User Manual

200 ENGINE INSTALLATION & TESTING
Page 8-3
A new S3B turbocharger with a 3.5-inch push-on
compressor discharge has replaced the earlier
S3B turbocharger with cast elbow required for
V-band connection. You will need to know which
type turbocharger is used on your engine when
ordering replacement parts.
11. Connect tube to turbocharger and air
cleaner assembly.
12. Connect heater hoses and A/C refrigerant
lines, if applicable, where attached at lower
dash panel behind engine.
13. Install fan and fan clutch assembly.
Belts used on the same drive must be installed in
matched sets. Refer to the Maintenance and
Lubrication manual, TS494, for procedures and
specifications.
14. Install and adjust belts per specifications.
15. Install radiator using a lifting device and an
assistant, if required.
16. Install retaining capscrews to radiator
support mounts.
17. Install retaining capscrews to radiator
support rods at radiator support.
18. Install fastener to bracket that secures
radiator fan air clutch solenoid valve to
radiator support.
19. Locate engine coolant temperature sensor
and connect electrical connector. Install
sensor harness to radiator support.
20. Connect Chassis-Mounted Charge Air
Cooler (CMCAC) outlet hose at cooler.
21. Connect CMCAC inlet hose at cooler.
22. Install clamps that retain coolant overflow
tank and install tank.
23. Connect lower radiator hose to coolant inlet
of oil cooler assembly.
24. Connect upper radiator hose to engine
coolant outlet fitting.
25. If vehicle is equipped with air conditioning:
a. Connect electrical connector to low-
pressure cutout switch in A/C
refrigerant line.
b. Connect electrical connector to binary
(cycling clutch) pressure switch on
receiver/dryer.
c. Connect A/C line at receiver/dryer.
d. Connect A/C compressor discharge
hose at connection near radiator
support.
e. Obtain A/C refrigerant recovery and
recycling equipment (J 38750-A for
R12 or J 39500-B for R134A), and
recover A/C system refrigerant.
26. Tighten clamps securing air intake tube to
turbocharger and air filter. Install intake tube.
27. Install hood. Refer to Hood Installation
procedures in the appropriate vehicle
manual.
Filter Element Installation
All filters and coolant conditioners must meet
MACK specifications. Prime oil filters before
installation using the correct specification engine
oil.
1. Install a new air filter in air filter housing.
2. Install Centri-Max™ assembly. Be sure to
use a new element and O-rings.
3. Using an appropriate filter wrench such as
J 29927, install oil filter elements and
coolant conditioner element.
Prime fuel filter elements before installation. Use
only clean, MACK-specified, Grade 2D diesel
fuel.
4. Prime the PRIMARY fuel filter element (red)
by filling with clean No. 2 fuel oil. Do not fill
filter through center hole; it must be filled
using outer holes. Lubricate gasket with oil
and install filter.
5-101.bk Page 3 Friday, March 17, 2006 11:05 AM