Service Bulletin

Mack Trucks, Inc.

Greensboro, NC USA Trucks
Date Group No. Release Page

1.2011 211 79 1(15)

Cylinder Head, Installation

MP8 Euro5
CMH, CMM

Cylinder Head, Installation

Contents
• “Cylinder Head, Installation”, page 2

PV776-88995497 USA45146
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2011 211 79 2(15)

Service Procedures
21124-1
Cylinder Head, Installation
Note: As the illustrations in the service literature are used for several different engine
variants, certain details may differ from the variant you are working with.
The essential information in the illustrations is, however, always correct.

Special tools: J42885, 9992669, 9996966,

85109034, 85111422, 88800014, 88800031,
88800188
1
1
Carefully clean the unit injector copper sleeves using
brush and extension.

Check that the copper sleeves are properly clean.

Poorly cleaned copper sleeves can cause leaks.

WARNING
When cleaning the unit injectors, under no
circumstances may rotary wire brushes, wire brushes
or similar tools be used on the injector nozzle. There
is a risk that this will damage or block the injector jets,
causing loss of power etc. If necessary use a rag
soaked in paraffin or similar instead.

W2006256
J42885
2
2
Clean the cylinder head bolts before reuse.

When cleaning of the cylinder head bolts under no

circumstances may rotary wire brushes, hand wire
brushes or similar tools be used. There is a risk that
the phosphate coating of the screws could be damaged
which would impair their corrosion protection.

Note: The cylinder head bolts may not be used more

than 5 times. Mark them with a punch.
T2025195
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2011 211 79 3(15)

3
3
Remove the press tools.

Carefully clean the cylinder block, cylinder head, timing

gear cover and timing gear plate. Check that the guide
washers on the engine block and cylinder head are clean
and free of rust.

Fit a new cylinder head gasket.

Note: Check that the seals are correctly positioned with

their holes all centred.

T2025185 9996966

4
4
Fit a new gasket in the coolant pipe.
5
5
Apply a 2 mm thick string of an approved sealant on the
side of the “groove” in the timing gear plate, see Function
Group 20, Specifications.

Note: Install all cylinder head bolts and all screws

through the timing gear plate in order. The cylinder head
must be fitted and tightened within 20 minutes of the
application of the sealant.

T2022794
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2011 211 79 4(15)

6
6
Carefully lower the cylinder head until it is in contact
with the cylinder head gasket. Make sure that the guide
washers (1) are correctly positioned. Press the cylinder
head onto the timing gear plate.

Make sure that the gasket in the coolant pipe is not

damaged when fitting the cylinder head.

Insert a bolt through the hub of the idler gear bolt and the
timing gear plate. Tighten bolt to specification.

88800188

W2006306

7
7
Insert 4 cylinder head bolts into locations 24, 26, 28 and
30. Tighten the bolts to specification.

Slacken off the bolt that goes through the timing gear
plate by 45°. Otherwise there is a risk that the screw will
shear off when the cylinder head bolts are tightened.

T2024951

8
8
Fit the remaining cylinder head bolts.

Torque and angle tighten the cylinder head bolts

according to the tightening diagram, see Function Group
20, Specifications.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2011 211 79 5(15)

9
9
Remove the plug from the flywheel casing and fit cranking
tool.

88800014

T2022960

10
10
Push a piece of rag into the flywheel housing to prevent
screws from falling into the engine.

Never turn round the engine whilst the rag is in place.

Fit the bolts (1) in the timing gear plate. Tighten according
to Function Group 20, Specifications.

Turn the engine so that the bolt holes in the timing gear
plate can be reached through the idler gear hole. Fit the
bolts (2) and tighten according to Function Group 20,
Specifications.

Fit the remaining bolts (3) for the idler gear in the hub.
T2025199
Tighten according to Function Group 20, Specifications.

Note: Remove the rag.

11
11
Inspect the upper and lower camshaft bearing shells
before fitting the camshaft.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2011 211 79 6(15)

12
12
Carefully lift the camshaft into place.

85109034

W2005134

13
13
Fit the camshaft bearing caps in the correct bearing
brackets.
14
14
Fit bolts to the right-hand side of the bearing brackets.
Tighten according to Function Group 20, Specifications.

Fit a spacer sleeve to the number 7 bearing bracket, to

protect the guide sleeve.

Fit shorter extra bolts to the left-hand side of the bearing

brackets. Do not fit bolts to the rocker arm bridge guide
sleeves. Tighten the bolts according to Function Group
20, Specifications.

Turn the camshaft after each tightening. If the camshaft

does not rotate easily, check the last tightened bearing
cap.

Remove the extra screws and spacer sleeve.

15
15
Install new O-rings on the unit injectors.

T2024930
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2011 211 79 7(15)

16
16
Fit the unit injectors with the yoke.

Fit the bolts. Tighten the bolts according to Function

Group 20, Specifications.

T2024928

17
17
Ensure that the camshaft mark (TDC) lies between the
markings on the bearing cap.

Check that the flywheel is at 0°.

T2022609
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2011 211 79 8(15)

18
18
Fit the camshaft gear, note the mark on the timing gear
plate.

Fit the vibration damper, spacer washer and bolts.

Tighten according to Function Group 20, Specifications.

T2025654

19
19
Check the backlash between the camshaft gear and the
adjustable idler gear.

Fit a rocker indicator against one of the teeth on the

camshaft gear and turn the gear forwards and backwards.
Read off the value on the rocker indicator and compare
with the value in Function Group 20, Specifications.

Adjust if necessary.

Note: Make sure the idler gear is locked during

measurement.

W2005136

20
20
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2011 211 79 9(15)

Install the rocker arm shaft.

21
21
Fit the electrical contact piece to the charge air sensor.

Fit a new sealing ring to the groove in the cable grommet.

Carefully thread the cable into the cylinder head.

Connect the unit injector connectors and the solenoid

valve connector. Push in the connectors until there is
a distinct “click”.

T2025656

22
22
Fit new tie straps to hold the wiring onto the control valve.

T2024956

23
23
Clean the contact surfaces on the timing gear cover,
timing gear plate and cylinder head.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2011 211 79 10(15)

24
24
Install new seals in the upper timing gear cover.

Apply sealing compound in accordance with Function

Group 20, Specifications.

Note: The timing gear cover must be fitted within 20

minutes of the sealant being applied.

T2024961

25
25
Fit the upper timing gear cover.

Fit screws in the oval holes. Do not tighten too hard.

Fit press tools. Press down the timing cover so that it is

level.

Fit the other bolts. Torque tighten according to

the tightening diagram, see Function Group 20,
Specifications.

85111422

W2006191

26
26
Wipe off any excess sealant from the joint (A) between
the cylinder head and the upper timing gear cover.

T2025659
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2011 211 79 11(15)

27
27
Turn the engine so that a tooth on the camshaft gear
wheel is in the middle of the camshaft sensor hole in the
upper timing gear cover.

88800014

T2024959

28
28
Check the distance to the camshaft gear wheel with tool
88800031.
• No edge = no adjustment shim
• One edge = one adjustment shim
• Two edges = two adjustment shims

88800031

T2024958

29
29
Fit the camshaft sensor with the correct number of
adjustment shims.

T2024962
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2011 211 79 12(15)

30
30
Adjust valves and unit injectors, see Function Group 214.
31
31
Fit the fuel line hollow screws with new seals onto the
front edge and left-hand side of the cylinder head.

T2026991

32
32
Fit the charge air hose between the intake manifold and
charge air cooler.
33
33
Fit the turbocharger, see Function Group 25.
34
34
Depending upon the model, position the air cleaner
housing against the cab and install the fasteners to
secure.
35
35
Fit the main intake air pipe between the turbocharger inlet
elbow and the air cleaner housing. Position the clamps
and secure.
36
36
Fit screws in the fan ring attachment, left and right-hand
sides.
37
37
Connect the connector to the temperature sensor.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2011 211 79 13(15)

38
38
Clean the contact surface on the valve cover, check the
gasket. If damaged replace with a new gasket.

Apply a 2 mm thick bead of sealant to the contact surface

(A) between the timing gear cover and the cylinder head.

Note: The valve cover must be fitted within 20 minutes

after the sealant has been applied.

T2025659

39
39
Fit the valve cover. Tighten according to Function Group
20, Specifications.

T2025623

40
40
Install the fasteners securing the crankcase ventilation
tube and bracket to the valve cover and intake manifold.
Tighten the fasteners to specification.

Note: Inspect the crankcase ventilation tube O-ring and

replace if necessary.

Note: Ensure that the same fasteners that were removed

at disassembly are reinstalled in the same location.
Damage to the valve cover will result if too long of
fasteners are installed.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2011 211 79 14(15)

41
41
Using fasteners previously removed, secure the
compressor air intake pipe to the cylinder head over the
valve cover.

W2063053

1 Compressor Air Intake Pipe

2 Clamps
3 Bolts
4 Nuts
42
42
Refit the clamps on the hoses connecting the compressor
air intake pipe at the compressor and at the main intake
air pipe. Tighten to secure.
43
43
Check that the thermostat and gasket are in place. Fit the
thermostat housing cover.

T2022128
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2011 211 79 15(15)

44
44
Fit the screws to the coolant pipe.
45
45
Fit the coolant hose to the thermostat housing cover.
46
46
Fill with coolant.
47
47
Bleed the fuel system. Clean up any spills.
48
48
Refit the engine cover (inside the cab).
49
49
Fit all previously removed cables from the ground
(negative) battery terminals.
50
50

WARNING
Make sure that the parking brake has been applied
and that neutral is selected.

Start the engine and check the function and see if there
is any leakage.

Allow the engine to run at low idle for about 5 minutes

to allow the cylinder balancing system to set the correct
amount of fuel for the fuel injectors.

Note: For cylinder balancing to take place, no power

demanding components such as PTOs should be
connected.
51
51

Close and latch the hood.