Service Bulletin

Mack Trucks, Inc.

Allentown, PA USA Trucks
Date Number Page
(Does not apply to Mack Trucks Australia) 1(25)
11/04/08 SB215025
(Supersedes SB215025 dated 03/27/07)

Cooling System Revisions

ASET™ AC

SB215025, Cooling System Revisions

(November 2008)
To improve water pump seal life, and to reduce occurrences of coolant loss from the surge tank and
cooling system surge noise/vibration (a noise and very rapid vibration of the upper radiator tube), a
revised thermostat housing, water pump inlet tube, a new coolant static fill tube and a revised thermostat
arrangement were implemented into production as follows:
앫 Revised Thermostat Housing — April 12, 2004
앫 Revised Water Pump Inlet Tube and Static Fill Tube — January 12, 2005
앫 Revised Thermostat Arrangement — December 4, 2006 (beginning with engine serial No.
6X2772)
Revised Thermostat Housing, Water Pump Inlet Tube and Static Fill Tube
The thermostat housing consists of two sections (the thermostat section and bypass section), with a cast
wall separating the two. In order for the bypass feature to function, there must be a passage through the
cast wall to allow coolant flow between the two sections.
Beginning April 12, 2004, a thermostat housing having a larger opening in the divider wall between the
thermostat and bypass sections was phased into production. This change, which reduces the pressure
differential between the thermostat section and the bypass section, provides improved water pump seal
life and reduced cooling system noise and vibration.
1

Figure 1 — Thermostat Housing Comparison

1. Current Thermostat Housing (Part No. 493GB521P2) 4. Previous Thermostat Housing (Part No. 493520[A])
2. Larger Opening in Divider Wall 5. Two 1/2″ Openings in Divider Wall
3. Drill Point Mark Denotes Part No.
Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 2(25)

Previously, the coolant return lines for the cab heater, sleeper heater and fuel heater were connected to
the thermostat housing. Less pressure differential inside the thermostat housing, however, results in
insufficient coolant flow through the heaters. Because of this, return lines for the cab heater, sleeper
heater and fuel heater are now connected to the static fill tube.

The revised thermostat housing part No. 493GB521P2 includes

the five tapped ports originally used for the coolant return lines.
DO NOT use these ports for the cab and/or fuel heater coolant
return lines, as adequate pressure differential does not exist and
sufficient coolant flow will not be attained.

The water pump inlet tube now includes a connection for the new static fill tube. The new static fill tube
arrangement includes spuds for the cab heater and fuel heater coolant return line connections.
2

Figure 2 — Water Pump Inlet Tube

1. Water Pump Inlet Tube (Part No. 670GC5142 4. Fuel Heater Return Connection
2. Connection for Static Fill Tube 5. Cab Heater Return Connection
3. Static Fill Tube (Part No. 227GC516) 6. Sleeper Heater Return Connection

Should pushing coolant (coolant loss from the surge tank) or

cooling system surge noise/vibration be encountered, the
cooling system should be revised as outlined in the following
instructions.
Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 3(25)

Some chassis may already have been modified with some of the
revisions outlined in this bulletin. For example, some chassis
may be equipped with a revised thermostat housing (part No.
493GB521 or 493GB521P2), but not the static fill tube. On these
chassis, the cab, sleeper and fuel heater return lines may either
be connected to the lower radiator tube or to the thermostat
housing. The thermostat housing will not be replaced on these
chassis, but the new water pump inlet tube and static fill tube will
be required. Additionally, it will be necessary to reroute the
heater return lines from either the thermostat housing or the
lower radiator tube to the static fill tube. This service bulletin
covers all arrangements.

Thermostat Hosing and Thermostat Installation

Before proceeding, determine if the thermostat housing must be replaced by looking at the part number
located on the top of the housing (refer to Figure 1). For engines having thermostat housing part No.
493GB520(A), the existing thermostat housing must be replaced with the revised housing part No.
493GB521P2. If the engine is equipped with thermostat housing part No. 493GB521, DO NOT replace
the housing, but proceed with installing the water pump inlet tube and installing the static fill tube. If
equipped with 493GB521 thermostat housing, a plug (part No. 9032-7237X16) will be required to close
the static fill port in the side of the housing. Parts required for replacing the thermostat housing are as
follows:
3

Figure 3 — Thermostat Housing Assembly

Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 4(25)

Key Qty. Part No. Description

1 1 215SB169A Kit, thermostat (includes two vented with ball check thermostats, [one part No.
657GC324BP80 and one 657GC324BP85] and two seals (part No. 447GC216A)
2 2 492GC251 Shield, thermostat housing
3 5 49AX233 Plugs
4 1 493GB521P2 Housing, thermostat
*All five ports must be plugged. Reuse plugs from existing housing. One or two additional plugs will be required.

In addition to the parts listed above, the following parts will also be required (not shown in above
exploded view):
Qty. Part No. Description
1 446GC2149 O-ring, EGR mixer tube
1 449GC237M Wire mesh seal, EGR mass flow tube flange (required if mass flow tube has the bellows-
type connection)

Procedures for removing and reinstalling the thermostat housing are as follows:
1. Disconnect the batteries by disconnecting the negative battery cable(s) first, and then the positive
battery cable(s).
2. Open the hood.
3. Drain the coolant into a clean container. Cover the container to prevent dirt from contaminating the
coolant. The same coolant will be reused to fill the system.
4. Remove the EGR mixer tube as follows:
4

Figure 4 — EGR Mixer Tube

1. Pressure Sensor 5. Relief Valve Outlet Tube
2. Temperature Sensor 6. Mixer Tube
Boost Pressure Relief Valve 7. Relief Valve Outlet Tube Clamp
4. EGR Cool Tube 8. Capscrews
Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 5(25)

a. Loosen the clamps at both coupling hoses on the inlet air duct between the charge air cooler
outlet and the EGR mixer tube, and then remove the inlet air duct.
b. Disconnect the harness connectors for both the outlet pressure and temperature sensors.
c. Loosen the two clamps that secure the coupling hose to the boost pressure relief valve, and
then remove the coupling hose.
5

Figure 5 — Boost Pressure Relief Valve Coupling Hose

d. Remove the capscrew from the support bracket at the side of the EGR mixer tube. The bracket
is attached between the mixer tube and the coolant manifold.
6

Figure 6 — EGR Mixer Tube Support Bracket

1. Mixer Tube 3. Support Bracket
2 Mixer TUbe EGR Mass 4. Coolant Manifold
Flow Tube Flange
Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 6(25)

e. Loosen and remove the clamp attaching the upper EGR mass flow tube to the mixer tube. If
the mass flow tube uses the bellows-type connection, remove and discard the seal in the
flange.
7

Figure 7 — Upper Gas Tube-to-Mixer Connection (Bellows-Type SHown)

1. EGR Mixer Tube 2. EGR Mass Flow Tube

f. Remove the two capscrews securing the EGR mixer tube to the inlet manifold, and lift the
mixer tube out of the way to gain access to the thermostat housing.
5. Disconnect the cab/sleeper heater and fuel heater (as equipped) return lines from the side of the
thermostat housing.
6. Disconnect the bypass hose and the surge tank hose from the thermostat housing.
7. Remove and discard the coupling hose between the upper radiator tube and the thermostat
housing.
8. Remove the thermostat housing from the water manifold.
9. Remove the 3/8Ð pipe plugs from the ports in the original thermostat housing and install them into
the new housing (part No. 493GB521P2). Use thread sealant (either Teflon® tape or pipe thread
sealant) and tighten the plugs to 18 lb-ft (24 N•m).
10. Place the new thermostat housing top side down (with the thermostat openings facing up) on a
workbench, and then install a new shield (part No. 492GC251) with the flat side facing up (toward
the installer), into each thermostat bore. An installation tool is not required. It is only necessary to
use finger pressure to push the shields to their fully seated position on the bottom of the thermostat
housing.
Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 7(25)

11. Install a new seal (part No. 447GC216A) into each of the thermostat bores. Install the seal with the
metal portion facing up (toward the installer), and use seal installation tool No. J 26637-A to install
the seals. The installation tool ensures that the seals are installed to the proper depth.

The two seals (part No. 447GC216A) and thermostats (part No.
657GC324BP80 [180°] and 657GC324BP85 [185°]) are
included in the thermostat kit (part No. 215SB169A).
8

Figure 8 — Installing Thermostat Housing Shields and Seals

1. Thermostat Housing 3. Seal (Part No.
(Part No. 493GB521P2) 447GC216A), Metal
2. Shields (Part No. Side Faces Up, Toward
492GC251), Flat Side the Opening in the
Faces Up, Toward the Housing
Opening in the Housing.
Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 8(25)

12. With the ball check valve facing forward, position the thermostats (one part No. 657GC324BP80
and one part No. 657GC324BP85) into the thermostat bores.

For proper vent function, it is very important that the thermostat

be installed with the ball check valve facing forward.
The straps that retain the thermostat spring must face forward in
the same direction as the vent port/ball check valve. If the straps
are not facing the same direction, grasp the body of the
thermostat and rotate the top portion until the straps are properly
oriented.
It does not matter into which bore the 180° and 185° thermostats
are installed.
9

Figure 9 — Thermostat Installation

1. Strap Must Face Same Direction as Vent Port/Ball Check 2. Vent Port/Ball Check Valve Faces Front
Valve

13. Place the thermostat housing assembly on the water manifold mounting surface, then install the
three mounting capscrews. Tighten the capscrews to 21 lb-ft (29 N•m).
14. Reinstall the EGR mixer tube as follows:
a. If the mass flow tube uses the bellows-type connection, install a new wire-mesh seal (part No.
449GGC237M) in the upper mass flow tube flange of the mixer tube.
Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 9(25)

b. Install a new O-ring (part No. 446GC2149) to the EGR mixer tube mounting collar on the inlet
manifold.
10

Figure 10 — EGR Mixer Tube O-Ring Installation

1. O-Ring (Part No. 2. Inlet Manifold
446GC2149)

c. Position the mixer tube on the inlet manifold and install the two capscrews. Tighten the
capscrews to 40 lb-ft (55 N•m).
d. Install the capscrew that attaches the support bracket to the side of the mixer tube and tighten
to 40 lb-ft (55 N•m).
e. With the new seal in place, position the upper EGR cool tube on the mixer tube. Install the
clamp and tighten the T-bolt to 110 lb-in (12 N•m).
f. Reconnect the boost pressure relief valve by reinstalling the coupling hose and tightening the
hose clamps to 28 lb-in (3.1 N•m).
g. Reconnect the outlet pressure and temperature sensor harness connectors.
Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 10(25)

15. Continue with installation of the water pump inlet and static fill tubes.

On certain chassis with the original thermostat housing (part No.

493GB520), the housing included a port for a vent line that was
connected between the thermostat housing and the upper
radiator tube. This port has been eliminated on the revised
housings (part No. 493GB521P2). For chassis having this vent
line, the line must be eliminated by removing the T-fitting from
the upper radiator tube and then installing the existing 90-degree
elbow fitting in the tube and reconnecting the line from the surge
tank.
11

Figure 11 — Surge Tank Vent Line

1. Upper Radiator Tube 4. Eliminate T-Fitting
2. Intake Air Duct 5. Eliminate Line
3. Install Elbow to Tube 6. Eliminate Elbow
Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 11(25)

On chassis manufactured between January 2002 and July 2003,

the oil cooler vent line may have been connected to a T-fitting in
the surge tank vent line, between the thermostat housing and
upper radiator tube as shown in the illustration below. When
installing the revised thermostat housing (part No.
493GB521P2) on one of these chassis, the oil cooler vent line
must be rerouted and connected to any available 1/8" port on the
water manifold. If a 1/8" port is not available, an available 3/8"
port may be used. The water manifold used on early ASET™ AC
engines only had three available ports. If this is the case and
there are no available 1/8" or 3/8" ports, the oil cooler vent line
can be connected to one of the available 3/8" ports on the
thermostat housing. When connecting to a 3/8" port, a reducer
fitting (part No. 63AX1026 will be required. For optimum routing,
elbow fittings (45-degree elbow fitting part No. 63AX3909 and
90-degree elbow fitting part No. 63AX3900) may be used.
12

Figure 12 — Oil Cooler Vent Line (Chassis Manufactured Between January 2002 and July 2003)
1. To Upper Radiator Tube 2. Oil Cooler Vent Line
Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 12(25)

Water Pump Inlet Tube/Static Fill Tube Installation

Parts required for installation of the water pump inlet and static fill tubes are as follows:
13

Figure 13 — Water Pump Inlet Tube and Static FIll Tube

Key Qty. Part No. Description
1 1 446GC2145 O-ring
2 1 670GC5142 Water pump inlet tube
3 2 83AX1026 Hose clamps
4* — 160AX543P36 Hose, 5/8" heater, 3" (7.62 mm) length
5 1 227GC516 Static fill tube
6 3** 63AX3488 Fittings, 90-degree elbow
7 1 66AM3 Bolt, M6 x 1.0 x 16 mm long with patch lock
8 1 160AX521P4 Hose, upper radiator tube-to-thermostat housing, silicone hose
1 11MF3682M10 Hose, upper radiator tube-to-thermostat housing, Gates Blue-Stripe®
9 2 83AX979 Hose clamp, for silicone hose
2 560AM3 Hose clamp, for Gates Blue-Stripe® hose
*An additional 3 feet (0.91 M) length of 5/8" heater hose will be required to replace the cab heater return line.
**Quantity dependent upon chassis equipment.

In addition to the parts listed above, the following parts may also be required:
Qty. Part No. Description
2 56AX393 O-rings, coolant conditioner mounting adapter (if equipped with coolant conditioner)
1 83AX827 Cushioned P-clamp, single hose
1 83AX722 Cushioned P-clamp, double hose
Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 13(25)

Installation procedures for the water pump inlet tube and the static fill tube are as follows:

If not done previously, disconnect the batteries by disconnecting

the negative battery cable(s) first, then the positive cable(s) and
drain the coolant into a clean container.

1. Remove the Centri-Max® oil filter cover and rotor. Cover the Centri-Max® mounting adapter to
prevent dirt entry.
2. If equipped with a coolant conditioner, remove the coolant conditioner canister and mounting
adapter as an assembly.
14

Figure 14 — Remove Coolant Conditioner Canister and Mounting Adapter

3. Remove the bolt securing the EECU harness clamp to the stand-off bracket below the EECU.
15

Figure 15 — EECU Harness Clamp

Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 14(25)

4. Disconnect the harness connectors from the EECU, and then position the harnesses out of the way
where they will not interfere with the remaining disassembly/reassembly procedures.
5. If there are coolant lines and/or fuel lines clamped to the stand-off bracket located at the top rear of
the oil cooler, remove the fastener securing the clamp(s) to the bracket.
16

Figure 16 — Remove Fuel and Coolant Line Clamps from Stand-Off Bracket
Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 15(25)

6. Disconnect the fuel outlet line from the front fitting of the EECU cooling plate (leave the fuel inlet line
connected).

Avoid damaging the EECU cooling plate. Always hold the fitting
boss on the cooling plate with a wrench when loosening or
tightening the fuel inlet or outlet lines.
17

Figure 17 — Disconnect Fuel Outlet Line from EECU Cooling Plate

1. Fuel Outlet Line (To Fuel Supply Pump) 3. EECU Cooling Plate
2. Hold Cooling Plate Boss with a Wrench 4. Fuel Inlet Line

7. Disconnect the static fill hose from the elbow fitting located on the side of the thermostat housing.
18

Figure 18 — Disconnect Static Fill Line

8. Remove the EECU and cooling plate and position in a location where it will not interfere with the
remaining procedures.
Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 16(25)

9. Remove the lower radiator tube.

19

Figure 19 — Remove Lower Radiator Tube

10. Remove the thermostat bypass tube and the Y-shaped hose.
20

Figure 20 — Remove Thermostat Bypass Tube and Y-Shaped Hose

1. Thermostat Bypass Tube 2. Y-Shaped Hose

11. Loosen the hose clamps securing the water pump inlet tube to the coupling hose at the oil cooler
coolant outlet pipe.
Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 17(25)

12. Remove the bolt securing the wire harness to the tab on the water pump inlet tube and the three
screws securing the tube to the water pump housing assembly. Remove the inlet tube.
21

Figure 21 — Remove Water Pump Inlet Tube

1. Water Pump Inlet Tube

13. Install a new O-ring (part No. 446GC2145) in the groove of the water pump inlet flange, and then
apply a thin coating of MACK O-ring lubricant (part No. 243SX53).
22

Figure 22 — Install O-Ring

1. O-Ring (Part No. 446GC2145)
Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 18(25)

14. Install the new water pump inlet tube (part No. 670GC5142) by sliding the tube into the coupling
hose at the oil cooler and then positioning the flange against the mounting surface. Use the existing
screws to secure the tube to the water pump assembly. Tighten the screws to 40 lb-ft (55 N•m).
Tighten the hose clamp at the oil cooler-to-inlet tube coupling hose to 28 lb-in (3.1 N•m).
15. Install a new oil cooler inlet screen (part No. 387GC32) into the Y-shaped oil cooler coolant inlet
coupling hose.
23

Figure 23 — Oil Cooler Inlet Screen

1. Oil Cooler Inlet Screen
(Part No. 387GC32)

16. Reinstall the thermostat bypass tube to the elbow hose at the thermostat housing and to the
coupling hose at the front of the engine. Tighten the hose clamps to 28 lb-in (3.1 N•m).
17. Insert the cleaned coolant screen into the Y-shaped hose, and then install the hose. Tighten the
clamps to 28 lb-in (3.1 N•m).
18. Thoroughly clean the lower radiator tube, and then install the tube. Tighten the hose clamps to 28
lb-in (3.1 N•m).
19. Reinstall the clamp that secures the lower radiator tube to the engine block.
20. Slide a hose clamp (part No. 83AX1026) over each end of a 3" (76.2 mm) length of 5/8" heater hose
(part No. 160AX543P36), and then install the hose onto the spud on the water pump inlet tube.
21. Prepare the static fill tube (part No. 227GC516) for installation by removing the plugs from the
spuds for the cab heater, sleeper heater return and fuel heater return lines as required, and then
installing the fittings. Orient the fittings so that the open ends are facing in the approximate
directions shown in the following illustration.
24

Figure 24 — Preparing Static Fill Tube for Installation

1. Fuel Heater Fitting 3. Sleeper Heater Fitting
2. Cab Heater Fitting
Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 19(25)

If equipped with heater shut-off valves, install the existing shut-

off valves in the static fill pipe instead of the elbow fittings. For
sleeper equipped chassis, an additional shut-off valve will be
required, because with the original heater return line routing, the
sleeper return line and the cab return line are connected
together with a coupling and share the same shut-off valve.

22. Install the static fill tube to the coupling hose at the water pump inlet tube and tighten the hose
clamp to 28 lb-in (3.1 N•m).
23. Reroute the static fill hose from the surge tank, and connect the hose to the static fill tube. Tighten
the hose clamp to 28 lb-in (3.1 N•m). For optimum routing, it may be necessary to cut the hose to
the appropriate length.

Be sure to leave enough slack in the static fill hose to allow for a
full range of motion of the air suspended cab.
For engines having the 493GB521 thermostat housing, it will be
necessary to remove the 90-degree elbow fitting from the static
fill port on the side of the housing and install a plug and O-ring
(part No. 9032-7237X16) in the port.
25

Figure 25 — Thermostat Housing Plug

1. Plug with O-RIng (Part No. 9032-7237X16)

The plug (part No.9032-7237X16) is only used if the engine is

equipped with the 493GB521 thermostat housing.
Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 20(25)

or optimum static fill hose routing on CXN and CHN model

chassis, it may be necessary to reposition the clamp that
secures the air conditioner hoses to the stand-off bracket located
at the top of the engine by removing the clamp, rotating it 180
degrees and reinstalling as shown in the following illustration.
26

Figure 26 — Repositioning Air Conditioner Hose Clamp

Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 21(25)

24. Reroute and connect the cab heater return, sleeper heater return (if equipped) and fuel heater
return (if equipped) hoses to the appropriate connections on the static fuel tube as shown in the
following illustration. For optimum routing, it may be necessary to cut the return hoses to proper
length.

On chassis equipped with a sleeper, the return lines for both the
cab and sleeper heaters are connected together by a Y-coupling
located near the thermostat housing. Disconnect the sleeper
heater return line from the Y-coupling and disconnect the cab
heater return line from the heater core. The cab heater return
line must be replaced with a single length of hose.
Approximately 3 feet (1 M) of hose will be required.
27

Figure 27 — Coolant Return Hose Routing

1. To Surge Tank 3. Sleeper Heater Return
2. Cab Heater Return 4. Fuel Heater Return
Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 22(25)

For chassis on which the cab, sleeper and fuel heater return
lines are routed to the lower radiator tube, reroute the heater
return lines to the static fill tube. Use the plugs removed from the
static fill tube to close the ports in the lower radiator tube.

On CXN and CHN models equipped with a fuel heater, it will be

necessary to reorient the elbow fitting located in the fuel heater
coolant outlet port toward the front.
28

Figure 28 — Fuel Heater Return Line Fitting Orientation — CXN and CHN Models
25. Reinstall the EECU/cooling plate assembly and tighten the upper and lower mounting nuts to 108
lb-in (12 N•m).
26. Reconnect the fuel line to the outlet fitting of the cooling plate, and secure the cooling plate fuel inlet
line to the stand-off bracket located at the rear of the oil cooler.

Avoid damaging the EECU cooling plate. Always hold the fitting
boss on the cooling plate with a wrench when loosening or
tightening the fuel inlet or outlet lines.
Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 23(25)

27. Route and clamp the return lines and fuel lines to provide adequate clearance and to prevent
rubbing and chafing. Use a new bolt (part No. 66AM3) to secure the static fill tube and the various
coolant and fuel line clamps to the stand-off bracket located at the top rear of the oil cooler.

Depending upon chassis model and equipment (sleeper, fuel

heater, etc.), the coolant supply and return lines for the sleeper
and fuel heater, and the fuel supply line to the EECU cooling
plate were secured to the same stand-off bracket where the
static fill tube is secured. With the coolant return lines rerouted to
the static fill tube, only the coolant supply lines for the fuel heater
and/or sleeper heater, along with the fuel supply line, will be
clamped to the stand-off bracket. Use cushioned P-clamps (part
No. 83AX722 for two hoses or part No. 83AX827 for a single
hose) to secure the hose(s) to the stand-off bracket. Use tie
wraps to secure the hoses as necessary to prevent rubbing and
chafing.
29

Figure 29 — Cab Heater, Sleeper Heater and Fuel Heater Line Routing
Key Qty, Part No. Description
1 1 66AM3 Bolt, M6 x 1.0 x 16 mm long with patch lock
2 1 83AX722 P-clamp, cushioned (for two hoses)
1 83AX827 P-clamp, cushioned (for one hose)
Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 24(25)

28. Install a new radiator tube-to-thermostat housing coupling hose and new hose clamps. Tighten the
hose clamps to 27.5 lb-in (3.1 N•m).
30

Figure 30 — Upper Radiator Tube Coupling Hose

Key Qty, Part No. Description
1 1 160AX521P4 Hose, silicone, upper radiator tube-to-thermostat housing
1 11MF3682M10 Hose, Gates Blue Stripe®, upper radiator tube-to-thermostat housing
2 2 83AX979 Clamps, for use with silicone hose
2 560AM3 Clamps, for use with Gates Blue Stripe® hose

29. Reinstall the Centri-Max® rotor and filter cover, and tighten the cover nut to 19 lb-ft (26 N•m).
30. Install O-rings (part No. 56AX393) into the two ports on the coolant conditioner mounting adapter
and apply a thin coating of MACK O-ring lubricant (part No. 243SX41).
31. Reinstall the coolant conditioner mounting adapter and canister. Tighten the mounting bolts to 15
lb-ft (20 N•m).
32. Refill the cooling system with the same coolant that was originally drained.
33. Reconnect the batteries by connecting the positive battery cable(s) first, and then the negative
cable(s).
34. Start the engine and check for coolant leaks.
35. Stop the engine and recheck the coolant level. Replenish with coolant as required, start the engine
and recheck the coolant level as required until the cooling system has been thoroughly de-aerated.
Mack Trucks, Inc. Date Number Page
Service Bulletin 11/04/08 SB215025 25(25)

Reimbursement
Expenses incurred for failed components will be reimbursed through the standard warranty claim
process. Pro-active upgrades are not accepted as warrantable. Labor codes and maximum labor
allowances are as follows:
This Repair may be eligible for reimbursement if a product failure was experienced within the time and mileage limits
of the applicable warranty coverage. Reimbursement is obtained via normal claim handling process.
Claim Type (used only when uploading from the Dealer Bus. Sys.) 01
Labor Code
Primary Labor Code 215 9D 23 80 — 2.0 hr., time allowed to remove and
replace existing water pump inlet tube, install new
static fill tube, reroute and connect cab heater
coolant return line. Does not include “take-charge”
time.
215 9E 23 80 — 0.2 hr., additional time to reroute
and connect sleeper heater coolant return line.
Does not include “take-charge” time.
215 9F 23 80 — 0.2 hr., additional time to reroute
and connect fuel heater coolant return line. Does
not include “take-charge” time.
215 9G 23 80 — 0.6 hr., Additional time to remove
and replace thermostat housing. Does not include
“take-charge” time.
Causal Part Not Applicable

Mack Trucks, Inc. engages in a continuous program of testing and evaluating to provide the best possible
product. Mack Trucks, Inc., however, is not committed to, or liable for updating existing chassis.