42. Install the new EGR mass flow sensor module to the EECU cooling plate, then connect the mass flow sensor harness connectors to the module. 43. Install the EECU. The mass flow sensor electronic module is part of the mass flow system assembly and must be installed along with the new tube and sensor assembly. The EECU cooling plate used on ASET AC engine from the beginning of production through mid-may 2003 (cooling plate part No. 32GB460AM) has two diameter mounting holes at the two lower corners of the plate. The lower mounting isolators are installed through these holes, and each isolator is then secured with two washers (part No. 35AX858) and one nut (part No. 189AM1). Due to the tolerance stack-up between the thickness of the cooling plate and the dimensions of the isolators, some isolators may not clamp onto the cooling plate when the nut is tightened. When this occurs, tightening the nut further will cause the washers to rotate, which places force on the rubber portion of the isolator, resulting in tearing or breaking of the rubber. To prevent this from occurring, it is recommended that another washer (part No. 35AX1446X) be added between the two washers. This should be done whenever the EECU or cooling plate is removed for any reason, or if torn or broken mounting isolators are encountered. SB Page 24 of 25

25 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 bushings at the two lower mounting bolt holes. The inside diameter of the integral bushings is The lower mounting isolators are installed through these bushings and secured by one thick washer (part No. 26AM13) and one nut (part No. 189AM1). The upper isolators are secured with flanged-nuts only; washers are not used. The upper mounting nuts must be tightened to 108 lb-in (12 N m), and the lower mounting nuts must be tightened to 180 lb-in (20 N m). For warrantable repairs, the following labor code and maximum labor allowance apply: REV REV 214 5A hr. Time allowed to replace two-piece EGR mass flow system with new one-piece design on an ASET AC engine, either PowerLeash -equipped or non-brake. Does not include take-charge time B hr. Time allowed to replace two-piece EGR mass flow system with new one-piece design on an ASET AC engine equipped with a J-Tech engine brake. Does not include take-charge time. Mack Trucks, Inc. engages in a continuous program of evaluation and testing to provide the best possible product. While product enhancements are a natural result, Mack Trucks, Inc. is not liable for or committed to updating existing chassis. SB Page 25 of 25

Actions Required to Avoid Repeat Turbocharger Failures

SERVICE BULLETIN (Also applies to Mack Trucks Australia) (Supersedes SB214020 dated 7/26/04) Number: SB214020 Date: 07/21/05 Model: ASET, E-Tech Actions Required to Avoid Repeat Turbocharger Failures When