Service Bulletin

Mack Trucks, Inc.

Greensboro, NC USA Trucks
Date Group No. Release Page
1.2014 251 48 01 1(10)

Intake Manifold, Replacement

MP8

Intake Manifold, Replacement

This information covers the proper procedure for replacing the intake manifold on the MP8
engine.

Note: Information is subject to change without notice.

Illustrations are used for reference only, and may differ slightly from the actual engine
version. However, key components addressed in this information are represented as
accurately as possible.

PV776-89125588 USA61554
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2014 251 48 01 2(10)

Service Procedures
2511-03-02-04
Intake Manifold, Replacement
You must read and understand the precautions and guide-
lines in Service Information, Function Group 20, "Engine
Safety Practices" before performing this procedure. If you
are not properly trained and certified in this procedure, ask
your supervisor for training before you perform it.

Removal
1
Secure the vehicle for service by parking it on a level surface,
applying the parking brake, chocking the wheels, and placing
the transmission in neutral or park.

2
Disconnect all cables from the negative (ground) battery ter-
minals to prevent personal injury from electrical shock and
prevent damage to electrical components.

3
Remove the engine charge air cooler pipe between the en-
gine charge air cooler and the EGR mixing chamber. Discard
the O-rings.

W2006091

4
Remove the EGR temperature sensor from the EGR cross-
over pipe.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2014 251 48 01 3(10)

5
Remove the EGR crossover pipe and the flex pipe as an as-
sembly by (1) removing the fasteners and mounting bracket
securing the middle of the crossover pipe, (2) removing the
V-band clamp securing the lower end of the crossover pipe to
the venturi outlet, and (3) removing the hose clamp connect-
ing the flex pipe.
Note: Discard the removed flex pipe and O-ring. Use a new
flex pipe and O-ring when the EGR crossover pipe is re-
installed.

W2083919

1 – EGR Flex Hose Clamps

2 – EGR Flex Hose

6
Remove the fasteners securing the fan ring support bracket
to the EGR mixing chamber. Remove the fasteners securing
the mixing chamber to the intake air heater (IAH) or spacer
block. Remove the mixing chamber and inlet pipe as an as-
sembly. Discard the EGR mixing chamber gasket.

W2083932

1 – EGR Mixing Chamber Fasteners

2 – EGR Mixing Chamber
3 – Mounting Spacers
4 – EGR Mixing Chamber Gasket
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2014 251 48 01 4(10)

7
If equipped, remove all power and ground cables from the
IAH. Remove the IAH from the intake manifold. Remove the
IAH relay (with the bracket and wires attached) from the in-
take manifold.
Note: Mark the cable locations before removal to ensure cor-
rect installation at reassembly.

W2006121

8
Loosen the clamp and the mounting brackets to allow air
compressor intake air line to be relocated.

9
Remove the crankcase ventilation tube from both ends and
remove the clamp.

W2083757

1– Crankcase Ventilation Tube Quick Disconnect

10
Remove the bracket securing the air compressor intake air
line to the intake manifold.

11
Disconnect the discharge line and the mounting brackets
from the air compressor and the intake manifold. Move the
discharge line out of the way and strap in place.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2014 251 48 01 5(10)

12
Remove the P-clamp fasteners securing the engine harness
to the intake manifold.

13
Cut the cable ties from the wiring harness. Remove the wiring
harness connector from the intake manifold air temperature/
pressure sensor located on the top of the intake manifold.

W2006123

14
Remove two of the top intake manifold mounting fasteners.
Install two alignment dowels to support the intake manifold.

15
Remove the remaining intake manifold mounting fasteners.
Using a plastic mallet, carefully tap the manifold loose and re-
move. Discard the intake manifold gasket.

W2006117

16
Inspect the cylinder head and ensure the sealing surface is
clean and undamaged.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2014 251 48 01 6(10)

Install
1
Install a new rubber seal (molded gasket) into the groove of
the intake manifold.

2
Position the intake manifold onto the two previously installed
alignment dowels. Start two mounting fasteners to hold the
intake manifold in place. Remove the alignment dowels. In-
stall the remaining intake manifold fasteners.

W2006117

3
Tighten the intake manifold fasteners to specification in the
sequence shown, refer to Function Group 20,
“Specifications”.

W2006010

4
Secure the wiring harness to the intake manifold using the
previously removed P-clamps.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2014 251 48 01 7(10)

5
Reconnect the wiring harness connector to the intake mani-
fold air temperature/pressure sensor located on the top of the
intake. Secure the wiring harness with cable ties.

W2006123

6
Connect the discharge line and the mounting brackets to the
air compressor and the intake manifold.

7
Install the bracket securing the air compressor intake air line
to the intake manifold.

8
Position the clamp onto the crankcase ventilation tube. Con-
nect the crankcase ventilation tube to both ends where previ-
ously removed. Install the clamp and tighten to specification.

W2083757

1– Crankcase Ventilation Tube Quick Connect

9
Position the air compressor intake air pipe. Install the mount-
ing brackets and the hose clamp to secure.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2014 251 48 01 8(10)

10
Clean the forward sealing surface on the intake manifold, the
IAH or spacer block, and the EGR mixing chamber.

11
Install the EGR mixing chamber assembly onto the IAH or
spacer block with a new gasket. Install EGR mixing chamber
fasteners and tighten to specification.

W2083932

1 – EGR Mixing Chamber Fasteners

2 – EGR Mixing Chamber
3 – Mounting Spacers
4 – EGR Mixing Chamber Gasket

12
Install the fan ring support bracket to the EGR mixing cham-
ber and tighten the fasteners to specification.

13
If equipped with an IAH, position and install the IAH relay
bracket (with relay attached) to the mounting surface on the
intake manifold. Connect and secure the power and ground
cables as marked at disassembly.

W2006121
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2014 251 48 01 9(10)

14
Install the engine charge air cooler pipe between the engine
charge air cooler and the EGR mixing chamber, using new
O-rings. Tighten clamps to specification.

W2006091

15
Install the EGR crossover pipe using a new crossover-to-
venturi O-ring. To do this, connect the upper end of the cross-
over pipe using a new flex pipe and two hose clamps. Then,
position the lower part of the EGR crossover pipe onto the
venturi outlet and secure with a V-band clamp. Secure the
middle of the pipe with the mounting bracket and fasteners.
Note: Lubricate the V-band clamp threads and V-inserts be-
fore using to secure the pipe.

Note: V-band clamps are one-time use only. Do not reuse.

Note: Make sure the O-ring between the venturi and the
crossover pipe remains in place while positioning the pipe.

W2083919

1 – EGR Flex Hose Clamps

2 – EGR Flex Hose

16
Tighten the flex pipe hose clamps and the V-band clamp to
specification.

17
Install the EGR temperature sensor in the EGR crossover
pipe.

18
Reconnect all previously removed cables to the negative
(ground) battery terminals.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2014 251 48 01 10(10)

19
Start the engine, check for leaks and proper operation. After
shutdown, replenish fluids as necessary.

20
Remove the wheel chocks.