Service Bulletin
Mack Trucks, Inc.
Greensboro, NC USA Trucks
Date Group No. Release Page
This service bulletin replaces bulletin
213-43 dated 7.2009. 7.2011 213 43 02 1(11)
Piston and Liner, Replacement
MP8
Piston and Liner, Replacement
T2022501
Contents
• “Piston and Liner, Replacement (One)”, page 2
Note: Information is subject to change without notice.
Illustrations are used for reference only and may differ slightly from the actual vehicle
being serviced. However, key components addressed in this information are represented
as accurately as possible.
PV776-89027178 USA49620
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 7.2011 213 43 02 2(11)
2131-03-03-02
Piston and Liner, Replacement (One)
Cylinder head and oil pan removed
You must read and understand the precautions and guidelines in Service Information,
group 20, "General Safety Practices, Engine" before performing this procedure. If you
are not properly trained and certified in this procedure, ask your supervisor for training
before you perform it.
The cylinder liner O-rings are made of fluorocarbon rubber.
When fluorine-rubber is exposed to high temperatures (above 300 °C/
572 °F) hydrofluoric acid can be generated. Hydrofluoric acid is extremely corrosive!
• Contact with skin can result in serious corrosion injuries.
• Splash in the eyes can result in corrosion sores.
• Inhalation of vapors can damage the respiratory tract.
WARNING
Take great care when working on engines which can
have been exposed to high temperatures, resulting
for example from overheating, cutting or fire.
Under no circumstances are cylinder liner O-rings to
be burnt off when dismantling or destroyed by burning
under uncontrolled conditions.
• Always use neoprene gloves (gloves approved for handling chemicals) and protective
goggles.
• Handle removed O-rings in the same way as corrosive acids.
• Never blow clean using compressed air.
All remnants, including ashes, can be highly corrosive.
• Place all remnants in plastic containers, to which warning text is attached.
• Before taking the gloves off, they must be washed under running water.
Special tools: 9989876, 9990158, 9996394,
9996395, 9996599, 9996606, 9996645,
85109123, PT-6400-C, 9998511, 9992479,
8880014
Remove
1
1
Remove the pipe and strainer from the reinforcing frame.
Remove the pressure pipe from the pump. Remove the
reinforcement frame.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 7.2011 213 43 02 3(11)
2
2
Remove the plug from the flywheel housing and install
turning tool. Turn the crankshaft until it is possible to
get at the screws on the connecting rod which is to be
removed.
88800014
T2022378
3
3
Remove the piston cooling jet.
T2022286
4
4
Remove main bearing cap and bearing shells.
5
5
Remove the piston with the connecting rod.
T2022287
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 7.2011 213 43 02 4(11)
6
6
Pull the cylinder liner out of the block.
PT-6400-C
W2005255
7
7
Remove the cylinder liner sealing rings.
T2019854
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 7.2011 213 43 02 5(11)
8
8
Remove the snap ring from the piston and push out the
piston pin. Remove the piston from the connecting rod.
T2022501
9
9
Clean the sealing surfaces on the cylinder block and the
groove for the sealing rings. Do not use scrapers or other
tools which can damage the sealing surfaces.
Installation
10
10
Check the cylinder block liner seat for damage.
11
11
Install the cylinder liner, without the sealing ring. Fix the
cylinder liner with two clamping tools.
85109123
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 7.2011 213 43 02 6(11)
12
12
Mount dial gauge in dial indicator holder. Place the holder
with the dial gauge across the cylinder liner. Zero the
dial gauge with a couple of millimeters preload against
the cylinder block’s surface.
9989876, 9992479
T2019670
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 7.2011 213 43 02 7(11)
13
13
Measure the height between the cylinder liner and the
cylinder block surface. Measure the liner height at two
different diagonally opposite positions. Calculate the
average of both the measurements.
For correct liner height above the block surface see
specifications, Function Group 20. If the height of
the liner above the surface of the block is outside the
specified tolerance, the liner seat on the cylinder block
should be milled.
Note: Always measure at the highest point on the sealing
surface.
T2019761
14
14
Mark the liner position on the cylinder block with a felt
tip pen, so that it will be put back in the same position
on assembly. Repeat the procedure for the remaining
cylinder liners.
15
15
Remove the press tool. Pull the cylinder liner out of the
block. Place cylinder liners in the same sequence that
they are installed, together with their adjustment spacers.
PT-6400-C
W2005255
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 7.2011 213 43 02 8(11)
16
16
Install the liner sealing rings to the engine block.
Note: The purple sealing ring is installed furthest down.
T2019854
17
17
If the liner is installed with a shim, a bead of sealing
compound should be put on the engine block liner seat.
Note: No sealant is to be used between the adjustment
spacer and the cylinder liner’s collar.
Note: Once the sealing compound has been applied,
the liner must be installed within 20 minutes. If the
cylinder head cannot be installed and tightened within 20
minutes, the liner must be fixed in the engine block with
two press tools.
T2009013
85109123
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 7.2011 213 43 02 9(11)
18
18
Install one of the cylinder head bolts (A). Position press
tool (D) above the cylinder liner together with a suitable
spacer (C) and press the cylinder liner down using lever
(B).
9996599, 9996963, 9998511
T2019950
19
19
Lubricate the piston pin and the piston bushing with
engine oil.
T2022502
20
20
Install the connecting rod in the piston with the marking
“FRONT” on the connecting rod and the arrow on the
piston facing the same direction. Push the piston pin in.
Install the snap ring.
Note: The piston pin should go in when pushed without
any great force. If the resistance is too great, the piston
needs to be heated. The connecting rod should rotate
freely on the piston pin.
T2022504
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 7.2011 213 43 02 10(11)
21
21
Using piston ring pliers, install the piston rings. Regarding
the oil ring, the gap in the spring should be situated
diametrically opposite the ring gap.
Note: All the piston rings (even the oil scraper) are
marked with letters or punch marks. These marks should
face upwards.
22
22
Lubricate the piston and the piston rings with engine oil.
Check that the piston rings gaps are radically displaced.
The piston ring gaps should be situated with the equal
spacing in relation to one another 60°.
23
23
Use a piston ring compressor to insert the piston with its
connecting rod. Temporarily remove the press tool when
the piston is installed. Reinstall the press tools when the
piston is in position.
9998531, 85109123
W2006211
24
24
Lubricate the crankshaft bearing shells and crankshaft
pin with engine oil. Install the connecting rod caps.
Check that they sit correctly in the connecting rod and
caps. Install the connecting rod cap according to the
markings and tighten to specification.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 7.2011 213 43 02 11(11)
25
25
Clean the piston cooling jet and check that it is not
damaged. Install the piston cooling jet with new bolts.
Tighten to specification.
Note: Use only new bolts, pretreated with locking
material.
T2022286
26
26
Remove cranking tool and replace the plug.
88800014
27
27
Install the reinforcement frame and tighten specification.
Install the pressure pipe on the pump and tighten
to specification. Install the pipe and strainer on the
reinforcement frame. Secure the bolts with thread lock
and tighten to specification.
