Service Bulletin

MACK Trucks Corporation

Greensboro, NC, USA Trucks
Date Group No Release page

11.2016 2533 001 01 1 (1)

2533-03-02-02 Engine Compression Brake

Actuator, Replacement
CHU, CXU, GU

2533‒03‒02‒02 Engine Compression Brake Actuator, Replacement

engUS–M–SB2533–00101 SB2533–001eng_M
MACK Trucks Corporation Date Group No Release page
Service Bulletin 11.2016 2533 001 01 1 (20)

Table of contents
2533‒03‒02‒02 Engine Compression Brake Actuator, Replacement . . . . . . . . . . . . . . . . . . . . . . 2
EM-USA17, ENG-VE13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MACK Trucks Corporation Date Group No Release page
Service Bulletin 11.2016 2533 001 01 2 (20)

2533‒03‒02‒02 Engine Compression Brake Actuator, Replacement

EM-USA17, ENG-VE13

Illustrations may differ slightly from the actual vehicle being serviced. However, key components ad-
dressed in this information are represented as accurately as possible.

CAUTION
Service Information Advisory. If you are not properly trained and certified in this procedure, ask your
supervisor for training before you perform it.
▶ You must read and understand the precautions and guidelines in Service Information, Function
Group 2, "General Safety Practices, Engine" before performing this procedure.

1. Park the vehicle on a level surface.

2. Apply the parking brake.
3. Place the transmission in neutral or park.

4. Install the wheel chocks.

5. Disconnect the cable from the battery's negative

terminal.

6. Unlatch and raise the hood.

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7. Loosen the clamps.

8. Remove the hose.

9. Loosen the clamps.

10. Remove the duct.

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11. Disconnect the connector.

12. Remove the screws and nuts.

13. Remove the housing.

14. Remove the screws and washer.

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15. Remove the mounting bracket.

16. Disconnect the connector.

17. Remove the ties.

18. Remove the screws.

19. Remove the clamp.
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20. Loosen the clamps.

21. Remove the pipe.

22. Remove the pipe.

23. Loosen the screws.

24. Remove the valve cover.

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25. Drain the fuel from the cylinder head.

Note
Position a container to collect the fuel.

CAUTION
Risk of material damage. Risk of impurities being introduced into the fuel system.
▶ Ensure conditions of maximum cleanliness when carrying out any work on the fuel system.

CAUTION
Risk of skin injury. High fuel pressure.
▶ The injection system may be pressurised. When working on the injection system, remove the first
part cautiously

CAUTION
Risk of skin injury. Grease, oil and chemical substances can cause skin and eye injuries. Oils and
grease can cause acne and eczema. Used lubricants are more harmful than unused lubricants.
▶ Protective equipment such as gloves and eye protection must be used when working with grease,
oils and chemical substances.

CAUTION
Risk of material damage. Risk of impurities being introduced into the fuel system.
▶ Seal off all apertures in the fuel system using the protection kit. Do not remove these protective
elements until it is time to reconnect.

26. Remove the cap nuts.

27. Remove the pipe.
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Service Bulletin 11.2016 2533 001 01 8 (20)

CAUTION
Risk of material damage. Risk of impurities being introduced into the fuel system.
▶ Ensure conditions of maximum cleanliness when carrying out any work on the fuel system.

CAUTION
Risk of material damage. Risk of impurities being introduced into the fuel system.
▶ Seal off all apertures in the fuel system using the protection kit. Do not remove these protective
elements until it is time to reconnect.

CAUTION
Risk of skin injury. High fuel pressure.
▶ The injection system may be pressurised. When working on the injection system, remove the first
part cautiously

CAUTION
Risk of skin injury. Grease, oil and chemical substances can cause skin and eye injuries. Oils and
grease can cause acne and eczema. Used lubricants are more harmful than unused lubricants.
▶ Protective equipment such as gloves and eye protection must be used when working with grease,
oils and chemical substances.

28. Remove the cap nuts.

29. Remove the pipe.

30. Remove the other pipes in the same way.

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Service Bulletin 11.2016 2533 001 01 9 (20)

31. Disconnect the connectors.

CAUTION
Risk of material damage. Risk of impurities being introduced into the fuel system.
▶ Ensure conditions of maximum cleanliness when carrying out any work on the fuel system.

CAUTION
Risk of skin injury. High fuel pressure.
▶ The injection system may be pressurised. When working on the injection system, remove the first
part cautiously

CAUTION
Risk of skin injury. Grease, oil and chemical substances can cause skin and eye injuries. Oils and
grease can cause acne and eczema. Used lubricants are more harmful than unused lubricants.
▶ Protective equipment such as gloves and eye protection must be used when working with grease,
oils and chemical substances.

CAUTION
Risk of material damage. Risk of impurities being introduced into the fuel system.
▶ Seal off all apertures in the fuel system using the protection kit. Do not remove these protective
elements until it is time to reconnect.

32. Disconnect the connector.

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Service Bulletin 11.2016 2533 001 01 10 (20)

33. Remove the screws.

34. Remove the common rail.

35. Clean around the valve.

36. Disconnect the connector.

37. Remove the screws.

38. Remove the valve.

CAUTION
Service Information Advisory. If you are not properly trained and certified in this procedure, ask your
supervisor for training before you perform it.
▶ You must read and understand the precautions and guidelines in Service Information, Function
Group 2, "General Safety Practices, Engine" before performing this procedure.

39. Clean the valve.

40. Clean the contact surfaces.

41. Replace the seal.

Note
Use a new part.

Note
Check that the oil channels are free of impuri-
ties.
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42. Remove the screw.

Note
If not previously removed.
43. Replace the pipe.
Note
Use new parts.
44. Lubricate the seals.
Note
Use a recommended oil.
45. Install the screw.

46. Install the valve.

47. Install the screws.
48. Torque tighten the screws.
Tightening torque
Screw M8
24 ±4 Nm
(18 ±3 lbf⋅ft)
49. Torque tighten the pipe screw.
Tightening torque
Screw M8
24 ±4 Nm
(18 ±3 lbf⋅ft)

50. Connect the connector.

CAUTION
Risk of skin injury. Grease, oil and chemical substances can cause skin and eye injuries. Oils and
grease can cause acne and eczema. Used lubricants are more harmful than unused lubricants.
▶ Protective equipment such as gloves and eye protection must be used when working with grease,
oils and chemical substances.

51. Install the common rail.

52. Torque tighten the screws.
Tightening torque
Common rail, screw 24 ±4 Nm
(18 ±3 lbf⋅ft)
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53. Connect the connectors.

54. Install the pressure pipe.

Note
Use a new part.

Note
Use no lubricant when installing the pipe.
Install the pipe on the common rail first.
55. To avoid damaging the pressure pipe when the nuts
are tightened, check that it is correctly positioned.

56. Torque tighten the cap nut.

Tightening torque
Pressure pipe, cap nut 15 ±2 Nm
(11 ±1 lbf⋅ft)
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57. Torque tighten the cap nut.

Tightening torque
Pressure pipe, cap nut 15 ±2 Nm
(11 ±1 lbf⋅ft)

58. Angle-tighten the cap nut.

Tightening torque
Pressure pipe, cap nut (common 60 ±5°
rail)

59. Angle-tighten the cap nut.

Tightening torque
Pressure pipe, cap nut (injector) 60 ±5°

60. Perform this procedure when the condition below is met.

Conditions
● Applies to the installation of return pipes.
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▶ Check the torque on the adapter.

Tightening torque
Adapter 50 ±8 Nm
(37 ±6 lbf⋅ft)

▶ Install the pipe.

Note
Use no lubricant when installing the pipe.
Install the pipe on the common rail first.
▶ To avoid damaging the pipe when the nuts are
tightened, check that it is correctly positioned.

▶ Torque tighten the cap nuts.

Tightening torque
Pressure pipe, cap nut 23 ±6 Nm
(17 ±4 lbf⋅ft)

Note
Hold the adapter in place when tightening
the nut.
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61. Connect the connector.

62. Clean the groove.

63. Install the gasket.
Note
Check the gasket for wear and damage.
Replace if necessary.

64. Position the screws.

Note
Inspect the gasket, replace as needed.

Service tip
Temporarily securing the screws at the rear of
the cover in the uppermost position will aid in
installation
65. Install the valve cover.

66. Tighten the screws to torque.

Tightening torque
Valve cover, screw Tightening sequence:
1–20
24 ±4 Nm
(18 ±3 lbf⋅ft)
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67. Install the pipe.

Note
Inspect the internal sealing ring.

68. Install the pipe.

Note
Check the sealing ring and hose for damage;
replace as needed.

69. Tighten the clamps to torque.

Tightening torque
V band clamp screw 10.2 ±1 Nm
(90 ±9 lbf⋅in)

Tightening torque
Hose clamp 11.9 ±2 Nm
(105 ±18 lbf⋅in)

70. Install the clamp.

71. Torque-tighten the screws.
Tightening torque
Screw M8
24 ±4 Nm
(18 ±3 lbf⋅ft)
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Service Bulletin 11.2016 2533 001 01 17 (20)

72. Connect the connector.

73. Install the ties as needed.

74. Install the mounting bracket.

75. Tighten the screws to torque.
Tightening torque
Screw M10
48 ±8 Nm
(35 ±6 lbf⋅ft)

76. Position the housing.

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77. Install the screws and nuts.

78. Tighten the screws and nuts to torque.
Tightening torque
Air filter housing screws M8 screws.
5.6 ±0.6 Nm
(50 ±5 lbf⋅in)

79. Connect the connector.

80. Install the air duct.

81. Tighten the clamps to torque.

Tightening torque
Air duct clamp 9 ±1 Nm
(80 ±9 lbf⋅in)
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82. Install the hose.

83. Tighten the clamps to torque.

Tightening torque
Clamp, screw 3.95 ±0.6 Nm
(35.0 ±5 lbf⋅in)

84. Connect the battery cable to negative (ground) termi-

nal.

DANGER
Risk of serious personal injury or death. Failure to do so may result in serious personal injury or
death.
▶ Ensure the engine cannot start while working around the fan area.

85. Start the engine and check for leaks and proper operation. After shutdown, replenish fluids as neces-
sary.
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86. Lower the hood.

Note
Ensure that the hood is latched.

87. Remove the wheel chocks.