Mack Trucks, Inc.

Service Alert SA-210-005

Electronic Service Bulletin

Date: 13 August 2003 Number: 200-2003-225-01

To: All U.S. & Canadian Distributors
Attention: Service Manager, Warranty Manager, Parts Manager
From: Mack Powertrain Service Engineering
Subject: ASET AC Cylinder Cut-Out Test Reports Incorrect Cylinder Number

COMPLAINT:

The cylinder cut-out test used to identify which cylinder has a problem is providing the wrong cylinder
number.

CAUSE:

The ASET AC cut-out test from start of ASET AC production thru 6/25/03 has been reporting the
FIRING ORDER SEQUENCE of the cylinder rather than the actual and traditionally used, POSITION
NUMBER of the cylinder.

CYLINDER FIRING ORDER-------------1---5---3---6---2---4

CYLINDER POSITION NUMBER-------1---2---3---4---5---6

Cylinder numbers 1 & 3 are reported by the same number, whether firing order or cylinder position is
used, so these cylinders are not affected.

Cylinders # 2, 4, 5, & 6 are affected.

For these cylinders:

When number 2 is shown the problem is at cylinder 5.

When number 4 is shown the problem is at cylinder 6.
When number 5 is shown the problem is at cylinder 2.
When number 6 is shown the problem is at cylinder 4.

CORRECTION:

1MS334A software, used in approximately the first 200 ASET AC engines, will be corrected as soon
as possible (the availability date has not yet been determined).

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1MS368 software used in all subsequent ASET AC engines was corrected 6/26/03. All engines
programmed at Hagerstown or the field on or after this date have the correct cylinder number
identified when the cylinder cut-out test is used.

If the cylinder cut-out test is being used for troubleshooting purposes it is recommended to download
the current data file if this has not already been done on 6/26/03 or later.

WARRANTY REPAIR STRATEGY:

Download costs will be reimbursed only when necessary for diagnosis of a warrantable repair.

Labor code: 230EG2R18 = 0.8

(Note: Existing time of 1.2 has been re-evaluated, re-studied, and updated to 0.8 and will appear in
the October release)

Mack Powertrain Service Engineering

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