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Number: SB211007
Date: 02/12/07
Model: ASET™,
E-Tech™, E7
(Also applies to Mack Trucks Australia)
(Supersedes SB211007 dated 03/05/04)
SB211007 — Page 1 of 6
SERVICE PUBLICATIONS, ALLENTOWN, PA 18105 ©MACK TRUCKS, INC. 2007
Rust corrosion may be noticed at the cylinder block upper pilot
bore. This corrosion is not detrimental to the engine.
1. Remove all six cylinder sleeves and thoroughly clean each cylinder block sleeve seat.
2. Examine each sleeve seat in the block and use visual judgement to determine which
sleeve seat appears to have the most severe pitting.
3. Using service tool No. PT2210 and cutter No. PT2210-3, cut the sleeve seat which has
the most severe pitting until it is free of any erosion, or to the maximum allowable recut
dimension of 4.040" (102.616 mm), whichever occurs first.
4. If it has been determined that the sleeve seat with the most severe pitting is still
salvageable, proceed with recutting the remaining seats as needed. Cut each seat to
the depth required by the following criteria:
a. Attempt to clean up pitting, but do not exceed a maximum depth of 4.040"
(102.616 mm).
b. Attempt to provide a counterbore depth where a single shim of the least thickness
can be used to achieve the correct cylinder sleeve stand-up height. Cylinder
sleeve stand-up height specifications for the different engines are as follows:
앫 E7 engines — 0.559–0.656 mm (0.022"–0.027")
앫 E-Tech™ engines — 0.584–0.737 mm (0.023"–0.029")
앫 E-Tech™ CCRS engines (except 380/410, 427 and 460 Models) —
0.584–0.737 mm (0.023"–0.029")
앫 E-Tech™ CCRS engines (380/410, 427 and 460 models) —
0.610–0.737 mm (0.024"–0.029")
앫 ASET™ AC engines — 0.610–0.737 mm (0.024"–0.029")
앫 ASET™ AI/AMI engines — 0.584–0.737 mm (0.023"–0.029")
SB211007 — Page 2 of 6
5. Measure each counterbore depth as the recut is being performed. The goal is to
provide a depth where only a single shim is necessary to obtain the proper cylinder
sleeve stand-up height. Effective March 2004, thicker shims became available through
the MACK Parts System. With the availability of these thicker shims, usage
recommendations are as follows:
앫 The new thicker shims (part numbers 505GC26P20, P30 and P40) are available in
0.020", 0.031" and 0.042" thicknesses, and are to be used as a single shim repair
whenever possible.
앫 The previous shim part numbers, 505GC26P2, P3, P4, P10, P12 and P14 range
in thicknesses from 0.002" through 0.014", and the shim thicknesses are
designated by the “P” number. Effective March 2004, with the availability of the
thicker shims, the thinner shims (P2 through P14) are to be used as a single shim
repair only, either when a single shim of the required thickness is all that is
necessary to achieve the specified cylinder sleeve stand-up height, or in cases
where a single shim of a required thickness must be used in conjunction with a
thicker shim (0.020", 0.031" or 0.042" thicknesses).
앫 Along with the introduction of the thicker shims, the nominal inside diameter of all
the shims (both thick shims and thin shims) was reduced by 0.064" (from 5.225" to
5.161") to provide a better fit between the shim and liner.
From the beginning of E7 PLN and E-Tech™ engine production, a crevice seal, similar to
an O-ring, was installed in the groove located in the outside diameter of the cylinder sleeve,
near the sleeve top.
It has been determined, however, that the crevice seal is not necessary. Therefore, effective
approximately December 1998 (engine serial number series 8Y), the crevice seal is no
longer used in production engines. Additionally, effective January 1999 (engine serial
number series 9A), the crevice seal groove in the cylinder sleeve has been eliminated on all
cylinder sleeve part numbers for production and service.
It is recommended that use of the crevice seal be discontinued in all engine repairs or
rebuilds, whether or not the liner has a crevice seal groove.
2. If the seats have been cut, place the shims on the cylinder block sleeve seat. Always try
to use a single shim, if possible. If more than one shim is necessary, always use the
least amount of shims possible to obtain the proper cylinder sleeve height, and always
place the thickest shim on the bottom.
SB211007 — Page 4 of 6
3. Apply a bead of RTV silicone (MACK part No. 342SX33, Dow-Corning “Silastic”
832RTV), approximately 0.090"–0.130" high in the corner of the cylinder block sleeve
seat, 360 degrees around the cylinder wall. DO NOT use excessive amounts of RTV,
and do not apply the bead more than 0.130" high.
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SB211007 — Page 5 of 6
The primary goal is to have the RTV fill the gap that exists between the lower diameter
of the sleeve “wet” section and the cylinder block wall. This gap is 0.006"–0.013" wide
by 0.519" high, around the entire circumference of the sleeve. This RTV “dam” will aid
in protecting this area of the sleeve seat from cavitation damage.
The secondary goal is to allow an extremely thin layer of RTV on the sleeve seat to fill
in any of the very slight irregularities that may exist between the sleeve and block at the
sleeve seat.
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SB211007 — Page 6 of 6