Service Bulletin Mack Trucks, Inc. Trucks Date Grup (Na, Release © Page 4215 237 46 «02 «9 mack. ‘This service bulletin replaces bulletin 237-59 dated 9.2013. Sleeve, Engine injector Replacement (Copper) MP7, MP8, MP10 Sleeve, Engine Injector, Replacement (Copper) Q\ CAUTION This bulletin describes important tools and procedure for injector sleeve replacement. ‘These tools and procedure replace all existing tools and procedures for copper sleeve replacement. Ifthe procedure in this bulletin not followed exactly, damage to the engine may result, Note: Failure to follow the procedure inthis bulletin exactly may result in warranty claim deni Contents “Special Tools’, page 2 * “Sleeve, Engine injector, Replacement (Copper)" page 4 \Note: Information s subject to change without notice. IMustrations are used for reference only, and may difer slightly from the actual engine version. However, Key components addressed in this information are represented as accurately as possible, Pv7i 7689198181 saro2soMack Trucks, Inc. fn Gee Fe to Peas Service Bulletin 4205-237 46 206 Tools Special Tools For special tools ordering instructions eer to Tools Informa- tion, Function Group 08, s90ce65 s098249 9990250 Frye Turing Took, Protection Sleeve Fuel Bore Sealing Ring 9990261 oso82s2 990259 Seating Plug “Topping Tol Ecractor 200014 8000196 ssss0054 Flywhe! Turing Tot ‘Sleeve instalation Too wedging | onto 88800281 Forming Tap, M8.5 / ‘88800282 Btractor Bit, Ma.5 2815-2700 or 85112740, Coolant Extractor 3BMack Trucks, Inc. Service Bulletin Date «Group, No, Rosse Page 425-237 46 02 58) 5 Remove the valve cover. Refer to Function Group 211 for procedure. Note: Rotate the valve cover as needed, to clear the cam- shaft gear and damper. Note: Dependent upon chassis, engine cover may need to bbe removed for clearance to remove valve cover. 6 Remove the rocker shaft Refer to Function Group 214 for procedure, 7 Remove the engine brake control valve, if equipped. Refer to Function Group 253 for procedure. 8 ‘Thoroughly clean around the engine injectors that are to be removed. Remove the engine injectors). Referto Function Group 237 for procedure. ° Install the protective sleeve over the engine injector to pre- vent damage, 098249,Mack Trucks, Inc. pate «Group No. Release Page Service Bulletin 4205-237 AG 02 st) 18 install ap holderin the engine injector bore. Apply moderate downward force to get the tap started while turning the tap handle clockwise, Continue turning in the same direction, ‘without reversing, unil the copper sleeve is tapped all the ‘way through. The shoulder ofthe tap handle bottoms on the copper sleeve. Ensure that the tap is completely through the copper sleeve QA CAUTION threads are not cul completely through the tip of the cop~ per sleeve, the tip can break off and fall into the cylinder. This can result in damage to the cylinder, piston, valves or turbocharger. These types of failures are not covered by warranty. 19998252, 88800261 17 Install the extractor bot into the end of the extractor tool. Ad-~ just the bolt untilit extends approximately 22 mm (0.9 inch) 16 Remove the tap and tapping tool beyond the end of the tool (dimension A). ‘38800282, 9998253 \) 18 Tighten the set screw ofthe extracortooto secure the bot fake sure thatthe set screw is seated against the flat part of the extractor botMack Trucks, Inc. Service Bulletin ry == 9999253 Date Group Release Page No 42016 237 46 02 og 19 A\ CAUTION Make sure the extractor boltis threaded completely into the copper sleeve before attempting to remove itor the tip of the sleeve may break off as it is removed. This broken sleeve tip can seriously damage the piston, valves or tur- bocharger. These types of failures are not covered by warranty, Lubricate the threads of the forcing screw on the puller. Lubri- cate under the face of the nut, Place the extractor tool with the bolt into the injector bore. Make sure the nut on the spin- dle is backed off so that the threaded end can be completely installed through the copper sleeve tip, Hand tighten until the bolt bottoms out in the sleeve. Note: Ifitis necessary to replace other copper sleeves, con- tinue the procedure on pairs of companion cylinders (1 and 6, 2and 5, 3.and 4). Itis necessary to rotate the crankshaft {and place each pair of companion cylinders at the lowest po- sition in the cylinder. 20 While holding the top of the tool stationary, turn the large nut Clockwise to extract the copper sleeve Note: When the copper sleeve is removed, make sure that the extractor boltis extended at least one thread beyond the copper sleeve. If not, make sure that no part of the copper sleeve has broken off and fallen into the cylinder. Q\ CAUTION ee Do not use air tools to remove copper sleeves, or damage to the injector bore can result, | 9998253 2 ‘Absorb any remaining coolant with a lint-free cloth. Note: Check that the piston is free of any fluids.Mack Trucks, Inc. Service Bulletin 920.1 mm bate No. Release Page Group 42523746 02 1306) 4 Q\ CAUTION Failure to use the proper bit can resuitin the bit breaking off into the cylinder head. These types of falures are not covered by warranty. Using calipers, measurethe swedging bit to make sure that the proper swedging toolis used. Measurement should read 7.90.05 mm, Also, vey thatthe swedging bit has four ‘stages and the length is 120 mm, ‘wossrt Note: Any swedging bit wom past the tolerance must be replaced Note: Swedging bit 88880054 can be ordered as a spare parti the bit is worn or broken, 38880054 5 Place the new injector sleeve on the installation tool. Thread the swedging bit completely into the flaring tool unt it stops (finger tight) Lubricate the swedging bit and the threads on the tool with fresh, extreme pressure NLGI#2 grease or equivalent. Note: Do not place the injector nozzle gasket (Nat washer) in the copper sleeve, as this will damage the swedging bit A CAUTION Before installing the sleeve on the installation too), inspect the toolo ensure that tis the correct tool. The correct tool | identifed by a bottom surface that is perfectly lat with no ‘machined circular recess. Use of a tool with a machined circular recess on the bottom may result in damage tothe copper sleeve, vwoozn 800196,