Service Bulletin

Mack Trucks, Inc.

Greensboro, NC USA Trucks
Date Group No. Release Page

10.2011 253 20 01 1(10)

Control Valve, Engine Brake, Replacement

MP10 Euro5
CLX, CXX

Control Valve, Engine Brake, Replacement

This information covers the procedures for replacing the engine brake control valve on
MACK CLX and CXX model vehicles equipped with the MP10 Euro5 engines.

Note: This service bulletin applies to MACK Trucks Australia.

Contents
• “Control Valve, Engine Brake, Replacement”, 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.

PV776-89032902 USA50329
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 10.2011 253 20 01 2(10)

25302-2
Control Valve, Engine Brake, Replacement
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 the procedure.

DANGER
Do not attempt to repair or service this vehicle without
sufficient training, the correct service literature and the
proper tools. Failure to follow this could make the vehicle
unsafe and lead to serious personal injury or death.

DANGER
Before working on a vehicle, set the parking brake, place
the shift lever in Neutral, and block the wheels. Failure to
do so can result in unexpected vehicle movement and can
cause serious personal injury or death.

1
1
Apply the parking brake and place the shift lever in
neutral.
2
2
Unlatch and raise the hood.
3
3
Remove all cables from the negative (ground) battery
terminals to prevent personal injury from electrical shock
and damage to electrical components.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 10.2011 253 20 01 3(10)

4
4
Remove the fasteners attaching the left-side fender
extension and remove the fender extension from the
vehicle.

Note: Store the left-side fender extension in a secure

location for later reinstallation.

W2067444

5
5
Loosen the clamps and remove the Y-pipe and the fresh
air pipes from the turbocharger and air cleaners.

W2068025
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 10.2011 253 20 01 4(10)

6
6
Remove the fasteners attaching the crankcase ventilation
tube to the valve cover.

Note: The two fasteners differ in length. Note the location

of each fastener so it can be used at the same location
during installation.

W2067368

7
7
Remove the P-clamp that attaches the crankcase
ventilation tube to the intake manifold.
8
8
Loosen the band clamps attaching the end of the
crankcase ventilation tube to the separator and remove
the tube from the engine.
9
9
Remove the fasteners securing the valve cover to the
engine and lift the valve cover off the engine.

W2068027
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 10.2011 253 20 01 5(10)

10
10
Thoroughly clean the area around the solenoid brake
control valve.
11
11
Disconnect the wiring harness from the solenoid brake
control valve connector.

W2068390

12
12
Cut the cable ties securing the fuel injector electrical
wiring harness to the top of the control valve and move
the harness out of the way.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 10.2011 253 20 01 6(10)

13
13
Remove the engine brake valve mounting fasteners.
Remove the defective engine brake control valve, along
with the spacer and the oil pipe between the control valve
and rocker arm shaft. Discard the old seals.

W2068391

14
14
Install a new O-ring at the bottom of the replacement
control valve.
15
15
Clean the cylinder head sealing surface for the engine
brake control valve. Check that there is no dirt in the
cylinder head oil gallery.
16
16
Install new O-rings on each end of a new engine brake
control valve oil pipe. Using clean engine oil, lubricate
the pipe hole in the rocker arm shaft and the O-rings on
the oil pipe.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 10.2011 253 20 01 7(10)

17
17
Insert the oil pipe into the oil hole of the replacement
engine brake control valve. Make sure that the O-ring is
seated fully in the control valve.

W2004854

18
18
Using a new engine brake control valve sealing washer,
position the replacement engine brake control valve on
the cylinder head.
19
19
Before securing the control valve to the cylinder head,
align the engine brake oil pipe and O-ring with the hole in
the rocker shaft.

W2004857
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 10.2011 253 20 01 8(10)

20
20
Use the engine brake control valve bolts to attach
the control valve to the cylinder head and tighten to
specification; refer to Function Group 20, Specifications.

Note: Make sure the engine brake oil pipe O-ring is fully
seated.

W2068391

21
21
Plug the engine brake control valve wiring harness into
the control valve connector and secure the wiring harness
with cable ties as needed.

W2068390

22
22
Reposition the fuel injector electrical wiring harness over
the control valve and secure the harness to the control
valve with cable ties.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 10.2011 253 20 01 9(10)

23
23
Clean and inspect the valve cover seal and sealing
surface on the cylinder head. Replace the seal, if
necessary.
24
24
Position the valve cover onto the cylinder head and install
the attaching bolts in the valve cover. Tighten the valve
cover bolts to specification.
25
25
Using band clamps, install the lower end of the crankcase
ventilation tube to the separator; use the P-clamp to
attach the crankcase ventilation tube to the intake
manifold and attach the upper end of the tube to the
valve cover using the fasteners. Tighten fasteners to
specification.

Note: Use new seals; inspect the O-ring and replace if

necessary.

CAUTION
The two bolts attaching the upper end of the tube to
the valve cover are different lengths. Be sure to use
the bolts at the same position they were removed. The
valve cover will be damaged if the longer bolt is used
at the wrong location.

W2067368
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 10.2011 253 20 01 10(10)

26
26
Using the clamps, install the Y-pipe and the fresh air
pipes to the turbocharger and air cleaners.

W2068025

27
27
Use the fasteners to attach the left-side fender extension
to the vehicle.

W2067444

28
28
Install all previously removed cables to the negative
(ground) battery terminals.
29
29
Start the engine and check for oil leaks and proper
operation.
30
30
Close and latch the hood.