NHTSA ID Number: 10045822
Manufacturer Communication Number: PI-0796
TSB/Document Date: 2012-09-18
Summary
MACK TRUCK
: INFORMATION PROVIDED REGARDING MODIFICATION OF EGR VALVE ON ENGINES AND REMOVAL OF POPPET SHAFT END CAP O RINGS. MODELS CHU, CXU, GU, LEU, MRU. NO MODEL YEARS LISTED. *PE
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TSB/Document ID: PI-0796
Replacement Service Bulletin Number:
MFR Communication Date: 2012-08-01
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:GAS RECIRCULATION VALVE (EGR VALVE)
MFR Component System:
MFR Component Subsystem:
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SB-10045822-3750
S ervic e P rogram
Tr u c k s
M a c k Tr u c k s , I n c .
Greensboro, NC USA
This Service Program replaces program PI0796 dated 7.2012.
Date
Group
No.
Release
Page
8.2012
293
014
02
1(12)
EGR Valve Modification
MP7 and MP8 US2010
CHU, CXU, GU, LEU, MRU
P I 0 7 9 6 , E G R Va l v e M o d i f i c a t i o n
(Au gust 2 012)
Mack Trucks has authorized an EGR valve modification on certain EPA2010 emission level
vehicles equipped with MACK MP7 and MP8 engines built April through June 2012 that have
accumulated less than 8000 km (5000 mi). The poppet shaft end cap O-rings must be
removed from the EGR valves on these engines. The O-rings were designed to be consumed
during the first major heat cycle, but cases have been reported where the O-rings have
caused the valve to malfunction. N o a c t i o n i s r e q u i r e d o n v e h i c l e s t h a t h a v e a c c u mu l a t e d
8 0 0 0 k m ( 5 0 0 0 mi ) o r m o r e a s t h e O - r i n g s h a v e b e e n c o n s u me d a s d e s i g n e d . Before
proceeding, verify campaign eligibility by checking Service Program status in eWarranty.
CA UTION
Removal and installation of EGR valve can cause progressive damage if care is not taken.
Please ensure that all components and mounting surfaces are clean and free of debris
before removal and reassembly.
N o t e : This bulletin does not apply to Mack Trucks Australia.
P a rt s R equi re d
P art N u mber
De sc riptio n
20850815
EGR Valve Gasket (1)
20841816
Hot Pipe Gaskets (2)
21007187
Diffuser Gasket (1, MP7 only)
21095721
Exhaust Piping Gasket (1 for MP7, 2 for
MP8)
976014
N o t e : Part number 976014 O-rings come in quantity of 25.
For this procedure the existing EGR mounting bolts and EGR hot pipe mounting clamps are
to be reinstalled unless damaged.
P V 7 2 9 - PI0796
USA55094
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
8.2012
Group
No.
Release
293
014
02
P roc edu re
You must read and understand the precautions and guidelines in Service Information,
Function Group 20, "Engine Safety Practices" before performing this procedure. If you are
not properly trained and certified in this procedure, ask your supervisor for training before
you perform it.
1 Apply parking brake and place shift lever in neutral.
2 Remove all cables from ground (negative) battery terminals to prevent personal injury from
electrical shock.
3 Remove EGR valve from engine. Refer to Function Group 29.
4 Secure valve in vise, do NOT clamp on the EGR valve mounting surface. Remove 4
fasteners from EGR valve. Remove hydraulic actuator with heat shield, end cap and
poppet from casting. Retain spacer for reassembly.
N o t e : Mark orientation of actuator before removing from casting.
W2075169
Page
2(12)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
8.2012
Group
No.
Release
293
014
02
5 Remove T-shaped clevis joint on shaft by pushing the shaft in opposite directions to
separate actuator and heat shield from end cap and poppet.
W2075291
Page
3(12)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
8.2012
6 Retain the clevis joint washer for reassembly.
W2075099
W2075265
Group
No.
Release
293
014
02
Page
4(12)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
8.2012
Group
No.
Release
293
014
02
7 Remove the poppet shaft from end cap.
N o t e : If the shaft is stuck and can not be removed from the casting, replace the EGR valve
using part kit number 85133799.
W2075295
8 Remove internal O-ring from end cap and discard. Check the bore surface and remove
any additional debris.
W2075167
Page
5(12)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
8.2012
Group
No.
Release
293
014
02
9 If O-ring has been consumed, make sure any debris is thoroughly cleaned and removed.
W2075306
10 Remove end cap external O-ring and discard.
W2075168
Page
6(12)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
8.2012
Group
No.
Release
293
014
02
11 Clean the end cap with proper cleaning material/solution to remove debris from the bore
and enclosure area.
CAUTION
Removal and installation of EGR valve can cause progressive damage if care is not
taken. Please ensure that all components and mounting surfaces are clean and free of
debris before removal and reassembly.
12 Install poppet shaft in end cap. Slide the end cap to the poppet flange providing the
maximum visibility and clearance for poppet and piston coupling.
N o t e : Shaft should slide with no interference in the end cap bore. If interference exists,
make sure all debris is removed from end cap bore. If cleaning does not allow shaft to slide
with no interference, replace EGR valve using part kit number 85133799 and file under
standard warranty procedures.
W2075282
Page
7(12)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
8.2012
Group
No.
Release
293
014
02
13 Position clevis joint washer with dished side toward the hydraulic actuator.
W2075281
14 Connect the shaft clevis joint.
W2075291
Page
8(12)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
8.2012
Group
No.
Release
293
014
02
15 Position end cap aligning orientation marks on casting with spacer and install fasteners.
16 Tighten fasteners in three stages as shown.
W2075169
Stage 1
Tighten fasteners 1 and 4 to 40 in-lbs, then
tighten fasteners 2 and 3 to 40 in-lbs.
Stage 2
Tighten fasteners 2 and 3 to 120 in-lbs,
then tighten fasteners 1 and 4 to 120 in-lbs
Stage 3
Retighten fasteners 2 and 3 to 120 in-lbs,
then tighten fasteners 1 and 4 to 120 in-lbs
17 Activate poppet by hand to ensure proper function.
Page
9(12)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
8.2012
Group
No.
Release
293
014
02
18 Mark the valve with a punch to indicate work completed.
W2075266
19 Install new gaskets into the EGR valve end of the hot pipe and the inlet of the EGR cooler.
Make sure the gaskets lay flat against the flange surfaces with the bead of the gaskets
facing toward the hot pipe. Install EGR valve. Refer to Function Group 29. For this
procedure the existing EGR mounting bolts and EGR hot pipe mounting clamps are to be
reinstalled unless damaged.
CAUTION
Hot pipe gaskets can easily slip out of position causing damage to turbocharger. Please
insure gaskets are securely in place when reinstalling pipe.
W2006187
Page
10(12)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
8.2012
Group
No.
Release
293
014
02
20 Reconnect all previously removed cables to the negative (ground) battery terminals.
21 Start the engine. Check for leaks and proper operation.
22 To signify that the campaign has been completed, using a permanent-type marker (such
as a Sharpie®) to write the campaign number (PI0796) and completion date in the spaces
provided on the Campaign Completion label located inside the cab as shown in the
illustration below. If a label is not already affixed inside the cab, apply a label (part number
TS897) and supply the information as required. Campaign Completion labels are available
in packs of 50 and can be ordered by faxing a completed BR313 to Pacesetters Business
Services at 610-264-9465.
W8034103
Page
11(12)
M a c k Tr u c k s , I n c .
S e rv ic e P ro gra m
Date
8.2012
Group
No.
Release
293
014
02
R ei mbu rs ement
Thi s repai r is c ov ered by an aut hori z ed S erv i c e P rogram. R ei mburs ement i s
obt ain ed v i a the n ormal c l ai m hand li ng proc es s .
C l a i m Ty p e ( u s e d o n l y w h e n u p l o a d i n g f r o m t h e D e a l e r B u s .
Sys.)
41
Rec all Sta tus
Vehicle inspected, repair not required
1- Inspected OK
Vehicle repaired per instruction
2- Modified per
instruction
Labor Code
Primary Labor Code for EGR Valve Modification
2145G-01-96 —
0.3 hrs
Labor Code for EGR Removal and Installation
214QD-36-45
•
CHU, CXU GU
with MP7 —
2.8 hrs
•
LEU, MRU with
MP7 — 1.5 hrs
214QD-37-45
•
CHU, CXU,
GU, MRU with
MP8 — 1.7 hrs
Time to take charge and determine campaign status
101AA–0A–00 —
0.3 hrs
Caus al P art Number
20940438
Other Ma teri al s
Parts Dispo sition
A ut hori z at io n N umbe r
PI0796
Ex piration Date
30–Nov–12
N o t e : Take Charge Time is not included in the Labor Code for this operation. Take charge
may be eligible but can only be used once per repair visit. If vehicle is having other warranty
repairs performed, take charge should be charged to the warranty repair, otherwise take
charge can be charged to this service program.
Page
12(12)
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