SERVICE BULLETIN

Number: SB222008
Date: 03/02/06
Model: ASET™,
E-Tech™
(Also applies to Mack Trucks Australia)
(Supersedes SB222008 dated 09/17/04)

High-Pressure Fuel Injection Lines — ASET™ and

E-Tech™ Engines
Effective June 2004, high-pressure fuel lines (part No. 203GC4380AM) designed to provide
a leak-free joint at both the pump and nozzle connections were made available for E-Tech™
and ASET™ engines. Improvements to the high-pressure fuel lines include the following:
앫 Pump end connection — threads extend deeper into the clamp nut to ensure proper
clamping
앫 Nozzle end connection — increased collar hardness to prevent deformation
앫 Line tubing — pre-stressed at a higher pressure for improved durability
1

Figure 1 — High-Pressure Fuel Injection Line (Part No. 203GC4380AM)

DO NOT BEND A FUEL LINE. The fuel line manufacturing

process includes a pre-stress operation where the lines are
subjected to a high hydraulic pressure after the lines have been
bent to proper design specifications. Bending a fuel line after this
process will destroy the strengthening benefits of the pre-stress
operation, and will result in an increased risk of a subsequent
fuel line split/breakage types of failure. The fuel lines must not
be bent in any way, whether to facilitate removal or installation,
or for any other reason. Even bending the line slightly and then
bending it back to its original shape can damage the line.
On ASET™ AC engines, difficulty removing the No. 3 high-
pressure injection line may be encountered due to interference
with the turbocharger. Refer to SB222012 for proper procedures.

SB222008 — Page 1 of 2
SERVICE PUBLICATIONS, ALLENTOWN, PA 18105 ©MACK TRUCKS, INC. 2006
High-pressure fuel injection lines having the above improvements can be identified by two
number 4s stamped on the top of the line nut, and by the absence of the green rubber collar
at the clamp nut on the nozzle end. During the third quarter 2004, the stamped numbers will
change each month to denote the month the line was manufactured.

If the collar of an existing high-pressure fuel line is

“mushroomed” or exhibits other type of damage, replace the line
with a new 203GC4380AM high-pressure fuel line. An example
of a “mushroomed” collar is shown in the illustration below.
2

Figure 2 — “Mushroomed” Collar

Always tighten the line nuts to proper specifications. Torque specifications are as follows:
앫 Line end at cylinder head — 35 lb-ft (48 N•m)
앫 Line end at unit pump — 30 lb-ft (41 N•m)

To accurately achieve the above torque specifications, a flare nut crowfoot must be used, as
an open-end crowfoot will begin to spread above 25 lb-ft (34 N•m).

Mack Trucks, Inc. engages in a continuous program of evaluation and testing to provide the
best possible product. While product enhancements are a natural result, Mack Trucks, Inc. is
not liable for or committed to updating existing chassis.

SB222008 — Page 2 of 2