SERVICE BULLETIN

NUMBER: SB-211-007
DATE: 3/5/04
MODEL: ASET™,
E-Tech™, E7
(Also Applies To Mack Trucks Australia)
(Supersedes Bulletin SB-211-007 Dated 5/21/02)

CYLINDER SLEEVE SEAT REPAIR

When performing an overhaul on an ASET™, E-Tech™ or E7 engine, or if pressure tests to
determine coolant-in-oil show that coolant is leaking into the crankcase between the cylinder
sleeve and block bore, first remove the sleeve or sleeves where the coolant leak was
observed and inspect the cylinder block sleeve seats at those locations. If erosion is found
on one or more sleeve seats, it will be necessary to remove all six sleeves to inspect and
repair the seats as required, using the procedures outlined in this bulletin.

Extensive information concerning cylinder block pressure testing

can be found in service bulletin SB-210-015.
1

Figure 1 — RTV “Dam” to Prevent Cavitation Damage

Cylinder Block Sleeve Seat Preparation

In most instances, the block can be used as is and the cylinder sleeves installed by the
following “Cylinder Sleeve Installation” procedure outlined in this bulletin, in conjunction with
the procedures given in the applicable engine service manual. If erosion is severe enough
that it would allow coolant to leak past the seat, the block is still serviceable by cutting and
shimming the leaking sleeve seat as follows:

SB-211-007 — Page 1 of 6
SERVICE PUBLICATIONS, ALLENTOWN, PA 18105 ©MACK TRUCKS, INC. 2004
 Rust corrosion may be noticed at the cylinder block upper pilot
bore. This corrosion is not detrimental to the engine.

REV 1. Remove all six cylinder sleeves and thoroughly clean each cylinder block sleeve seat.
REV 2. Examine each sleeve seat in the block and use visual judgement to determine which
sleeve seat appears to have the most severe pitting.
REV 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.

Do not cut the seats deeper than 4.040 inches (102.616 mm).

REV Multiple incremental recuts are required in order to avoid a “tool

chatter” surface finish on the recut surface of the seat.

If the maximum recut dimension is reached and visible pitting

remains, the pitting is acceptable as long as there is not a
complete leak path all the way across the sleeve seat surface.

REV 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 — 0.022″–0.027″ (0.559–0.656 mm)
앫 E-Tech™ engines — 0.023″–0.029″ (0.584–0.737 mm)
앫 E-Tech™ CCRS engines (except 380/410, 427 and 460 models) —
0.023″–0.029″ (0.584–0.737 mm)
앫 E-Tech™ CCRS engines (380/410, 427 and 460 models) — 0.024″–0.029″
(0.610–0.737 mm)
앫 ASET™ AC engines — 0.024″–0.029″ (0.610–0.737 mm)
앫 ASET™ AI/AMI engines — 0.023″–0.029″ (0.584–0.737 mm)

SB-211-007 — Page 2 of 6
 5. Measure each counterbore depth as the recut is being performed. The goal is to
REV
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).

The 505GC26P20, P30 and P40 shims have a greater

manufacturing tolerance (±0.003″) than the thinner shims
(505GC26P2 through P14). In all cases (thick or thin shims), the
actual shim thickness should be measured before recutting the
sleeve seat.

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.

If necessary, it is acceptable to use a combination of shims

having the 5.225″ and the 5.161″ inside diameters on the same
sleeve seat.

SB-211-007 — Page 3 of 6
2

Figure 2 — Counterbore Depth

Elimination of Cylinder Sleeve Crevice Seal

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.

CYLINDER SLEEVE INSTALLATION

1. Thoroughly clean and dry the cylinder block sleeve seats and the cylinder sleeves.

Some very early E7 engines have an O-ring groove below the

cylinder sleeve seat and some do not. It has been determined
that this O-ring is not required as long as RTV is used at the
sleeve seat. The O-ring is no longer available through the MACK
Parts System.

SB-211-007 — Page 4 of 6
 2. If the seats have been cut, place the shims on the cylinder block sleeve seat. Always try
REV
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.

If shims are used, they must be placed on a clean, dry cylinder

block sleeve seat, with the thickest shim on the bottom. Apply
RTV on top of the shims only. If RTV is applied under the shims,
the shims may be displaced when the sleeve is installed.

3. Apply a bead of RTV silicone (MACK part No. 342SX32 [Dow-Corning “Silastic”
732RTV] or equivalent), approximately 0.090–0.130 inch 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 inch high.
3

Figure 3 — Applying RTV Bead

RTV must be applied just prior to installation of the sleeves to

prevent partial curing and questionable sealing and bonding.
The cylinder block sleeve seat and the cylinder sleeve must be
kept clean and free of any oil residue to ensure that the RTV
seals and bonds properly.

SB-211-007 — 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.
4

Figure 4 — Cylinder Sleeve Installation

4. Install sleeves in the cylinder block according to the procedures as outlined in the
applicable engine service manual.
5. Clean any RTV from around the bottom of the cylinder sleeve and block which may
have pressed between the block and sleeve during installation.
REV For warrantable repairs, the labor codes and maximum labor allowance for recutting the
cylinder sleeve seats are as follows:

211 DF 2J 77 ............................................................ 0.5 hr. — Time allowed to recut one cylinder sleeve
seat on E7 engine. Does not include “take-
charge” time.
211 DF 2L 77............................................................ 0.5 hr. — Time allowed to recut one cylinder sleeve
seat on E-Tech™ engine. Does not include
“take-charge” time.
211 DF 23 77............................................................ 0.5 hr. — Time allowed to recut one cylinder sleeve
seat on ASET™ AC engine. Does not
include “take-charge” time.
211 DF 24 77............................................................ 0.5 hr. — Time allowed to recut one cylinder sleeve
seat on ASET™ AI or AMI engine. Does
not include “take-charge” time.

SB-211-007 — Page 6 of 6