SERVICE

BULLETIN
NUMBER: DATE: MODEL: SB-637-019 2/26/02 CH, CX

(Does not apply to Mack Trucks Australia)

AIR CONDITIONER EXPANSION VALVE INTERFERENCE WITH CYLINDER HEAD COVER CH612 AND CX612 MODEL CHASSIS
On CH612 and CX612 model chassis equipped with air conditioning and an engine brake, the engine is mounted at an angle that may result in an interference condition between the air conditioner expansion valve and the cylinder head cover. On these chassis, a special fabricated cylinder head cover is used at the rear cylinder head to provide necessary clearance for the expansion valve (refer to the information under the heading Cylinder Head Covers at the end of this bulletin). Even with the special fabricated cylinder head cover, clearance between the expansion valve and cylinder head cover may not be sufficient. If the expansion valve contacts the cylinder head cover, the valve can be relocated as described in this bulletin. To relocate the valve, the following parts are necessary:
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Figure 1 Expansion Valve Relocation Bracket, Extension Tubes and Hardware Key 1 2 3 4 5 6 7 8 9 Qty. 1 1 1 1 1 1 1 2 2 Part No. 3198-O201084243 3198-O201104244 230RD31 191AM1 77AM14 21AX897 1AX48 335AM9 26AM3 5166-81731 Tube, extension Tube, extension Bracket, expansion valve Nut, flange head, M6 x 1.0 Screw, Torx head, M6 x 1.0 x 12 Locknut, 1/4-28 UNF-2A Bolt, hex head, 1/4-28 UNF-2A x 1-3/8 Rivnut, M6 x 1.0 Bolt, flange head, M6 x 1.0 x 20 Weatherstrip adhesive (yellow) Description

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SERVICE PUBLICATIONS, ALLENTOWN, PA 18105 MACK TRUCKS, INC. 2002

Procedures 1. Using an approved evacuation and recovery system, evacuate the charge from the air conditioner. 2. Remove the air cleaner canister assembly along with the air cleaner center support bracket. 3. Remove the cylinder head cover from the rear head. Cover the head with clean shop rags to prevent contamination from entering the engine. 4. If replacement of the expansion valve is necessary, disconnect and remove the air conditioning hoses. If it is not necessary to replace the expansion valve, the hoses may remain connected.
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Figure 2 Air Conditioner Hoses

5. Loosen both evaporator tube fittings at the expansion valve 1/4 turn. After the tubes are loosened, remove the expansion valve retaining bolt.
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Figure 3 Loosen Evaporator Tubes and Remove Retaining Bolt

6. Disconnect the evaporator tube fittings from the expansion valve and move the valve out of the way. 7. Remove and discard the expansion valve retaining nut clip.

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8. Remove or flatten the bent tab located on the left-hand side of the existing expansion valve mounting bracket.
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Figure 4 Bend Mounting Bracket Tab

9. Secure the expansion valve relocation bracket (part No. 230RD31) to the existing mounting bracket. Use a Torx head screw (part No. 77AM14) and flanged locknut (part No. 191AM1) to secure the bracket. Position the bracket as shown below.
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Figure 5 Relocation Bracket Position

10. Tighten the Torx head screw and nut only enough so that play is minimal, while the bracket can still be rotated out of the way so that the mounting holes can be drilled in the bulkhead. 11. With the mounting bracket positioned level with the floor, use a center punch to mark the location on the bulkhead for drilling the two mounting bolt holes for the bracket.

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12. Rotate the bracket out of the way, and drill two small pilot holes. After drilling the pilot holes, enlarge the holes to 25/64.

Do not drill the holes deeper than 1 inch. Drilling the holes deeper than 1 inch will result in damage to the heater/air conditioner unit.
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Figure 6 Locating Mounting Bracket Bolt Holes

13. Apply a bead of weatherstrip adhesive (part No. 5166-81731) on the body of the two Rivnuts (part No. 335AM9). 14. Using the proper Rivnut installation tool, install the Rivnuts in the holes drilled in the bulkhead. 15. Apply a bead of weatherstrip adhesive (part No. 5166-81731) to the threads of the two flange head hex bolts (part No. 26AM3). 16. Rotate the mounting bracket back into position and install the two flange head mounting bolts. Tighten the mounting bolts and the 6 mm Torx head screw to 5 lb-ft (7 Nm). 17. Prepare the extension tubes (part Nos. 3198-O201084243 and 3198-O201104244) by removing the caps and plugs from the fittings and applying refrigerant oil to the O-rings. Apply a light coating of anti-seize compound to the threads of the fitting nuts.

Do not allow anti-seize compound to get inside the extension tubes or on the O-rings. 18. Remove and discard the O-rings on the evaporator tubes and install the new O-rings supplied with the extension tubes. Coat the O-rings with refrigerant oil and apply a light coating of anti-seize compound to the fitting threads. 19. Install the extension tubes to the evaporator fittings. The nut flats of the extension tubes must lie flat against the expansion valve mounting bracket. Tighten the evaporator tube fitting nuts until snug.

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20. Position the expansion valve against the mounting bracket and install the extension tube fittings into the ports of the expansion valve. Alternately tighten the fittings 1/4 turn each until snug to avoid stressing the evaporator core. 21. Secure the expansion valve to the mounting bracket using a hex head bolt (part No. 1AX48) and a locknut (part No. 21AX897). Tighten the bolt until the valve is snug in the bracket. Do not overtighten, as the expansion valve must be able to slide on the bracket as the extension tube fittings are tightened. 22. Alternately tighten the extension tube and evaporator fittings until completely tight. 23. Tighten the expansion valve retaining nut and bolt to 5 lb-ft (7 Nm).
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Figure 7 Relocated Expansion Valve

24. If the expansion valve has been replaced, install the hoses. 25. To accommodate the additional 3 of length created by the installation of the extension tubes, reposition the air conditioning hoses by pulling the hoses between the expansion valve and engine. It is not necessary to loosen any of the hose clamps. 26. Remove the rags covering the cylinder head and reinstall the cylinder head cover. 27. Reinstall the air cleaner canister bracket and the air cleaner. 28. Recharge the air conditioning system 29. Test the air conditioning system operation. 30. Check for leakage at the cylinder head covers.

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Cylinder Head Covers

A special fabricated cylinder head cover is used for the rear cylinder head on CH model chassis equipped with air conditioning, and an engine brake with either an E7 or E-Tech engine. This cylinder head cover has a cutout at the back of the cover to provide some clearance for the air conditioner expansion valve. On E-Tech engines manufactured July 2001 and later, a new-style cylinder head cover was phased into production on all engines whether or not the engine is equipped with an engine brake. This cylinder head cover includes the special cutout at the rear of the cover. Make sure that the proper cylinder head cover is used on the engine. If the cylinder head cover does not have the cutout at the back, it must be replaced. Refer to the cylinder head cover illustrations below for both E7 and E-Tech engines. The cylinder head cover illustrated below (part No. 337GB4108M) was used on E7 engines equipped with an engine brake.
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Figure 8 E7 Cylinder Head Cover 337GB4108M

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The cylinder head cover illustrated below (part No. 337GB4109) was used on E-Tech engines manufactured prior to July 2001 and equipped with an engine brake.
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Figure 9 E-Tech Cylinder Head Cover Prior to July 2001 337GB4109

The cylinder head cover illustrated below (part No. 337GB545) was implemented into production during July 2001 on all E-Tech engines with or without an engine brake. This cylinder head cover can be used on any E-Tech engine regardless of the build date.
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Figure 10 E-Tech Cylinder Head Cover after July 2001 337GB545

The labor code and maximum labor allowance for this operation is as follows:
637 2A 01 80 .............................................. 4.5 hr. Time allowed to relocate air conditioner expansion valve. Does not include take-charge time.

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