Service Bulletin

Mack Trucks, Inc.

Greensboro, NC USA Trucks
Date Group No. Release Page

5.2010 213 42 1(16)

Piston and Liner

Replacement
MP10

Piston and Liner, Replacement

T2022501

This information covers the replacement procedures for the pistons and cylinder liners on
the MACK MP10 engines.

Contents
• “Special Tools”, page 2
• “Piston and Liner, Replacement (One)”, page 3

Note: Information is subject to change without notice. Illustrations are used for reference
only and can differ slightly from the actual vehicle being serviced. However, key
components addressed in this information are represented as accurately as possible.

PV776-88972098 USA41990
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2010 213 42 2(16)

Tools
Special Tools
For Special Tools ordering instructions, refer to Tool Information, Group 08.

C0000223
T0010788

T0012612

85109123 88800014 9989876

Cylinder Liner Press Tool Flywheel Turning Tool Dial Indicator Tool

T0011180 W0001770 W2057087

9990158 9992479 9996963

Ring Compressor Tool Dial Indicator Holder Tool Cylinder Liner Driver Tool

T0011078 W0001790 W0002114

9998511 9999696 PT6400C

Lever Tool Magnetic Stand Tool Cylinder Liner Puller Tool

W0001720

PT6410–4A
Puller Feet (Used With PT6400C Tool)
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2010 213 42 3(16)

Service Procedures
2131-03-03-02
Piston and Liner, Replacement (One)
Cylinder head and oil pan removed

You must read and understand the precautions and

guidelines in Service Information, Group 20, "General
Safety Practices, Engine" before performing this
procedure. If you are not properly trained and certified
in this procedure, ask your supervisor for training before
you perform it.

WARNING
The cylinder liner’s O-rings are made from fluorine-rubber.
When fluorine-rubber is exposed to high temperatures
(above 300 °C / 572 °F) hydrofluoric acid can be
generated. Hydrofluoric acid is extremely corrosive!
Contact with skin can result in serious corrosion injuries.
If splashed in the eyes, corrosion sores can occur.
Inhalation of vapors can damage the respiratory tract.

WARNING
Take great care when working on engines which have
been exposed to high temperatures, resulting for
example from overheating, cutting, or fire. Under no
circumstances are cylinder liner O-rings to be burned
off when dismantling or destroyed by burning under
uncontrolled conditions. Always use neoprene gloves
(gloves approved for handling chemicals) and protective
goggles. Handle removed O-rings in the same way as
corrosive acids. Never blow clean using compressed air.
All remnants, including ashes, can be highly corrosive.
Place all remnants in plastic containers, to which warning
text is attached. Before taking the gloves off, they must
be washed under running water.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2010 213 42 4(16)

Removal
Special tools: 85109123, 88800014, 9989876,
9990158, 9992479, 9996963, 9998511,
9999696, PT6400C, PT6410–4A
1
1
Remove the fasteners from the oil strainer.

W2004952

2
2
Remove the oil strainer and suction tube from the oil
pump.

Note: Use care when removing the oil strainer from the
oil pump assembly. The plastic oil strainer has an O-ring
attached to the tube that is installed into the oil pump.

W2004957

3
3
Loosen the coupling nut securing the oil pump outlet
(pressure) pipe at the cylinder block. Carefully pull the
outlet pipe from the oil pump housing and remove the
pipe from the engine.

W2004958

4
4
Remove the O-rings from the suction and outlet pipes
and discard.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2010 213 42 5(16)

5
5
With assistance, support the engine stiffening frame and
remove the fasteners securing the frame to the cylinder
block. Remove the stiffening frame from the engine.

WARNING
The stiffening frame has sharp edges. To prevent
personal injury, use protective gloves.

W2005149

6
6
Remove the plug from the flywheel housing and install
the flywheel turning tool. Turn the crankshaft until it is
possible to get at the bolts on the connecting rod that is
to be removed.

88800014

T2022960

7
7
Remove the fastener from the piston cooling nozzle and
remove the nozzle from the cylinder block for the cylinder
that is being serviced.

Note: Inspect the piston cooling nozzle. Clean the nozzle

of any contamination.

CAUTION
Do not bend the tube of the piston cooling nozzle;
doing so will permanently damage the nozzle.

T2023154
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2010 213 42 6(16)

8
8
Remove the connecting rod bearing cap bolts. Remove
the cap.

T2023670

9
9
Push the piston up until the piston rings are above the
top edge of the cylinder liner. Lift out the piston and
connecting rod.

Note: Use a wooden handle or similar tool to force the

piston and connecting rod out of the top of the cylinder
block.

Note: If the cylinder liner is excessively worn, polish the

top edge of the liner to remove the ridge and make it
easier to remove the piston.

T2023445

10
10
Label the connecting rods as they are removed so they
can be reinstalled in their original location.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2010 213 42 7(16)

11
11

Use the cylinder liner puller tool and puller feet to remove
the cylinder liner from the cylinder block.

PT6400C, PT6410–4A

W2005255

12
12
Remove the cylinder liner sealing rings.
13
13
Remove the snap rings from the piston and push out the
piston pin. Remove the piston from the connecting rod.

T2022501

14
14
Repeat the procedure for all pistons and liners.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2010 213 42 8(16)

15
15
Carefully clean the sealing surfaces on the cylinder block
and the grooves for the sealing rings using a brush and
appropriate cleaning agent.

CAUTION
Do not use scrapers or other tools that can damage
the sealing surfaces.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2010 213 42 9(16)

Installation
1
1

Install the new cylinder liner, without the sealing rings.

Secure the cylinder liner with two cylinder liner press
tools. Tighten the press tools to specification.

85109123

W2006210

2
2

Install the dial indicator gauge onto the dial indicator

gauge holder. Place the holder with the dial indicator
gauge across the cylinder liner. Zero the dial indicator
gauge to the cylinder block face.

9989876, 9992479

T2019670
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2010 213 42 10(16)

3
3

Measure the height between the cylinder liner and the

engine block face. Measure the height of the liner at two
diagonally opposite locations. Calculate the average
of both the measurements. For the correct liner height
above the block surface see Specifications, Function
Group 20.

Note: Always measure at the highest point on the sealing

surface.

Mark the liner’s position on the cylinder block with a felt

tip pen so that it can be put back in the same position
during assembly. Repeat the procedure for the remaining
cylinder liners.
T2019761
Note: Make sure any required shims remain matched
with the cylinder liner.
4
4
Remove the cylinder liner press tools (retainers).

Remove the cylinder liner from the cylinder block.

5
5
Lubricate the sealing rings with the lubricant provided in
the cylinder liner kit and install them on the cylinder liner.
Place the cylinder liners in the cylinder block in the same
position as previously marked, together with any shims.

Note: Place the sealing rings in accordance with color

coding: small black ring at the top of liner, large black ring
on lower upper groove, large violet ring on lower groove.

T2019856
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2010 213 42 11(16)

6
6
If the cylinder liner is installed without a shim, apply an
even 0.8 mm (0.031 inch) bead of approved sealant to
the underside of the cylinder liner collar.

Note: Once the sealant has been applied, the liner must
be inserted within 20 minutes and be pressed down into
the engine block with two press tools.

85109123

T2008973

7
7
If the cylinder liner is installed with shims, apply the
approved sealant on the cylinder block liner seat before
the cylinder liner is inserted.

Note: If the liner has a shim, the sealant must be applied

before the shim. No sealant is to be used between the
adjustment shim and the cylinder liner’s collar.

Note: Once the sealant has been applied, the liner must
be inserted within 20 minutes and be pressed down into
the engine block with two press tools.

T2009013
85109123
8
8
Install the cylinder liner and any required shim(s) into the
cylinder block.
9
9

Install a cylinder head bolt (A) into a cylinder head bolt

hole next to the cylinder liner to be installed. Place the
cylinder liner driver over the cylinder liner along with a
suitable spacer (B). Using the pry bar tool, press the
cylinder liner into place until fully seated. Install a press
tool on each side of the cylinder liner until the sealant has
cured. Tighten the press tools to specification.

85109123, 9996963, 9998511

W2006223
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2010 213 42 12(16)

10
10
Lubricate the piston pin, piston pin bushing, and
connecting rod bushing with clean engine oil.

Note: Check the condition of the piston pin bushing in the

connecting rod before assembly. Replace if necessary.

T2022502

11
11

Install the connecting rod in the piston with the marking

“FRONT” on the connecting rod and the arrow on the
piston facing the same direction. Push in the piston pin.

Note: The piston pin should go in when pushed without

any great force. If the resistance is too great, the piston
needs to be heated. The connecting rod should rotate
freely on the piston pin.

T2022504

12
12
Install the snap rings.

T2022501
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2010 213 42 13(16)

13
13
Install the piston rings using piston ring pliers.

Note: All the piston rings are marked with letters or

punch marks. These marks should face upwards when
installed.

T2022726

14
14
Rotate the piston rings so that the ring gaps are not
aligned with each other. The piston ring gaps should be
spaced 60° apart.
15
15
Lubricate the piston and the piston rings with clean
engine oil.
16
16

Insert the piston/connecting rod assembly into the

cylinder block using a piston ring compressor. The
piston/rod assembly should be installed in its original
location in the cylinder block.

Note: Temporarily remove the cylinder liner press tools

when the piston is installed. Reinstall the press tools
when the piston is in position.

Note: The pistons/rod assemblies should be installed

with the marked front of the assembly toward the front of
the engine.

85109123, 9990158

W2006230

17
17
Use compressed air to carefully clean the mating and
bearing surfaces of the connecting rods and bearing
caps. Inspect the connecting rods and bearing caps for
damage. Replace the assemblies as needed.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2010 213 42 14(16)

18
18
Lubricate the connecting rod bearings and the crankshaft
with clean engine oil. Install the connecting rod bearings.
Make sure the bearings are positioned correctly on the
connecting rod and connecting rod bearing cap.
19
19
Install the connecting rod bearing cap according to the
markings. Lubricate the bearing cap bolts with clean
engine oil. Install and tighten the bearing cap bolts to
specification.

T2019085

20
20
Install all remaining piston and connecting rod
assemblies, if applicable.
21
21
After the connecting rod bearing cap bolts have been
tightened, check the axial (side) clearance between the
connecting rod and the crankshaft for each assembly
being replaced. Maximum axial (side) clearance is 0.25
mm (0.0098 inch). If the connecting rod axial clearance
is beyond the limit, replace the connecting rod and/or
the crankshaft.
22
22
Clean the piston cooling nozzle using compressed air and
check that it is not damaged. Install the piston cooling
nozzle with a new fastener.

Note: Use only new fasteners, pretreated with thread

locking material.

Tighten the fastener to specification.

CAUTION
Do not bend the tube of the piston cooling nozzle;
doing so will permanently damage the nozzle.

23
23
Install all remaining piston cooling nozzles in the same
manner, if applicable.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2010 213 42 15(16)

24
24
If the cylinder block deck surface has not been machined,
proceed with Step 25 below. If the cylinder block deck
surface has been machined, measure the height of all
replaced pistons as follows:
1 Install the magnetic stand and dial indicator. Zero the
dial indicator gauge on the surface of the cylinder
block.
2 With the piston at top dead center (TDC), use the dial
indicator gauge to measure the height of the piston
above the deck surface of the cylinder block. The
height (protrusion) should be within 0.15–0.65 mm
(0.006–0.026 inch).
3 If the piston height is not within the specifications,
replace the piston and/or the connecting rod.

9989876, 9999696
25
25
Remove flywheel turning tool and replace the plug in the
flywheel housing.

88800014
26
26
With assistance, carefully place the engine stiffening
frame in position on the cylinder block and install the
fasteners.

WARNING
The stiffening frame has sharp edges. To prevent
personal injury, use protective gloves.

W2005149

27
27
Tighten the stiffening frame bolts in sequence to
specification.

T2020549
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 5.2010 213 42 16(16)

28
28
Install a new O-ring on the oil pump outlet (pressure)
pipe and lubricate with clean engine oil. Install the outlet
pipe into the oil pump housing using care to properly
seat the pipe and O-ring. Install the coupling nut to
secure the outlet pipe to the cylinder block and tighten
to specification.

W2004958

29
29
Clean and inspect the oil strainer and suction tube for
cracks. Replace if necessary.
30
30
Install a new O-ring on the suction tube and lubricate with
clean engine oil. Install the oil strainer and suction tube
into the oil pump.

Note: Use care to properly seat the suction pipe and

O-ring in the oil pump housing.

W2004957

31
31
Install the fasteners to secure the oil strainer to the
cylinder block. Tighten the fasteners to specification.

W2004952