Mack E-TECH SB-210-034 Service Manual

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OCTOBER 2000

(REVISED)

SERVICE MANUAL

5-106

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Page 1 OCTOBER 2000 (REVISED) SERVICE MANUAL 5-106 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 2 front.fm Page -ii Friday, August 4, 2000 11:16 AM BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 3 Name: ________________________________ Phone: (_____) _____-_______ Company: _______________________________________________________ Address: ________________________________________________________ City: _________________________________ State: _______ Zip: _______ Position Title: ____________________________________________________ Thank You For Your Assistance Mack Trucks, Inc. (ATTENTION: RTS STAFF, 6S3) DO NOT STAPLE — USE TRANSPARENT TAPE BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 4 UNITED STATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO. 1602 ALLENTOWN, PA POSTAGE WILL BE PAID BY ADDRESSEE SERVICE PUBLICATIONS (RTS), 6S3 MACK TRUCKS INC WORLD HEADQUARTERS PO BOX M ALLENTOWN PA 18105-9972 FOLD ALONG THIS LINE BDC for engine manuals and specs...
Page 5 10_125erb.fm Page 2 Tuesday, April 18, 2006 11:43 AM ERRATA SHEET — ENGINE Crankshaft Center Main Bearing Specification Update Effective January 2006, Mack Powertrain Engineering has widened the crankshaft center main bearing runout specification. The maximum allowable crankshaft runout specification was changed from 0.005 in. (0.127 mm) to 0.007 in.
Page 6 DATE: 5/14/02 MODEL: E-Tech™ (Also applies to Mack Trucks Australia) MISCELLANEOUS FASTENER CHANGES — E-TECH™ ENGINES The following fastener changes were made on E-Tech™ engines: Injection Nozzle Hold-Down Screws — Beginning 3/00, the injection nozzle hold- down screws having the 15 mm external hex head have been changed to a new screw (part No.
Page 7 MAY 2006 REPRINTED 2.5M SEPTEMBER 2004 REPRINTED 2.5M APRIL 2003 REPRINTED 2.5M JUNE 2002 REPRINTED 2.5M OCTOBER 2001 REPRINTED 2.5M © MACK TRUCKS, INC. 2000 OCTOBER 2000 (REVISED – SUPERSEDED ISSUE JULY 1999) 5-106 BDC for engine manuals and specs...
Page 8 No part of this publication may be reproduced, stored in a retrieval system, or be transmitted in any form by any means including electronic, mechanical, photocopying, recording, or otherwise without prior written permission of Mack Trucks, Inc. BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 9 front.fm Page iii Friday, August 4, 2000 11:16 AM TABLE OF CONTENTS TABLE OF CONTENTS BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 10: Table Of Contents
front.fm Page iv Friday, August 4, 2000 11:16 AM TABLE OF CONTENTS INTRODUCTION ..............1 SAFETY INFORMATION .
Page 11 front.fm Page v Friday, August 4, 2000 11:16 AM TABLE OF CONTENTS Core Inspection ............. 70 CMCAC Preventive Maintenance .
Page 12 front.fm Page vi Friday, August 4, 2000 11:16 AM TABLE OF CONTENTS Air Compressor Removal ........... . . 117 Valve Cover and Spacer Removal .
Page 13 front.fm Page vii Friday, August 4, 2000 11:16 AM TABLE OF CONTENTS Valve Seat Insert Replacement ..........191 Valve Spring Inspection .
Page 14 front.fm Page viii Friday, August 4, 2000 11:16 AM TABLE OF CONTENTS Air Compressor Installation ........... 267 Electronic Unit Pump Installation .
Page 15 front.fm Page ix Friday, August 4, 2000 11:16 AM TABLE OF CONTENTS SCHEMATICS & DIAGRAMS ............333 ENGINE SYSTEM SCHEMATICS (FLUIDS FLOW) .
Page 16 front.fm Page x Friday, August 4, 2000 11:16 AM NOTES BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 17: Introduction
5_106_00.bk Page 1 Friday, August 4, 2000 11:17 AM INTRODUCTION INTRODUCTION Page 1 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 18: Safety Information
5_106_00.bk Page 2 Friday, August 4, 2000 11:17 AM INTRODUCTION SAFETY INFORMATION Advisory Labels Cautionary signal words (Danger-Warning-Caution) may appear in various locations throughout this manual. Information accented by one of these signal words must be observed to minimize the risk of personal injury to service personnel, or the possibility of improper service methods which may damage the vehicle or cause it to be unsafe.
Page 19: Service Procedures And Tool Usage
5_106_00.bk Page 3 Friday, August 4, 2000 11:17 AM INTRODUCTION Service Procedures and Tool Usage Anyone using a service procedure or tool not recommended in this manual must first satisfy himself thoroughly that neither his safety nor vehicle safety will be jeopardized by the service method he selects. Individuals deviating in any manner from the instructions provided assume all risks of consequential personal injury or damage to equipment involved.
Page 20 5_106_00.bk Page 4 Friday, August 4, 2000 11:17 AM INTRODUCTION Mack Trucks, Inc. cannot anticipate every Use hoists or jacks to lift or move heavy possible occurrence that may involve a potential objects. hazard. Accidents can be avoided by recognizing...
Page 21: Explanation Of Numerical Code
GROUP 400 — STEERING, AXLES, WHEELS AND TIRES, DRIVELINE CODE GROUP 500 — BRAKES, AUXILIARY The organization of MACK service manuals has SYSTEMS been upgraded to standardize manual content according to a reference system based on GROUP 600 — CAB, TRUCK BODY component identification.
Page 22: About This Manual
Changes from the Existing E-Tech™ longer service life. Service Procedures Manual Under Engine Setup and Adjustments, the latest Mack Trucks, Inc. has made many major setup information is provided for adjusting all improvements to this E-Tech™ Service E-Tech™ engine models. Engines perform best...
Page 23: About The E-Tech™ Engine And Its Service
The E-Tech™ engine is used in MACK trucks and European Renault VI trucks. Page 7 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 24 5_106_00.bk Page 8 Friday, August 4, 2000 11:17 AM NOTES Page 8 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 25: Identification
5_106_00.bk Page 9 Friday, August 4, 2000 11:17 AM IDENTIFICATION IDENTIFICATION Page 9 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 26: Engine Model Identification
5_106_00.bk Page 10 Friday, August 4, 2000 11:17 AM IDENTIFICATION ENGINE MODEL Block 3 — ADR Regulations IDENTIFICATION An “X” in block three means the engine has been certified to meet Australian emissions regulations. Engine Information Plate Two dashes in block three mean the engine The E-Tech™...
Page 27 5_106_00.bk Page 11 Friday, August 4, 2000 11:17 AM IDENTIFICATION Figure 1 — Engine Information Plate Location Page 11 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 28: Engine Serial Number Identification
5_106_00.bk Page 12 Friday, August 4, 2000 11:17 AM IDENTIFICATION Figure 2 — Engine Information Plate Engine Serial Number Identification In addition to the engine information plate on the front cylinder head cover, the engine is also identified by the engine serial number stamped into the cylinder block.
Page 29: Description & Operation
5_106_00.bk Page 13 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION DESCRIPTION & OPERATION Page 13 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 30: E-Tech™ Engine Design Features
5_106_00.bk Page 14 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION E-TECH™ ENGINE DESIGN The EUP is very similar to a unit injector. The primary difference is that the EUP delivers fuel FEATURES through a fuel injection line to a conventional- style nozzle-holder assembly, whereas a unit The E-Tech™...
Page 31 Current production E-Tech™ engines contain EUPs with three O-rings. On future production engines the center O-ring will be eliminated. Present EUP service kits available through MACK service parts do not contain the center (brown) O-ring. Page 15 BDC for engine manuals and specs...
Page 32: V-Mac Iii
5_106_00.bk Page 16 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION V-MAC III The V-MAC III engine control system has been developed specifically for the E-Tech™ engine. Features include electronic drivers and diagnostics for unit pumps, separate engine and vehicle control units, and a revised wiring harness.
Page 33 5_106_00.bk Page 17 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION For current-production engines, the EECU is With the two-module design, a more efficient and relocated to the left side of the engine (Figure 9) reliable electronic communication network, and mounted on a new one-piece air inlet known as multiplexing, can be used.
Page 34 5_106_00.bk Page 18 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION The chassis-mounted ambient air temperature sensor was not available with early-production engines. It was phased into production beginning approximately mid-July 1999 for CX model chassis, mid-September 1999 for CH, CL, RD8, MR, DM and DMM model chassis and early November 1999 for RD6, RB and LE model chassis.
Page 35 5_106_00.bk Page 19 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION Figure 11 — V-MAC III Engine-Mounted Sensor Locations (with Left-Side Mounted EECU) 1. Fuel Temperature Sensor (Behind Fittings) 5. Oil Temperature Sensor (on Filter Mounting Bracket) 2. Dash Gauge Coolant Temperature Sensor (on Side of 6.
Page 36 5_106_00.bk Page 20 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION On current-production engines with the left-side inlet is at the front, or the center). There is a large mounted EECU, the boost temperature sensor boss at the rear of the manifold for boost air port has been moved to the manifold inlet area supply to the air compressor and boost pressure (depending upon chassis model, the manifold...
Page 37 5_106_00.bk Page 21 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION Figure 14 — V-MAC Sensor Locations with Center Air Inlet Manifold (Left-Side Mounted EECU) A. Side View 4. Boost Pressure Port for Line-to-Dash Gauge or Boost B. Top View Pressure Sensor 1.
Page 38 5_106_00.bk Page 22 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION Fuel Temperature Sensor On current-production engines with the left-side mounted EECU, the fuel temperature sensor is On early-production engines with a right-side located at the fuel cylinder block fuel gallery inlet mounted EECU, a fuel temperature sensor is (Figure 16).
Page 39 5_106_00.bk Page 23 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION Engine Speed Sensor This sensor is located at the left side of the engine flywheel housing (Figure 17). It is flange- mounted and held in place by a retaining screw. The engine speed sensor is the same part number as the engine position sensor, located on the engine front cover.
Page 40: Belt Drive System
5_106_00.bk Page 24 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION Belt Drive System J-Tech™ Engine Brake The belt drive system uses a single 10-rib poly-v The J-Tech™ engine brake is a vehicle-slowing belt to drive the alternator, water pump, and fan device that allows the engine to act as an air drive (Figure 20).
Page 41 5_106_00.bk Page 25 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION ENGINE BRAKE FEATURES Unique exhaust rocker arm adjusting screws and nuts (Figure 21). Refer to Figure 22. There are major valve train changes relative to engine brake implementation on the E-Tech™ engine.
Page 42 5_106_00.bk Page 26 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION ENGINE BRAKE OPERATION Refer to Figure 23. To help prevent breaking or dislodging of the The J-Tech™ brake functions in the following control valve snap ring, the J-Tech™ control manner: valve components have been redesigned to incorporate a new-style collar (which replaces the...
Page 43: Camshaft
5_106_00.bk Page 27 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION Camshaft Valve Train The large diameter of the camshaft (Figure 24) The valve train accommodates the aggressive provides the strength necessary for actuating the cam profiles. Roller lifters and roller followers or unit pumps.
Page 44 5_106_00.bk Page 28 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION VALVE SEALS YOKES The engines are produced with a valve stem seal Pin-Type Yokes that features a multi-lip upper section, combined with a second lip to significantly reduce During February of 1999, the welded wear pad- crankcase blow-by.
Page 45 5_106_00.bk Page 29 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION On E-Tech™ and E7 engines, the valve yokes are very similar. However, it extremely critical that the correct valve yokes are used with the correct engine. The previous configuration yokes were identified with the letter “M”...
Page 46 5_106_00.bk Page 30 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION Do not interchange yokes. If an E-Tech™ yoke is used on an earlier E7 engine, the valve keepers will become dislodged and cause a dropped valve. This will cause severe engine damage. If the E7 yoke is used on an exhaust location of a J-Tech™...
Page 47 5_106_00.bk Page 31 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION Pinless Valve Yokes — Inlet Valve Locations screw. For the exhaust valves, it is still necessary to adjust the valve yoke first, then the rocker arm Beginning on March 2, 2000 (engine serial lash.
Page 48: Low-Pressure Fuel System
5_106_00.bk Page 32 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION ROCKER ARMS Low-Pressure Fuel System Early-production E-Tech™ used the older-style The flow of fuel through the low-pressure side of E7 rocker arms. Effective second quarter 1997, a the fuel system is essentially the same as that in newly designed rocker arm (Figure 33) on which the E7 engine for current-production engines with the slipper-end wear surface is a hardened,...
Page 49 5_106_00.bk Page 33 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION Figure 34 — Low-Pressure Fuel System Page 33 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 50: Fuel Filtration System
5_106_00.bk Page 34 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION Fuel Filtration System The fuel filter mounting adapter is made from a casting, on which the primary and secondary To build up the extremely high pressures required mounting flanges are the same large size for improved combustion, unit pumps must have (Figure 36).
Page 51: High-Pressure Fuel System
5_106_00.bk Page 35 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION High-Pressure Fuel System Fuel is supplied to each of the unit pumps by the fuel supply gallery in the cylinder block. The high The high-pressure fuel system (Figure 37) is pressure required for fuel injection is generated designed to provide fuel to the combustion by a pump plunger (10 mm diameter, 18 mm...
Page 52: High-Pressure Fuel Injection Lines
5_106_00.bk Page 36 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION High-Pressure Fuel Injection Lines High-pressure fuel lines for each cylinder A check valve is incorporated in the nozzle (Figure 38) are short (17 inches) and have the holders on current-production engines. same bends and the strength to withstand the high fuel pressure generated by electronic unit pumps.
Page 53: Cylinder Block
5_106_00.bk Page 37 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION Cylinder Block Due to the large camshaft diameter, the cam bore position is shifted up and outboard to operate the The cylinder block is a single-piece design made unit pumps and provide cam-to-crank clearance of high-strength alloyed gray cast iron.
Page 54 5_106_00.bk Page 38 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION The main oil gallery runs along the left side of the Current-production cylinder blocks were changed block. A second oil gallery — the valve lifter/EUP to accommodate a redesigned oil cooler/filter oil supply gallery —...
Page 55 5_106_00.bk Page 39 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION Figure 41 — Oil Filter Pedestal Mounting Pad and External Oil Drain Block-Off Plate 1. Oil Passage — Oil Pump-to-Oil Cooler and Filters 3. External Oil Drain Block-Off Plate 2.
Page 56: Crankshaft
5_106_00.bk Page 40 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION Crankshaft Block Heater for Front (Water Pump) Location The crankshaft is fully counterbalanced and has induction hardened journals. There are seven The engine accepts a straight element unit in the main bearings with thrust washers located at the rear location.
Page 57: Cylinder Head
5_106_00.bk Page 41 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION Cylinder Head exhaust valves per cylinder. Circular grooves correspond with the fire ring bead on the cylinder The cast iron cylinder head (Figure 43) is sleeves. This design sets the fire ring over the constructed using a special iron alloy.
Page 58 5_106_00.bk Page 42 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION Some characteristics of the E-Tech™ cylinder Lower exhaust stud holes intersect with head are not visually evident, but are still push rod holes; upper exhaust holes may significant (Figure 44). They include the following intersect as well.
Page 59: Cylinder Head Gasket
5_106_00.bk Page 43 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION Cylinder Head Gasket E7 and E-Tech™ engines use the same fire ring, but a different cylinder head gasket. The gaskets are identical except for obvious differences at the right-side push rod cutout areas.
Page 60: Gear Train
5_106_00.bk Page 44 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION Gear Train The larger camshaft on the E-Tech™ had to be relocated upward and outward from the original The gear train of the E-Tech™ engine (Figure 46) E7 location in order for the engine camshaft to is designed to accommodate the large diameter drive the unit pumps.
Page 61: Air Compressor
5_106_00.bk Page 45 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION Power Steering Pump E7 and E-Tech™ engines have the capability of There are 45 gear teeth on the crankshaft gear, driving a power steering pump from either the 90 teeth on the camshaft gear and 48 on the idler front or rear of the auxiliary shaft.
Page 62: Front Cover
5_106_00.bk Page 46 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION Front Cover Refer to Figure 49. The front cover has been designed with a boss for the automatic belt tensioner, room for the idler gear, a mounting for the crankcase breather, and a boss for the engine position sensor.
Page 63: Centri-Max® Oil Filter Breather Vent
5_106_00.bk Page 47 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION Figure 51 — Crankcase Breather (Current Production) 1. Fiberglass-Reinforced Nylon Housing 4. Filter Element 2. Cover 5. Assembly Mounting O-Ring/Gasket 3. Cover O-Ring ® Centri-Max Oil Filter Breather Vent MAIN OIL GALLERY The main oil gallery on the E-Tech™...
Page 64 5_106_00.bk Page 48 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION VALVE LIFTER/EUP OIL GALLERY OIL PASSAGES Refer to Figure 53. The passage from the main oil gallery to the No. 1 main bearing bore intersects the idler A second oil gallery, located above the camshaft, gear hub bore to provide lubrication to the supplies oil to the valve lifter bores and EUP idler gear bushing.
Page 65 In replacing any of these critical parts, always refer to part number information in the MACK Parts System to ensure the correct component is being used. Figure 55 — Auxiliary Shaft Figure 54 — Oil Pump Drive Gears 1.
Page 66 5_106_00.bk Page 50 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION OIL COOLER AND FILTER MOUNTING BRACKET Early-production E-Tech™ engines retained the same removable bundle-type oil cooler and filter arrangement as the E7. Current-production engines, however, have a plate-type oil cooler and a redesigned oil filter mounting arrangement.
Page 67 5_106_00.bk Page 51 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION Ports for the V-MAC III oil pressure and oil pressure for other items such as a turbo- temperature sensors are located on this mounting unloader, REPTO, a mechanical oil pressure assembly.
Page 68 5_106_00.bk Page 52 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION ® OIL FILTERS CENTRI-MAX PLUS OIL FILTER ASSEMBLY ® The oil filters on the E-Tech™ are the same as The Centri-Max PLUS oil filter assembly on those used on the E7 engine. However, the current-production engines is mounted at the top ®...
Page 69 5_106_00.bk Page 53 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION A 2-1/4-inch diameter steel coolant tube connects later engines, the O-ring connection was replaced the oil cooler water outlet to the water pump inlet. by a hose connection. The most commonly used The tube connects to the water pump with a tube has two smaller tubes attached to the main flange, and a gasket is used at the joint between...
Page 70 5_106_00.bk Page 54 Friday, August 4, 2000 11:17 AM DESCRIPTION & OPERATION OIL COOLER DE-AERATION LINE of the thermostat housing. This replaces the steel line used on CH model chassis with the To vent air which may otherwise become trapped removable bundle-type oil cooler.
Page 71: Glossary Of Terms
E-Tech™ engine. With the MACK design. Roller followers are used to provide the V-MAC III system, the EECU primarily controls...
Page 72 5_106_00.bk Page 56 Friday, August 4, 2000 11:17 AM NOTES Page 56 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 73: Troubleshooting
5_106_00.bk Page 57 Friday, August 4, 2000 11:17 AM TROUBLESHOOTING TROUBLESHOOTING Page 57 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 74: Engine Symptom Diagnosis
5. Poor quality fuel, or water in fuel. 5. Drain fuel from tank. Replace fuel filters and fill fuel tank with MACK-specified diesel fuel. 6. Incorrect engine oil viscosity. 6. Drain oil. Replace oil filters and fill crankcase with recommended grade oil.
Page 75 1. Broken or leaking high-pressure fuel lines. 1. Check for fuel leaks. Repair as necessary. 2. Poor quality fuel, or water or dirt in fuel. 2. Drain fuel from tanks. Replace fuel filters and fill tank with MACK- specified diesel fuel. 3. Air in fuel system.
Page 76 5. Poor quality fuel. 5. Drain fuel tank(s), clean system and replace fuel filters. Fill tank with MACK-specified diesel fuel. Bleed system. 6. Low fuel pressure. 6. Check for sufficient fuel in the fuel tank. Check fuel filters, replace if necessary.
Page 77 Repair or replace as required. 6. Improper grade of fuel. 6. Drain fuel from tank(s). Replace fuel filters and fill tank(s) with MACK-specified diesel fuel. 7. Defective fuel injection nozzle or unit pump. 7. Isolate defective nozzle and replace. Refer to item 8 under ENGINE MISFIRES —...
Page 78 4. Drain excess lubricating oil. If the oil is contaminated with either fuel or coolant, completely drain the oil pan. Change the oil filters. Locate the source of the leak and correct. Fill with MACK- specified engine oil. Check the oil level with the dipstick. DO NOT overfill.
Page 79 5_106_00.bk Page 63 Friday, August 4, 2000 11:17 AM TROUBLESHOOTING ENGINE OVERHEATS Possible Cause Correction 1. Coolant level low. 1. Locate cause. Look for leaking gaskets or loose or leaking hoses. Repair, replace or tighten as required. Replenish coolant. 2. Loose or worn fan belts. 2.
Page 80 MACK specifications. 5. Engine oil diluted with diesel fuel. 5. Check fuel system for leaks. Make necessary repairs. Drain diluted oil, change oil filters, and refill with oil meeting MACK specifications. 6. Defective oil pump. 6. Remove oil pressure relief valve and check condition of seat.
Page 81 5_106_00.bk Page 65 Friday, August 4, 2000 11:17 AM TROUBLESHOOTING LOW COMPRESSION Possible Cause Correction 1. Improper valve lash adjustment. 1. Adjust valve lash to specified clearance. 2. Blown head gasket. 2. Replace head gasket. 3. Broken or weak valve springs. 3.
Page 82: Camshaft Timing And Lobe Lift Checks
5_106_00.bk Page 66 Friday, August 4, 2000 11:17 AM TROUBLESHOOTING CAMSHAFT TIMING AND LOBE 3. Loosen (back off) the inlet valve rocker adjusting screw jam nut. Ensure that the LIFT CHECKS valve yoke is correctly adjusted. Adjust the [213 CH] inlet valve to zero lash.
Page 83: Chassis-Mounted Charge Air Cooling Tests
5_106_00.bk Page 67 Friday, August 4, 2000 11:17 AM TROUBLESHOOTING CHASSIS-MOUNTED CHARGE Hot turbocharged air, varying in pressure from 0.0–25 psi (0.0–172 kPa), passes through core AIR COOLING TESTS tubes where heat is transferred to the ambient air [233 FA] by heat-exchanging fins.
Page 84: Cmcac Pressure Test
5_106_00.bk Page 68 Friday, August 4, 2000 11:17 AM TROUBLESHOOTING CMCAC Pressure Test 5. When plugs are secured, attach an air line (fitted to a pressure regulator and gauge) to Refer to Figure 62. the air line adapter in the core outlet opening.
Page 85: Restriction Pressure Test
5_106_00.bk Page 69 Friday, August 4, 2000 11:17 AM TROUBLESHOOTING Restriction Pressure Test If using manometers for this test, the difference between readings should not exceed 4 in-Hg Perform the restriction pressure test at maximum (13.5 kPa). full-load condition. 4. Stop the engine. A restriction in the internal portion of the cooler 5.
Page 86: Core Inspection
5_106_00.bk Page 70 Friday, August 4, 2000 11:17 AM TROUBLESHOOTING Core Inspection damage is encountered. To ensure that the CMCAC system will function properly after repair GUIDELINES or replacement, a pressure/leak test is recommended. With the exception of straightening minor bends in the cold fins, the CMCAC core is not repairable and should be replaced when more extensive Recommended Repair...
Page 87: Cylinder Head And Cylinder Block Leak Test Procedure
5_106_00.bk Page 71 Friday, August 4, 2000 11:17 AM TROUBLESHOOTING CYLINDER HEAD AND CYLINDER BLOCK LEAK TEST PROCEDURE Verify suspected leaks in the cylinder heads or cylinder block by pressure testing before deciding to replace the cylinder head or block. Do not use magnaflux inspections alone as replacement criteria.
Page 88: Cylinder Head Fuel Passages Leak Check - In Chassis
5_106_00.bk Page 72 Friday, August 4, 2000 11:17 AM TROUBLESHOOTING Cylinder Head Fuel Passages Leak Cylinder Block/Cylinder Head Check — In Chassis Coolant Passages Leak Check — In Chassis Refer to Figure 64. The symptoms of coolant-in-fuel are a loss of 1.
Page 89 5_106_00.bk Page 73 Friday, August 4, 2000 11:17 AM TROUBLESHOOTING 10. Check for coolant leaks at the bottom of each cylinder bore. Coolant leaking between the cylinder Water leaking from the No. 2 or No. 5 cam sleeve outside diameter and cylinder bushings or from the No.
Page 90: Cylinder Head Oil Passage Leak Check - Out Of Chassis
5_106_00.bk Page 74 Friday, August 4, 2000 11:17 AM TROUBLESHOOTING Cylinder Head Oil Passage Leak 4. Bolt the modified bracket with air fitting to the cylinder head over the oil supply Check — Out of Chassis passage. Refer to Figure 65. 5.
Page 91: Cylinder Head Coolant Passage Leak Check - Out Of Chassis
5_106_00.bk Page 75 Friday, August 4, 2000 11:17 AM TROUBLESHOOTING Cylinder Head Coolant Passage 3. Use suitable plate and gasket to seal the water manifold openings. Install an air fitting Leak Check — Out of Chassis onto the plate. Refer to Figure 66. 4.
Page 92: Cylinder Block Coolant Passage Leak Check - Out Of Chassis
5_106_00.bk Page 76 Friday, August 4, 2000 11:17 AM TROUBLESHOOTING Cylinder Block Coolant Passage Leak Check — Out of Chassis Refer to Figure 67. 1. Fabricate two 3/4-inch thick (19.1 mm) steel plates to simulate cylinder heads. The plates must have cutouts for the head capscrews and liners.
Page 93 5_106_00.bk Page 77 Friday, August 4, 2000 11:17 AM TROUBLESHOOTING Figure 67 — Cylinder Block Coolant Passage Leak Check (Out of Chassis) 1. Cylinder Block 4. Rubber Gasket 2. 1/4-inch Rubber Gaskets 5. Plate with Air/Water Inlet Fittings 3. 3/4-inch Steel Plates Page 77 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 94: Engine Brake Tests
1100 rpm — 8 psi Boost If there is a report of engine or engine brake MACK EM7 275, 300 and E7 310/330 E-Tech™ Engines (Schwitzer S-300 Pre-12/99 — S-400S Post 12/99 noise, remove the engine covers to determine the Turbo) cause.
Page 95: Electrical Troubleshooting
5_106_00.bk Page 79 Friday, August 4, 2000 11:17 AM TROUBLESHOOTING If insufficient electrical power is reaching the engine brake, perform the preliminary checks outlined below. For more information, see the If the vehicle does not have a boost pressure ® V-MAC III Service Manual, 8-211.
Page 96: Hydraulic/Mechanical Troubleshooting
5_106_00.bk Page 80 Friday, August 4, 2000 11:17 AM TROUBLESHOOTING SOLENOID SPECIFICATIONS 12-Volt Solenoid: Resistance — 8.7 to 10.0 ohms Valve clearance must be checked with the timing pointer hole on the flywheel housing aligned with Current Draw — 0.9 to 1.6 amps the proper valve setting mark on the flywheel for Pull In Voltage —...
Page 97 5_106_00.bk Page 81 Friday, August 4, 2000 11:17 AM TROUBLESHOOTING The engine oil temperature must be within normal Remove control valve retaining components operating range when the test is performed. carefully to avoid personal injury. Control valve retaining components are under load from the control valve springs.
Page 98: Final Test
5_106_00.bk Page 82 Friday, August 4, 2000 11:17 AM TROUBLESHOOTING 6. Check the screw and pin assembly to 4. Turn the handle slowly until the retainer is ensure that the pin is not bent or damaged. depressed to about 1/32 inch (1 mm), The pin should not stick in the screw at any relieving pressure against the retaining ring.
Page 99: Troubleshooting Guide
See solenoid specifications in the Table on page 80. Make sure wiring is in Some leakage will be seen at the master piston, accordance with MACK wiring instructions. slave piston and control valves. This is normal. Excessive leakage must be investigated (see Low engine oil pressure —...
Page 100 If any are present, clean the surface Have an oil analysis of lube oil to determine with crocus cloth. If unable to remove burrs, if fuel is present. Correct per MACK replace piston or housing. Inspect lube oil for procedures.
Page 101 Worn crankshaft bearings or camshaft bushings — Replace bearings and Solenoid valve exhaust plugged — bushings in accordance with MACK Remove any restrictions at exhaust (bottom) overhaul procedures. of solenoid valve. Clutch switch stuck in ON position or out ONE OR MORE CYLINDERS FAIL TO STOP of adjustment —...
Page 102 5_106_00.bk Page 86 Friday, August 4, 2000 11:17 AM NOTES Page 86 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 103: Maintenance
5_106_00.bk Page 87 Friday, August 4, 2000 11:17 AM MAINTENANCE MAINTENANCE Page 87 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 104: Belt Drive System Tensioning
5_106_00.bk Page 88 Friday, August 4, 2000 11:17 AM MAINTENANCE BELT DRIVE SYSTEM Manually Tensioned System TENSIONING INSTALLATION [216] Loosen the alternator mounting bolts and pivot the alternator inboard, far enough to allow the The belt drive system uses a single, 10-rib poly-v belt to be placed over the pulleys without force.
Page 105: Filter Element Replacement
5_106_00.bk Page 89 Friday, August 4, 2000 11:17 AM MAINTENANCE FILTER ELEMENT Figure 69. Regardless of the canister style, the breather filter element can be cleaned if it has REPLACEMENT become plugged following the procedure in this section. General Information The engine may be equipped with either a cast aluminum or fiberglass-reinforced nylon crankcase breather filter canister as shown in...
Page 106: Crankcase Breather Filter Cleaning
5_106_00.bk Page 90 Friday, August 4, 2000 11:17 AM MAINTENANCE Crankcase Breather Filter Cleaning Oil Filter Element Replacement [219 ER] [219 EV] 1. Remove the canister cover by unthreading it from the housing. SPECIAL TOOLS REQUIRED 2. Place a thin-blade screwdriver between the Fuel and Oil Filter Wrench J 24783 outside diameter of the element and the Oil Filter Wrench J 29927...
Page 107 2. Thoroughly clean the area around the filters before removing. 3. Using tool J 24783, remove both spin-on filters and wipe the filter mounting base Use of anything other than genuine MACK filters clean. may cause damage and void the engine warranty. Change filters according to the 4.
Page 108 5_106_00.bk Page 92 Friday, August 4, 2000 11:17 AM MAINTENANCE ® ® CENTRI-MAX FILTER REPLACEMENT CENTRI-MAX PLUS FILTER REPLACEMENT (Externally Drained Filter) (Internally Drained Filter) 1. Clean the area around the centrifugal filter 1. To prevent contamination from entering the before removing the drain hose.
Page 109: Fuel Filter Replacement
5_106_00.bk Page 93 Friday, August 4, 2000 11:17 AM MAINTENANCE ® CENTRI-MAX PLUS SPINDLE Fuel Filter Replacement REPLACEMENT [224 KP, 231 PV] [219 EV] Normally, it should never be necessary to replace GENERAL INFORMATION ® the Centri-Max PLUS rotor spindle. However, if the spindle is damaged in any way, replacement Special high filtration fuel filters have been procedures are as follows:...
Page 110: Coolant Conditioner Replacement
3. Apply a light film of oil on the face of the new filter element gasket seal. Use of anything other than genuine MACK filters may cause damage and void the engine 4. Install the filter element on the coolant warranty.
Page 111: Repair Instructions
5_106_00.bk Page 95 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS REPAIR INSTRUCTIONS Page 95 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 112: Engine Removal
5_106_00.bk Page 96 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS ENGINE REMOVAL Removal from Vehicle 1. Remove the hood (if so equipped) and General Instructions position it away from the work area to prevent accidents or hood damage to Details of the engine removal procedure vary conventional models.
Page 113 5_106_00.bk Page 97 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 9. Disconnect the chassis-mounted charge air cooler inlet hose at the cooler. 10. Disconnect the chassis-mounted charge air Do not store the assembly horizontally with the cooler outlet hose at the cooler. fan face up (hub flange down).
Page 114 5_106_00.bk Page 98 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 19. Remove all coolant tubes, ground straps, air 27. Obtain the appropriate lifting equipment (bar lines, fuel lines, hydraulic hoses or tubes, or chain) and attach to the proper lift points throttle linkage and electrical wiring on the engine.
Page 115: Engine Disassembly
General Instructions This section includes step-by-step procedures for The fuel and oil filter elements, as well as the ® ® the complete disassembly of the MACK E-Tech™ Centri-Max or Centri-Max PLUS assembly, engine upon removal from the vehicle. Major must be removed before mounting the adapter components are removed as assemblies and plate to the engine.
Page 116 5_106_00.bk Page 100 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS ® 4. If equipped with the earlier Centri-Max design oil filter (Figure 78): Loosen drain hose assembly (4) from ® the Centri-Max filter housing assembly by loosening hose clamp (3) ®...
Page 117: Oil Cooler And Oil Filter Mounting Bracket Assembly Removal
5_106_00.bk Page 101 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Oil Cooler and Oil Filter Mounting 1. Disconnect the harness from the oil pressure and oil temperature sensors Bracket Assembly Removal (6 and 5) on the filter mounting bracket (9). [215 DW, 219 EP] 2.
Page 118 5_106_00.bk Page 102 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS REMOVABLE BUNDLE-TYPE OIL COOLER AND OIL FILTER MOUNTING BRACKET WITH ® EXTERNALLY DRAINED CENTRI-MAX Unless it is necessary to repair any portion of the (Early Production) oil cooler or oil filter mounting bracket, remove the units as an assembly.
Page 119: Mounting Engine In Stand
5_106_00.bk Page 103 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Mounting Engine in Stand Engine stand, Kent-Moore tool number J 29109, and adapter plate J 38048, are recommended to The engine weighs approximately 2,300 lbs. safely support the engine during disassembly and (1043 kg) wet.
Page 120 5_106_00.bk Page 104 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS SPECIAL TOOLS REQUIRED 1. Using three mounting capscrews (2), secure adapter plate J 38048 (1) to the left side of Engine Stand J 29109 the engine. Adapter Plate J 38048 2.
Page 121: Alternator Removal
5_106_00.bk Page 105 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Alternator Removal Engine Electronic Control Unit (EECU) Removal [271 CB] [230 EA] Refer to Figure 83. Left-Side Mounted Assembly 1. Loosen adjusting capscrew (1) and mounting capscrews (2). 2. Remove the poly-v drive belt. 3.
Page 122 5_106_00.bk Page 106 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 3. Remove the two top retaining nuts and isolating washers that secure the EECU to the EECU mounting bracket (Figure 85). Then, remove the two bottom retaining nuts and isolating washers that secure the EECU to the of the air inlet manifold.
Page 123: Fuel Filter Adapter Assembly Removal
5_106_00.bk Page 107 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Fuel Filter Adapter Assembly 2. Disconnect fuel lines from fittings (2, 3 and 5) on the adapter. Tag and cap all lines. Removal 3. Remove three capscrews (4) from the top of [231 PB] the fuel filter adapter assembly.
Page 124: Coolant Conditioner Element Removal
5_106_00.bk Page 108 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 1. Disconnect wiring harness leads at the coolant temperature sensor on the coolant manifold and the boost air temperature sensor on the air inlet manifold. Position leads out of way. 2.
Page 125: Oil Cooler-To-Water Pump Inlet Line Removal
5_106_00.bk Page 109 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 3. Place a suitable container below the coolant Oil Cooler-to-Water Pump Inlet Line filter area to catch any spilled coolant. Removal 4. Using a suitable filter wrench (J 29927, or If the engine is equipped with the plate-type oil equivalent), remove the coolant conditioner cooler, remove the oil cooler-to-water pump inlet...
Page 126: Thermostat Removal
5_106_00.bk Page 110 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Thermostat Removal 2. Loosen two hose clamps (10) on the coupling (12) that connect the oil cooler [215 NU] supply tube (11) to the thermostat housing. 3. Taking care to prevent the thermostat (7) Refer to Figure 90.
Page 127: Coolant Manifold Removal
5_106_00.bk Page 111 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Coolant Manifold Removal [215 NK] The hex-head capscrews and washers used to attach the manifold on early-production engines Refer to Figure 91. are replaced by flangehead capscrews in later production.
Page 128: Air Inlet Manifold Removal
5_106_00.bk Page 112 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Air Inlet Manifold Removal Water Pump Removal [214 HD] [215 SW] The following procedure applies for both the Refer to Figure 93. early-production engines (right-side mounted 1. Disconnect coolant return hose to air EECU) equipped with a two-piece air inlet compressor (1) at fitting on water pump.
Page 129: Turbocharger Removal
5_106_00.bk Page 113 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Turbocharger Removal Fuel Nozzle Inlet Tube Assembly Removal [214 SD] [222 KD] Refer to Figure 94. Refer to Figure 95. 1. Remove two capscrews (3) securing turbocharger lubrication drain tube (4) to 1.
Page 130: Exhaust Manifold Removal
5_106_00.bk Page 114 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Exhaust Manifold Removal 2. Remove the exhaust manifold. 3. Discard gaskets. [214 EG] 1. Support the exhaust manifold and remove 12 mounting nuts (Figure 96) securing the manifold to cylinder heads. Figure 96 —...
Page 131: Engine Wiring Harness Removal
5_106_00.bk Page 115 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Engine Wiring Harness Removal Engine Electronic Control Unit (EECU) and Cooling Plate Removal 1. Disconnect the harness at each of the EUP terminals. [230 EA] 2. Disconnect the harness at the EECU. Right-Side Mounted Assembly 3.
Page 132: Electronic Unit Pump (Eup) Removal
5_106_00.bk Page 116 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Electronic Unit Pump (EUP) 5. Remove outboard EUP screw completely and remove EUP from the cylinder block. Removal Refer to Figure 98. Place the EUP in a clean area and cover it to prevent entry of dirt and [221 GP] other contaminants.
Page 133: Air Compressor Removal
5_106_00.bk Page 117 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Air Compressor Removal [261 CK] The air compressor is heavy. Lifting the air compressor may require the help of an Refer to Figure 100. assistant or suitable lifting device. Attempting to lift the compressor without such Disconnect two coolant lines (1 and 3) from the assistance may result in severe personal...
Page 134: Valve Cover And Spacer Removal
5_106_00.bk Page 118 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 101 — Air Compressor Removal 1. Air Compressor 4. Oil Drain Openings 2. Oil Supply Tube 5. Capscrew 3. Auxiliary Shaft Valve Cover and Spacer Removal Refer to Figure 102 for disassembled view. 1.
Page 135: Rocker Arm, Valve Yoke And Push Rod Removal
5_106_00.bk Page 119 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS The valve roller follower has an insert in the top end to provide a hardened wear surface for contact with the push rod (Figure 103). The insert is staked in place during manufacture of the lifter (later production is press fit).
Page 136 5_106_00.bk Page 120 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 104 — Rocker Arm Shaft and Engine Brake Assembly 1. Valve Cover 8. Exhaust Valve Yokes 2. Spacer 9. Actuator Pin Assembly 3. Capscrew 10. Rocker Arm Shaft Assembly 4.
Page 137: Nozzle Holder Removal
5_106_00.bk Page 121 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Nozzle Holder Removal [222 KG] SPECIAL TOOL REQUIRED Injection Nozzle Puller J 37093 After removing the nozzles, it is a good practice to label or tag them for reinstallation into the same cylinders.
Page 138: Cylinder Head Assembly Removal
5_106_00.bk Page 122 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Cylinder Head Assembly Removal [213 EV] Cylinder head assemblies are heavy. Lifting a cylinder head requires the help of an Refer to Figure 106. assistant or suitable lifting device. Attempting to lift a cylinder head without assistance may 1.
Page 139: Vibration Damper And Crankshaft Hub Removal
5_106_00.bk Page 123 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Vibration Damper and Crankshaft Hub Removal [212 RB, RH] 1. Remove six mounting capscrews (3). Refer to Figure 107. Figure 108 — Crankshaft Hub Removal 1. Crankshaft Hub 2. Puller Oil Pan Removal [211 NB] Make sure all loose components are secured...
Page 140 5_106_00.bk Page 124 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Oil pans with isolating gaskets are secured with a combination of shouldered bolts and shouldered studs with separate nuts (two piece) or integral hex-head shoulder studs (one piece) along the pan rails.
Page 141: Oil Pump Removal
5_106_00.bk Page 125 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Oil Pump Removal Remove the oil pump as a unit by removing three retaining capscrews (1). [219 MU] Refer to Figure 110. If the oil pump must be disassembled for any reason, it will be easier to loosen the housing cover retaining capscrews, the screen, the oil inlet tube capscrews, the cover plate capscrews,...
Page 142: Front Cover Removal
5_106_00.bk Page 126 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Front Cover Removal [211 RP] For early-production engines equipped with studs, it is not recommended to remove the front cover without first removing the oil pan. Doing so may result in damage to the isolating oil pan gasket.
Page 143: Auxiliary Shaft Removal
5_106_00.bk Page 127 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Auxiliary Shaft Removal 3. Remove two retaining capscrews from auxiliary shaft captured thrust washer. [212 CV] Remove washer. Refer to Figure 114. Refer to Figure 112. Be very careful to avoid damaging the auxiliary shaft bushings or journals while removing the shaft.
Page 144: Camshaft Removal
5_106_00.bk Page 128 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Camshaft Removal [213 CH] Make sure all loose components are secured to, or removed from, the engine before rotating engine on the stand. Failure to do so may result in damage to components or severe personal injury.
Page 145: Piston And Connecting Rod Assembly Removal
5_106_00.bk Page 129 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 4. Taking care not to damage camshaft or Piston and Connecting Rod bushings, pull camshaft out of the front of Assembly Removal the engine (Figure 117). Carefully guide rear of shaft through the journals.
Page 146 5_106_00.bk Page 130 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 118 — Carbon Removal from Cylinder Sleeves Figure 119 — Piston and Connecting Rod Assembly Removal Refer to Figure 119. 5. Using a hammer handle, push piston 1 from 4.
Page 147: Flywheel Removal
5_106_00.bk Page 131 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Flywheel Removal [212 UC] Refer to Figure 120. 1. With engine stand rotated so that engine is inverted (crankshaft horizontal), loosen all six flywheel retaining capscrews. On vehicles equipped with an automatic transmission, it may be necessary to remove additional components to gain access to the flywheel retaining capscrews.
Page 148: Flywheel Housing Removal
5_106_00.bk Page 132 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Flywheel Housing Removal [211 HD] Refer to Figure 121. 1. Remove eight mounting capscrews (3) from flywheel housing (2). 2. Remove flywheel housing. It may be necessary to tap lightly on the housing with a soft mallet to separate housing from engine block.
Page 149: Main Bearing Cap Removal
5_106_00.bk Page 133 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Main Bearing Cap Removal Refer to Figure 122. 1. Remove eight buttress capscrews (2 and 3). [211 JA] 2. Remove main bearing capscrews (1) from each of the seven bearing caps (4 and 5). The center main bearing cap (5) houses the thrust washers.
Page 150: Crankshaft Removal
5_106_00.bk Page 134 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Crankshaft Removal CYLINDER BLOCK RECONDITIONING [212 HP] [211 DB] Refer to Figure 123. Special Tools Required 1. Using a suitable lifting device, secure a sling or crankshaft support tool around the Camshaft Bushing Installation/Removal Kit crankshaft and lifting device hook.
Page 151: Cylinder Sleeve Removal
5_106_00.bk Page 135 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Refer to Figure 125 and Figure 126. 1. Rotate the engine in the stand so that it is upright (deck surface upward). 2. Use puller PT6435, or equivalent, to remove the cylinder sleeve (1) from the cylinder block (4).
Page 152: Cleaning And Inspection
5_106_00.bk Page 136 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Compressed air used for cleaning can create airborne particles that may enter the eyes or irritate the skin. Pressure must not exceed 30 psi (207 kPa). Eye protection is required. Use only with effective chip guarding and personal protective equipment (goggles/ shield, gloves, etc.).
Page 153: Cylinder Sleeve Counterbore
5_106_00.bk Page 137 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS INSPECTION Cylinder Sleeve Counterbore [211 DB] A complete discussion of the proper methods of INSPECTION AND REPAIR precision measuring and inspection is outside the scope of this manual. However, every shop If the cylinder block deck is resurfaced, the should be equipped with standard gauges, such cylinder sleeve counterbore depth must be recut...
Page 154 5_106_00.bk Page 138 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 3. Measure and record the counterbore in four 3. Position the tool in the cylinder bore by places, 90 degrees apart. Using a depth backing off the depth-set collars (5 and 16) gauge with a three-inch extension, mark the and lowering the cutter plate (13) into the shallowest point.
Page 155 5_106_00.bk Page 139 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 11. Using hex key wrench PT2210-14 (18), turn the cutter bit adjusting screw clockwise until the cutter bit rests on the counterbore ledge. Do not force the collar beyond this point, as it will 12.
Page 156 5_106_00.bk Page 140 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 128 — Counterbore Ledge Tool Installation 1. Cutter Plate Holder 10. Cutter Bit Adjuster 2. T-Handle 11. Cutter Bit 3. Capscrews, M16 x 2 x 90 12. Hold-Down Cap 4.
Page 157 5_106_00.bk Page 141 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS CUTTING THE COUNTERBORE COUNTERBORE DEPTH MEASUREMENT Refer back to Figure 128. Measure the counterbore depth (Figure 129) and calculate the number of shims (part Nos. 1. Fill the oil fill tube (7) with 30W nondetergent 505GC26P2, P3, P4, P10, P12 and P14) needed oil to maintain lubrication during use.
Page 158: Cup Plug Replacement
5_106_00.bk Page 142 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Cup Plug Replacement INSTALLATION 1. After cleaning the plug hole, apply a thin REMOVAL ® coat of Loctite 277 to both the surface of Refer to Figure 130. the hole and the outer edge of the plug. 1.
Page 159: Pipe Plug Replacement
5_106_00.bk Page 143 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Pipe Plug Replacement H-Ring Replacement [213 LD] H-rings are placed in the lifter bores to prevent Any rust around a pipe plug is an indication of a the lifters from turning, and performing the same leak and the plug should be replaced.
Page 160 5_106_00.bk Page 144 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS In some cases, the H-ring remover tool may not position the collet far enough into the H-ring to provide proper engagement for removal. If this situation occurs, remove 0.375 inches (9.5 mm) of the threads by grinding or cutting them down;...
Page 161: Camshaft Bushing Replacement
5_106_00.bk Page 145 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Camshaft Bushing Replacement 2. Remove the remaining six bushings in sequence. [213 CC] 3. Check the bushing bore diameters and finish in the block, using a telescoping gauge or Typically, camshaft bushings have an extremely inside micrometer.
Page 162 5_106_00.bk Page 146 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 137 — Camshaft Bushing Locations Page 146 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 163 5_106_00.bk Page 147 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS BUSHING INSTALLATION 1. Clean the surfaces of the bushing and the bore. Dry both surfaces with compressed air. Correct installation of each camshaft bushing is very important. If a bushing is not properly 2.
Page 164: Auxiliary Shaft Bushing Replacement
5_106_00.bk Page 148 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Auxiliary Shaft Bushing BUSHING REMOVAL Replacement Use J 21428-01 to remove the bushings. If there is any indication that a bushing has turned in the [212 CB] block, check the bushing bore diameter with a telescoping gauge or inside micrometer.
Page 165 5_106_00.bk Page 149 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Oil hole alignment of the front bushing-to-cylinder the bushing oil holes, so simply install the block oil holes must be checked prior to, and at bushings with the indexing notches at the 5:30 the completion of, installation.
Page 166 5_106_00.bk Page 150 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 142 — Rear Auxiliary Bushing Alignment Figure 143 — Auxiliary Shaft Bushing Alignment 1. Clean the surfaces of the bushing and the 1. Alignment Mark 4. Camshaft Bushing bore.
Page 167 5_106_00.bk Page 151 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 7. Working from the front of the cylinder block, repeat steps 1 through 6 to install the front bushing. The front auxiliary shaft bushing must be flush or 8. Bushings must be installed to the depths recessed within 0.030 inch (0.763 mm) of the described in Figure 144.
Page 168: Cylinder Sleeve Installation
3. Apply approximately a 0.120–0.160-inch determined, however, that the crevice seal is not (3.048–4.064-mm) bead of RTV silicone necessary. Therefore, effective approximately ® (MACK Silastic 342SX32, Dow Corning December 1998, the crevice seal is no longer ® Silastic RTV732 or General Electric used in production engines.
Page 169 5_106_00.bk Page 153 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 145 — Cylinder Block Sleeve Seat 4. Position the cylinder sleeve (1) in the cylinder bore. 5. With the palms of the hands placed on the ® Applying a Silastic bead is now standard upper end of the cylinder sleeve 180 assembly procedure whenever cylinder sleeves...
Page 170 5_106_00.bk Page 154 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 146 — Sleeve Installation 1. Sleeve 3. Counterbore Ledge 2. Shims (as Required) 4. Cylinder Block Clean any RTV from around the bottom of the cylinder sleeve and the block which may have been pressed out from the sealing surfaces of the block and sleeve during installation.
Page 171 5_106_00.bk Page 155 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 147 — Cylinder Sleeve/Fire Ring Configuration Page 155 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 172 HONING THE CYLINDER SLEEVE BORE The height of the cylinder sleeves above the cylinder block deck (under the same cylinder All MACK engines currently produced have fine head) can vary as long as all are within the precision-finished cylinder sleeves. Because of 0.023–0.029-inch (0.584–0.737-mm)
Page 173: Piston Cooling Spray Nozzle Installation
5_106_00.bk Page 157 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Piston Cooling Spray Nozzle Installation [219 RV] SPECIAL TOOL REQUIRED Two-Piece Piston Cooling Nozzle Aimer J 39045 INSTALLATION PROCEDURE Refer to Figure 149. 1. Using a liberal amount of lubricant, install the elastomer sleeve (7) on the locator tube (6).
Page 174 5_106_00.bk Page 158 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS PISTON COOLING NOZZLE SPRAY POSITIONING Refer to Figure 150. For ease of installation and to reduce the amount of crankshaft rotation needed to facilitate access The piston cooling oil spray target location on the to the spray nozzles, install the spray nozzles in underside of the piston is important.
Page 175: Cylinder Block Dowel Pin Replacement
5_106_00.bk Page 159 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 4. The rod (6) should now be aligned in the Cylinder Block Dowel Pin target area (5). If the rod is at the edge of the Replacement target area, center the rod in the target area as follows: [211 HA] Loosen the nozzle setscrew.
Page 176 5_106_00.bk Page 160 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS ROUND DOWEL PIN INSTALLATION BLADE-TYPE DOWEL PIN INSTALLATION 1. Position the round end of the blade-type Refer to Figure 152. dowel pin into the dowel pin hole in the 1.
Page 177: Crankshaft And Flywheel Bench Procedures
MACK Parts Distribution Centers. Crankshaft Inspection [212 HP] Crankshaft regrinding by anyone other than Mack Trucks, Inc. is NOT recommended due to the tight control required on maintaining geometrical GENERAL INSTRUCTIONS tolerances, and the hardened characteristics of crankshaft journals and journal fillets.
Page 178: Crankshaft Dowel Pin Replacement
5_106_00.bk Page 162 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Crankshaft Dowel Pin Replacement Refer to Figure 153. [212 HA] All E-Tech™ engine crankshafts are equipped with a blade-type flywheel-to-crankshaft dowel pin installed in the rear flange directly opposite the manufacturing locator hole.
Page 179: Crankshaft Gear Replacement
5_106_00.bk Page 163 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS DOWEL PIN INSTALLATION REPLACEMENT To install a replacement crankshaft dowel pin: Refer to Figure 155. 1. Position the dowel pin in a 0.5562-inch 1. Using a suitable puller, such as J 21834-4A, (14.1275-mm) diameter unthreaded hole in or equivalent, remove the gear and key.
Page 180: Crankshaft Wear Ring Installation
5_106_00.bk Page 164 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 5. Position the gear over the end of the Crankshaft Wear Ring Installation crankshaft (2) with the timing mark facing [212 JH] outward, the chamfer (6) toward the rear of the shaft, and the key slot aligned with key in the shaft.
Page 181 5_106_00.bk Page 165 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 2. Thoroughly clean the flange area of the crankshaft. Check for nicks or scratches and repair any damaged areas with crocus cloth as necessary. Figure 157 — Proper Crankshaft Wear Ring Installation 1.
Page 182 5_106_00.bk Page 166 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS ® 2. Heat the wear ring and wear ring installer WEAR RING WITH DOUBLE-LIP TEFLON together in a temperature-controlled oven or SEAL (AUTOMATIC TRANSMISSION) on a hotplate, with the wear ring on the The oversize inside diameter lip seal and wear bottom and installed in the spring clips of the ring are shipped as an assembly with the seal...
Page 183: Flywheel Inspection And Resurfacing
5_106_00.bk Page 167 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Flywheel Inspection and Resurfacing When resurfacing a flat-style flywheel, it is very [212 UB] important that the machine shop NOT leave a step on the friction face outer diameter adjacent The flywheel is a design with an integral, non- to the clutch locating pilot.
Page 184: Auxiliary Shaft And Camshaft Bench Procedures
5_106_00.bk Page 168 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS AUXILIARY SHAFT AND Camshaft Inspection CAMSHAFT BENCH [213 CH] PROCEDURES GENERAL INSTRUCTIONS Auxiliary Shaft Inspection To optimize camshaft timing for certain engine [212 CV] models, an offset-type camshaft key (P/N 54GC29) is used.
Page 185 5_106_00.bk Page 169 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS CAMSHAFT GEAR REMOVAL 4. Remove the thrust washer. An extremely tight interference fit holds the cam gear on the camshaft. Typically, 10 tons of force is required to remove the gear. When cam gear removal or installation is required, use the following procedures.
Page 186 If an offset key is used parts. Do not use a press to install the gear. used, be sure the key is properly positioned for the engine model. Refer to the appropriate MACK Engine Tune-up Specifications for the correct key offset.
Page 187 5_106_00.bk Page 171 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 162 — Camshaft Assembly Components 1. Camshaft Gear 3. Camshaft 2. Camshaft Captured Thrust Washer 4. Key Page 171 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 188 5_106_00.bk Page 172 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 4. Set the camshaft close to the oven in which the camshaft gear will be heated. It should be set vertically on the floor with the front of Wear protective gloves when handling the the shaft up.
Page 189: Connecting Rod And Piston Bench Procedures
5_106_00.bk Page 173 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS CONNECTING ROD AND Each connecting rod assembly has two alignment sleeves (3), one sleeve in each capscrew hole of PISTON BENCH PROCEDURES the rod cap (1) to locate and align the cap and rod thrust faces.
Page 190 Wrist Pin Bushing Installation tolerance after a short time in operation. It is cost- efficient to replace components when rebuilding. Use genuine MACK replacement parts. The wrist pin bushing has a lubrication hole through it. This hole MUST be aligned with the...
Page 191 5_106_00.bk Page 175 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS CONNECTING ROD ALIGNMENT CHECK 1. Position the connecting rod in a connecting rod fixture, Sweeney 945-6041, or equivalent. Use the appropriate mandrel and plunger extension for the engine. Figure 167 — Burnishing Wrist Pin Bushing 4.
Page 192: Piston Inspection And Cleaning
5_106_00.bk Page 176 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Piston Inspection and Cleaning DISASSEMBLY Refer to Figure 169. [212 NP] 1. Using piston ring expander PT6587, remove the piston rings. GENERAL INFORMATION The E-Tech™ engine uses a two-piece piston design with the crown made from forged steel and the skirt from cast aluminum.
Page 193: Piston Ring Replacement
5_106_00.bk Page 177 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS INSPECTION KEYSTONE RING GROOVE CHECK Inspect the piston ring grooves, lands, piston skirt Refer to Figure 170. and combustion bowl for wear, scuffing, cracks or blow-by. Pistons are NOT repairable. Discard the Keystone piston-ring groove gauge J 29510 piston if it is damaged.
Page 194 5_106_00.bk Page 178 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 2. Using a four- to five-inch micrometer, 5. Check the oil control ring as follows: measure the distance between the outer Using a thickness gauge, check for edges of the two parallel pins. Check each excessive wear of the oil control ring compression ring groove in two locations: groove side clearance (1).
Page 195 5_106_00.bk Page 179 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS RING INSTALLATION 2. Stagger the piston rings so that no ring gap is directly over the wrist pin bore, and no ring end gaps are aligned over each other (Figure 174).
Page 196: Assembling Connecting Rod To Piston
5_106_00.bk Page 180 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Assembling Connecting Rod to Piston [212 LP & NP] Refer to Figure 175. 1. Install a retaining snap ring in one of the wrist pin retaining grooves. 2. Position the connecting rod in the piston assembly.
Page 197: Cylinder Head Overhaul
5_106_00.bk Page 181 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS CYLINDER HEAD OVERHAUL Inlet and Exhaust Valve Removal [213 EV] [213 NB] Special Tools Required GENERAL INFORMATION Valve Spring Compressor J 43887 (for Current-production engines use a tip-end valve valves with tip-end rotators) rotator (P/N 722GC314) as shown in Figure 176.
Page 198 5_106_00.bk Page 182 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 176 — Valve Spring, Rotator and Valve Seat Insert Combinations Page 182 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 199 5_106_00.bk Page 183 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 177 — Valve Key Protrusion REMOVAL PROCEDURE Refer to Figure 178. 1. Attach the valve spring compressor to the cylinder head. Use spring compressor J 43887 for valves with tip-end rotators or J 29294-B for valves with bottom rotators.
Page 200 5_106_00.bk Page 184 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 179 — Valve Stem Seal 4. With the valve spring keepers removed, remove the upper washer or tip-end rotator, valve spring, oil seal, lower washer After removing the valve springs, removal of the (Roto-Coil) if so equipped, and valve.
Page 201: Cylinder Head Inspection
5_106_00.bk Page 185 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Cylinder Head Inspection Fire Ring Groove Cutting GENERAL INFORMATION Fire ring grooves are located in the machined flat surface (deck) of the cylinder head that mates Pressure Test — It is recommended that cylinder with the engine block.
Page 202 5_106_00.bk Page 186 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS GROOVE CUTTING PROCEDURE 1. Place the cutter base on the cylinder head. Insert the hold-down capscrews into the appropriate mounting holes (per application) until the hold-down capscrews bottom out in the mounting holes.
Page 203 5_106_00.bk Page 187 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 5. Adjust the cutter head J 37719 until it bottoms out on the deck surface of the existing fire ring groove. Tighten the cutter head in this position and remove the two thickness gauges.
Page 204: Valve Guide Replacement
5_106_00.bk Page 188 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Valve Guide Replacement [213 EP] INLET AND EXHAUST VALVE GUIDE DIMENSIONS Refer to Figure 186. Valve guide ID (3) — 3/8 inch (9.53 mm) Top end of guide to valve spring seat (4) — 0.959 ±...
Page 205 5_106_00.bk Page 189 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 186 — Valve Guide Dimensions Figure 187 — Measuring Valve Guide Bore 1. Exhaust Valve Guide 5. Valve Guide Extension, 1. Bore Gauge 2. Valve Guide Bore 2. Inlet Valve Guide Fire Deck to Top of 3.
Page 206 5_106_00.bk Page 190 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 2. Press out the old valve guides from the cylinder head. 3. Check the valve guide bore in the cylinder When reconditioning the cylinder head, it is head for wear, cracks or other damage. recommended that all valve guides be replaced.
Page 207: Valve Seat Insert Replacement
5_106_00.bk Page 191 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 6. Repeat steps 1 through 5 to install the remaining valve guides. 7. Thoroughly clean all metal debris from the valve guides and the surrounding area. 8. Install the valves in the cylinder head and check for binding, looseness and other conditions that may result in premature valve or valve guide failure.
Page 208 5_106_00.bk Page 192 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS VALVE SEAT INSERT REMOVAL Valve seat extractor kit PT6391 and collet PT6390-4 are used to remove the inlet and Collet PT6390-4 is not included in the basic kit exhaust seat inserts. Refer to Figure 192. PT6391.
Page 209 5_106_00.bk Page 193 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Use care not to damage any machined surface of the cylinder head. 5. Attach the collet to the T-handle and shaft assembly. 6. Position the collet in the valve seat insert so ridge of the collet will be inside the groove.
Page 210 5_106_00.bk Page 194 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS VALVE SEAT INSERT COUNTERBORE INSPECTION Refer to Figure 196. 1. With the valve seat insert removed from the cylinder head, clean the surface thoroughly Valve seat counterbore depth (3): with a wire brush.
Page 211 5_106_00.bk Page 195 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS VALVE SEAT INSERT INSTALLATION 3. Grind the inlet/exhaust valve seat inserts to specification. Inlet valve inserts: 20° 30′ ± 15′ angle Exhaust valve inserts: 30° −0′/+30′ Oversize inlet and exhaust valve seat inserts are available in 0.005, 0.015, 0.031, 0.047 and 0.062 inch sizes if the counterbore requires machining.
Page 212: Valve Spring Inspection
5_106_00.bk Page 196 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Valve Spring Inspection [213 MB] 1. Visually inspect the inside surfaces of the spring coils. Also, feel the inside surfaces of each spring for any indication of roughness or grooving. If either of these conditions exist, replace the spring.
Page 213: Injection Nozzle Holder Insert Replacement
5_106_00.bk Page 197 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Injection Nozzle Holder Insert INSTALLATION PROCEDURE Replacement 1. Clean the nozzle insert bore in the cylinder ® head and the contact surfaces with Loctite [213 GB] Primer T. ® 2.
Page 214: Valve Yoke Guide Pin Replacement
5_106_00.bk Page 198 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 3. Install the insert in the cylinder head with the Valve Yoke Guide Pin Replacement indexing notch aligned in direction of the [213 FH] high-pressure fuel line hole in the head. 4.
Page 215: Cylinder Head Cup Plug Replacement
5_106_00.bk Page 199 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 4. Tap the broken yoke pin as deep as possible INSTALLATION PROCEDURE using a 3/8-inch NC starter tap and cutting If a new valve yoke guide pin is required, apply oil.
Page 216: Cylinder Head Pipe Plug Replacement
5_106_00.bk Page 200 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 3. Install cup plugs in the cylinder head, using Cylinder Head Pipe Plug the appropriate cylinder head core plug Replacement installer, J 34684 for 13/16-inch (20.64 mm) cup plugs, and J 34687 for 1-1/16 inch GENERAL INFORMATION (26.99 mm) cup plugs.
Page 217 5_106_00.bk Page 201 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS REPLACEMENT (1/8-, 1/16-INCH PLUGS) 3. Install a 1/8-inch NPT pipe plug in the fuel passage at the top front location of the front 1. If reusing a pipe plug, the threads on the cylinder head.
Page 218: Valve Replacement
5_106_00.bk Page 202 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Valve Replacement Visually inspect valves for cracks, pits or other conditions that may cause improper operation. [213 NB] Check valve seat angle. Also check stem length, diameter and condition. INSPECTION Refer to Figure 209.
Page 219 5_106_00.bk Page 203 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS INLET AND EXHAUST VALVE IDENTIFICATION To permit positive identification, exhaust valve With the new, more effective valve stem seals has two stem grooves and inlet valve has one (P/N 446GC328), pre-lubing the seals and valve stem groove in addition to the valve spring keeper stems during installation is extremely important.
Page 220 5_106_00.bk Page 204 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Before installing the valve stem seals, be sure the rotator has been installed. The rotator will not fit over the valve stem seal. 3. Lubricate the valve stem seals with engine oil and install the seals using valve seal installer J 42453.
Page 221 5_106_00.bk Page 205 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 212 — Inlet/Exhaust Valve Head Depth Measurement 1. Inlet Protrusion Above Deck: 0.0425 inch 3. Exhaust Valve +0.009/−0.007 inch (1.0795 +0.229/−0.178 mm) 4. Exhaust Valve Depth Below Deck: 0.021 inch 2.
Page 222: Valve Rocker Arm Shaft Bench Procedures
5_106_00.bk Page 206 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS VALVE ROCKER ARM SHAFT Valve Rocker Arm Shaft BENCH PROCEDURES Disassembly (without/with Engine Brake) [213 LP] Rocker Arms For early-production engines, six C-clips are used Early-production E-Tech™ engines used the to retain the rocker arms in position.
Page 223: Valve Rocker Arm Shaft Reassembly (Without Engine Brake)
5_106_00.bk Page 207 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Valve Rocker Arm Shaft 11. Lubricate the exhaust rocker arm and install on the shaft. Reassembly (without Engine Brake) 12. Lubricate a spring washer, install it on the shaft next to the exhaust rocker arm and press the center mounting bracket onto the shaft.
Page 224 5_106_00.bk Page 208 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 214 — Valve Rocker Arm Shaft Assembly (without Engine Brake) 1. Flat Washer and C-Clip 6. Mounting Bracket 2. Spring Washer 7. Inlet Rocker Arm 3. Locating Screw and Lock Washer 8.
Page 225: Valve Rocker Arm Shaft Reassembly (With J-Tech™ Engine Brake)
5_106_00.bk Page 209 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Valve Rocker Arm Shaft 8. Install a flat washer and C-clip (1) on the shaft to retain the exhaust rocker arm. Reassembly (with J-Tech™ Engine 9. Lubricate the inlet rocker arm (7) and install Brake) it on the shaft.
Page 226 5_106_00.bk Page 210 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 215 — Valve Rocker Arm Shaft Assembly (with J-Tech™ Engine Brake) 1. Flat Washer and C-Clip 8. Standard Adjusting Screw and Jam Nut 2. Spring Washer 9. Shaft 3.
Page 227: Lubrication System Bench Procedures
8. Turn the oil pump upside down and remove the MACK Parts System to ensure the the oil pump shaft nut (1) and washer (2). correct component/part is being used.
Page 228 5_106_00.bk Page 212 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 216 — Lubrication Oil Pump 1. Self-Locking Nut 9. Inlet Flange Plate 2. Washer 10. Capscrews 3. Driven Gear 11. Plunger 4. Housing 12. Relief Valve Spring 5. Key 13.
Page 229 5_106_00.bk Page 213 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS INSPECTION AND CLEARANCE CHECKS End Clearance Check Refer to Figure 216. Refer to Figure 217. With the pump gear and idler 1. Clean and inspect the oil pump housing (4) gear in place, position a straightedge across the for scoring, cracks or other damage.
Page 230 5_106_00.bk Page 214 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Side Clearance Check Backlash Check Refer to Figure 218. With the straightedge Refer to Figure 219. positioned across the housing and the face of the gears, check side clearance as follows: Check backlash between the pump gear (3) and idler gear (2) with a thickness gauge (1).
Page 231: Cooling System Components Bench Procedures
5_106_00.bk Page 215 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS REASSEMBLY Refer back to Figure 216. Because the inlet tube must be in a vertical 1. Install the one-piece pump gear/shaft (6) position when installed in the engine, the and thrust washer (15) in the housing and mounting flange bolt pattern is off-set to the same check for free spin.
Page 232 5_106_00.bk Page 216 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS GENERAL INSTRUCTIONS Refer to Figure 221. The presence of engine oil in the engine coolant Periodic visual inspection of the oil cooler will may indicate internal engine problems or worn, indicate condition of gaskets and O-rings.
Page 233 5_106_00.bk Page 217 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS DISASSEMBLY Refer to Figure 221. 1. Remove the coolant inlet end cap (20) by removing six capscrews (19). 2. Remove the coolant outlet end cap (2) by removing six capscrews (26). 3.
Page 234: Water Pump Reconditioning
The water pump is not a field-rebuildable unit. If a (24). pump failure occurs, exchange it for a new or remanufactured unit available through the MACK ® 1. Apply Permatex gasket sealer on the Parts System.
Page 235: Fuel System Components Bench Procedures
5_106_00.bk Page 219 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS FUEL SYSTEM COMPONENTS Installation of Electronic Unit Pump BENCH PROCEDURES Plunger Spring and Seat Improper removal of an electronic unit pump Electronic Unit Pump (EUP) (EUP) from an engine, or certain failures such as Inspection broken EUP hold-down bolts, will result in a rapid pop-up of the pump from the bore.
Page 236 5_106_00.bk Page 220 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 2. Pull the plunger out of the unit pump bore until the gold portion of the plunger is visible through the retaining clip slot. The shoulder of the plunger (where the silver-colored and gold-colored areas meet), will just align with the bottom of the unit pump housing.
Page 237: Fuel Injector Nozzle Cleaning
5_106_00.bk Page 221 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 9. Reinstall the unit pump into the engine using the procedures as outlined under Engine Reassembly in the REPAIR INSTRUCTIONS section. Fuel Injector Nozzle Cleaning [222 KG] Refer to Figure 231. When servicing the nozzle holder assemblies, cleaning of the nozzle tips may be necessary.
Page 238: Engine Reassembly
J 29653-A, use sound This section includes step-by-step procedures for waves or mechanical vibrations approximately complete reassembly of the MACK E-Tech™ 55,000 cycles per second above human hearing engine. Major components that were inspected range. The sound waves are generated by the...
Page 239 5_106_00.bk Page 223 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 4. Repeat the previous step to install the remaining upper inserts. Refer to Figure 233 for the part number and location of each bearing insert. A bearing insert installed at the wrong location can cause engine failure.
Page 240: Main Bearing Cap Installation
5_106_00.bk Page 224 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 5. Apply a light coat of clean engine oil on the insert surfaces and on the crankshaft main bearing journals. Do not mix the caps or inserts. The caps are numbered from 1 through 7, front to rear.
Page 241 5_106_00.bk Page 225 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 9. Place the upper thrust washer sections in position in the cylinder block at the center bearing, No. 4, location as shown in Figure 236. The steel side of the thrust washer goes toward the block, the copper or aluminum-faced side goes toward the crankshaft (this applies to upper and lower...
Page 242 5_106_00.bk Page 226 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 236 — Crankshaft Thrust Washer Installation 10. Position the lower thrust washer sections on the center bearing cap (aluminum-faced side toward crankshaft) and install the cap (Figure 237). Torque the capscrews to specification, 210 lb-ft (285 N•m), using torque wrench J 24407, or equivalent.
Page 243 5_106_00.bk Page 227 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 237 — Main Bearing Cap/Thrust Washer Installation 1. Bearing Cap 3. No. 4 Journal 2. Thrust Washer 11. Install a magnetic base indicator tool, 16. If the end play is out of specification, remove J 7872, or equivalent, on the block with the the thrust washers and install properly sized plunger against a crankshaft counterweight...
Page 244 5_106_00.bk Page 228 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS CHECKING RUNNING CLEARANCE When using the Plastigage method of checking running clearance, do not turn the crankshaft. Doing so will destroy the Plastigage. If checking the main bearing clearance with the engine in the upright position (such as in the chassis), the weight of the crankshaft must be removed from the lower half of the bearing being...
Page 245 5_106_00.bk Page 229 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 8. Reposition the cap on the journal. Lubricate the capscrews with clean engine oil of the proper specification. Lubricate and install the There are two buttress capscrew dimensions: bearing cap buttress capscrews as required, finger-tight.
Page 246: Piston And Connecting Rod Installation
5_106_00.bk Page 230 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Piston and Connecting Rod 2. Place the piston marked No. 1 on a clean, flat surface. Rest the piston and rod Installation assembly on the piston crown with the rod upward.
Page 247 5_106_00.bk Page 231 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 241 — Piston and Connecting Rod Installation 1. Connecting Rod Assembly 3. Cylinder Block 2. Piston Ring Compressor Tool 10. Make sure the connecting rod is aligned with 11.
Page 248 5_106_00.bk Page 232 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 242 — Pushing Piston into Cylinder Sleeve 1. Piston Ring Compressor Tool 3. Cylinder Block 2. Piston Do not force the piston. This indicates an incorrectly aligned ring. Remove the piston assembly, correct the problem, and then reinstall it.
Page 249 5_106_00.bk Page 233 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 12. Align the rod with the crankshaft journal and RUNNING CLEARANCE CHECK continue pushing the piston into the sleeve 1. Place a section of Plastigage on the rod cap while guiding the rod end to clear the piston bearing and assemble cap to the rod.
Page 250: Flywheel Housing Installation
5_106_00.bk Page 234 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Flywheel Housing Installation [211 HD] Production phase-in of a redesigned die-cast aluminum housing began approximately mid- November 1998. The noticeable design differences of the new die-cast aluminum housing compared with the permanent mold cast aluminum housing include a smaller diameter starter drive gear mounting housing with two large strengthening ribs along the top, and other...
Page 251 Service replacement flywheel housings are the standardized flywheel housing. The new appropriate mounting hardware comes with the The E-Tech™ flywheel housing castings are new-style flywheel housing supplied by the MACK Truck Parts System. manufactured to use standardized housing mounting hardware as follows: Two upper external mounting location capscrews —...
Page 252 5_106_00.bk Page 236 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS ® INSTALLATION 4. Apply an even coat of Silastic (approximately a 1/16-inch [2 mm] bead) to 1. Remove the rear crankshaft oil seal from the the flywheel housing mounting surface of the flywheel housing by drilling two 3-mm holes, cylinder block.
Page 253 5_106_00.bk Page 237 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS RUNOUT With the machined dowel method of installation, flywheel housing runout is well within the old service specification of 0.010 inch (0.254 mm) Total Indicated Runout (TIR), when checked with an alignment bar through the cylinder block main bearing bores.
Page 254: Crankshaft Rear Oil Seal Installation
5_106_00.bk Page 238 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Crankshaft Rear Oil Seal Installation [212 JH] MACK E-Tech™ engines are produced with ® Teflon oil seals. Engines with dry flywheel housings (standard transmission) use single-lip seals, while those with wet flywheel housings (automatic transmission) use double-lip seals.
Page 255 5_106_00.bk Page 239 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS INSTALLATION — WEAR RING WITH ® DOUBLE-LIP TEFLON SEAL (WET-TYPE FLYWHEEL HOUSING) The oversize inside diameter lip seal and wear ring are shipped as an assembly, with the seal installed on the wear ring.
Page 256: Flywheel Installation
5_106_00.bk Page 240 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Flywheel Installation [212 VC] TIMING SCALE The flywheel has a stamped timing scale of top center (TC) to 45 degrees of engine travel (engine timing) and three stamped locations, 120 degrees apart, for valve settings as shown in Figure 256.
Page 257 5_106_00.bk Page 241 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS INSTALLATION PROCEDURE 4. Tighten the capscrews to the specified torque, 185 lb-ft (251 N•m), alternating from opposite sides to apply even pressure to the flywheel (use torque wrench J 24407, or equivalent).
Page 258: Valve Lifter Installation
5_106_00.bk Page 242 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Valve Lifter Installation Camshaft Installation [213 LB] [213 CH] 1. Rotate the engine 180 degrees, so bottom of Before installing a camshaft in any engine, the engine is facing up. ensure that cam is clean, undamaged and well- 2.
Page 259: Camshaft Core Plug Installation
5_106_00.bk Page 243 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 4. Apply clean engine oil to the installation Camshaft Core Plug Installation guide. [213] After the camshaft is installed, install the core The camshaft is heavy, approximately 90 pounds plug.
Page 260: Camshaft Idler Gear Installation
5_106_00.bk Page 244 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Camshaft Idler Gear Installation [213 DE] Before installing the idler gear/hub assembly, determine which is the top mounting hole on the hub. The idler gear is held in place by a flanged hub mounted to the cylinder block by three bolts.
Page 261: Auxiliary Shaft Installation
5_106_00.bk Page 245 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Auxiliary Shaft Installation [212 CV] There are 45 gear teeth on the crankshaft gear, 90 teeth on the camshaft gear and 48 on the idler Before installing the auxiliary shaft in the engine, gear.
Page 262: Oil Pump Installation
In replacing any of these critical parts, always refer to part number information in 6. Install the auxiliary shaft nut (1) and tighten the MACK Parts System to ensure the to the specified torque, 300 lb-ft (407 N•m), correct component/part is being used.
Page 263: Front Cover Installation
5_106_00.bk Page 247 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 268 — Oil Pump Installation 1. Lubrication Oil Pump 3. Cylinder Block 2. Mounting Capscrews Front Cover Installation [211 RP] After the oil pump has been installed, check the backlash between the auxiliary shaft gear and the With the crankshaft, camshaft and auxiliary shaft oil pump driven gear.
Page 264: Crankshaft Front Seal Installation
5_106_00.bk Page 248 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Crankshaft Front Seal Installation [211 JB] SPECIAL TOOLS REQUIRED Crankshaft Front Seal Installer J 37715-A Crankshaft Front Seal Adapter J 37715-2 INSTALLATION PROCEDURE Installation depth of the E-Tech™ engine front crankshaft seal, relative to the front crankshaft stem, is controlled by the installation tool adapter.
Page 265: Crankshaft Hub Installation
Replace the hub if the removed seal shows signs of wear. Mack Trucks, Inc. does not recommend the use of a service sleeve to repair the crankshaft hub when there is hub damage. When there is damage to the hub, replace it.
Page 266: Oil Pan Installation
5_106_00.bk Page 250 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS INSTALLATION PROCEDURE 1. Position the vibration damper and drive pulley on the crankshaft hub. Through late August 1999, the isolated oil pan gasket mounting arrangement used shoulder 2. Install the six mounting capscrews. Tighten studs to secure the oil pan to the front timing the capscrews to the specified torque, cover, flywheel housing and at certain locations...
Page 267 5_106_00.bk Page 251 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS The isolating oil pan gasket contains 12 integral 4. In one motion, firmly press down on the locating/retaining cones which lock into holes gasket with one hand while carefully pulling drilled through the oil pan rails, and two large the rubber cone through the hole with the rectangular tabs located directly across from...
Page 268: Cylinder Head Installation
Refer to the cylinder head inspection procedures under Cylinder Head Reconditioning in the REPAIR INSTRUCTIONS section. All MACK head gaskets are precoated and do not require any type of additional sealing compound. Refer to Figure 275. 1. Place the head gaskets in position on the locating pins in the cylinder block deck.
Page 269 5_106_00.bk Page 253 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 275 — Cylinder Head Gasket and Fire Ring Positioning 1. Cylinder Head 4. Guide Pins 2. Fire Rings 5. Cylinder Block 3. Gasket 4. Check the condition of the capscrews and 6.
Page 270 5_106_00.bk Page 254 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 276 — Cylinder Head Alignment 1. Cylinder Heads 3. Straightedge 2. Cylinder Block Page 254 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 271: Exhaust Manifold Installation
5_106_00.bk Page 255 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 7. Oil all cylinder head capscrew bosses, Tighten all capscrews in sequence to capscrew threads and washers with engine 50 lb-ft (68 N•m). oil prior to assembly. Do not oil threads in Tighten all capscrews in sequence to cylinder block.
Page 272 5_106_00.bk Page 256 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS MANIFOLD INSTALLATION 3. Position the exhaust manifold on the mounting studs and secure with nuts. Refer to Figure 279. Tighten the nuts to the specified torque: 1. Install the 12 studs in position on the 55 lb-ft (75 N•m) for 10-mm nuts cylinder head.
Page 273: Nozzle Holder Assembly Installation
5_106_00.bk Page 257 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Nozzle Holder Assembly Installation [222 KG] Care must be taken with either method of installation to NOT misposition the gasket. If mis- positioned, the washer may be damaged and GENERAL INFORMATION result in severe combustion leakage.
Page 274 5_106_00.bk Page 258 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 282 — Nozzle Holder Alignment 1. Cylinder Head 3. Locator Pin and Sleeve 2. Nozzle Holder Notch Must Align. 5. After ensuring that the nozzle holder locator pin is properly aligned with the alignment notch in the nozzle holder sleeve, push downward on the handle of the installation tool driving the nozzle holder into position.
Page 275: Push Rod Installation
5_106_00.bk Page 259 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 7. Insert the gauge block into the nozzle holder 8. Lubricate the threads of the retaining plug sleeve bore. The gauge block should be and install it as shown in Figure 285. Tighten flush with the top surface of the cylinder the plug to the specified torque, 45 lb-ft head nozzle sleeve bore.
Page 276: Valve Yoke Installation
5_106_00.bk Page 260 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Valve Yoke Installation [213 NV] (Non-Brake and J-Tech™ Brake Equipped) There are two exhaust valves and two inlet valves for each cylinder. Each rocker arm, in conjunction with the valve yoke, operates both valves together as a set (exhaust or inlet).
Page 277: Rocker Arm And Engine Brake Installation
5_106_00.bk Page 261 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 2. Place the valve yokes (4) on the yoke guide pins from which they were removed for both inlet and exhaust (early production) or exhaust only (engine serial No. 0D0120 or later).
Page 278 5_106_00.bk Page 262 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS INSTALLATION (NON-BRAKE EQUIPPED INSTALLATION (J-TECH™ BRAKE-EQUIPPED ENGINES) ENGINES) 1. Make sure the locating screw and lock Refer to Figure 291. washer are in position on the rocker arm 1. Make sure the oil supply screw is in position mounting bracket for each cylinder head.
Page 279 5_106_00.bk Page 263 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 8. Starting with the center pair of mounting 9. After each brake housing is seated on the bolts, tighten all six bolts on each housing cylinder head, tighten the mounting bolts to just enough to seat the housing on the specification, 45 lb-ft (61 N•m).
Page 280: Valve Cover And Spacer Installation
5_106_00.bk Page 264 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Valve Cover and Spacer Installation [213 JB] GENERAL INFORMATION The valve cover (and spacer, if equipped with an engine brake) requires a strip-type seal valve cover gasket, 51 inches (130 cm) in length. Sealing compounds are not necessary.
Page 281: Oil Fill Tube Installation
5_106_00.bk Page 265 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 5. Position the valve covers (1) on the cylinder Oil Fill Tube Installation heads or on the spacers (4), if so equipped, 1. Add a bead of RTV sealant on the mounting as shown in Figure 293.
Page 282: Engine Ecu/Cooling Plate Installation
5_106_00.bk Page 266 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Engine ECU/Cooling Plate Refer to Figure 294. Installation 1. Install the four mounting studs in the cylinder block. [230 EA] 2. Install the four isolating washers on the studs and install the cooling plate. (Right-Side Mounted Assembly) 3.
Page 283: Air Compressor Installation
5_106_00.bk Page 267 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Air Compressor Installation 1. Install a new gasket on the air compressor mounting flange. [261 CK] 2. Check to ensure that the lubrication oil supply tube (2) is in place and position the Refer to Figure 295.
Page 284: Electronic Unit Pump Installation
5_106_00.bk Page 268 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Electronic Unit Pump Installation [221 GP] TAPPET INSTALLATION 1. Clean the cylinder block at the mounting surface and bore, if required. Use only a soft rag and solvent to clean the cylinder block.
Page 285: Engine Wiring Harness Installation
5_106_00.bk Page 269 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Engine Wiring Harness Installation 3. Connect the line (1) at the No. 1 unit pump. Tighten the clamping screw and sleeve nuts 1. Position the wiring harness on the engine to the specified torque, using torque wrench and secure it with the attaching hardware.
Page 286: Turbocharger Installation
5_106_00.bk Page 270 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Turbocharger Installation 8. If the clamp plates or V-bands are loosened for angular orientation of the compressor [214 SC] cover or turbine housing, ensure that the mating flanges are tightly seated and that (Includes Pre-Lubing Procedures) the fasteners are snug but will still allow cover orientation.
Page 287: Water Pump Installation
5_106_00.bk Page 271 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 1. Position a gasket on the water pump mounting flange. 2. Position the pump on the cylinder block and install the three mounting capscrews (3). 3. Install the refrigerant compressor support bracket, if required, on the front of the cylinder head with the appropriate mounting hardware.
Page 288: Oil Cooler And Oil Filter Mounting Bracket Installation
5_106_00.bk Page 272 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Oil Cooler and Oil Filter Mounting 2. Screw the spuds into the filter adapter until they protrude 0.703 inch (17.856 mm) when Bracket Installation measured from the bottom of the spud to the sealing surface of the oil filter head [215 DW and 219 EP] assembly.
Page 289 5_106_00.bk Page 273 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 6. Place a gasket on the water pump mounting flange (2). 7. Lubricate the threads of the two mounting The oil cooler and oil filter mounting bracket capscrews (1) and insert the capscrews to assembly can be installed separately, but secure the oil cooler flange (2) to the water assembling them together on a bench is easier...
Page 290: Coolant Manifold Installation
5_106_00.bk Page 274 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 302 — Removable Bundle-Type Oil Cooler and Oil Filter Mounting Bracket Assembly Installation 1. Capscrew 8. Oil Hose 2. Water Pump Mounting Flange 9. Fitting 3. Clamps 10. Capscrew 4.
Page 291 5_106_00.bk Page 275 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 3. Place couple (2) in position on the couple 6. Lubricate threads of the mounting mounting flange. Place two clamps (3) over capscrews (5) and secure the rear manifold the couple.
Page 292: Air Inlet Manifold Installation
5_106_00.bk Page 276 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Air Inlet Manifold Installation Thermostat, Housing and Seal Installation [214 HD] [215 NU, NG & LD] Refer to Figure 303 and Figure 304. Refer to Figure 305. 1. For two-piece manifolds place the front air inlet manifold section (8) into position on the 1.
Page 293 5_106_00.bk Page 277 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 5. Position the thermostat (7) in the housing (5) 7. Position the housing assembly on the with the jiggle pin or caged ball up. coolant manifold (9) mounting surface. 6.
Page 294: Coolant Conditioner Installation
5_106_00.bk Page 278 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Coolant Conditioner Installation Refer to Figure 305. 1. Position a check valve assembly (3) in the coolant conditioner head assembly (2). The ball end of the check valve must be inserted first.
Page 295 5_106_00.bk Page 279 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 307 — Fuel Filter Adapter Installation with One-Piece Inlet Manifold 1. Secondary Filter Fitting (Out) 5. Air Inlet Manifold 2. Secondary Filter Fitting (In) 6. Mounting Bracket 3. Primary Filter Fitting (Out) 7.
Page 296: Engine Ecu Installation
5_106_00.bk Page 280 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Engine ECU Installation Oil Cooler-to-Water Pump Inlet Line Installation [230 EA] If the engine is equipped with the plate-type oil Left-Side Mounted Assembly cooler, install the oil cooler-to-water pump inlet line (Figure 309) as follows: 1.
Page 297: Alternator Installation
5_106_00.bk Page 281 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Alternator Installation Removing Engine from Engine Stand [271 CB] [200 EA] Refer to Figure 310. 1. Attach a suitable lifting device to lifting points 1. Install the alternator plate and mounting on the engine.
Page 298: Plate-Type Oil Cooler And Oil Filter Mounting Bracket Assembly Installation
5_106_00.bk Page 282 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Plate-Type Oil Cooler and Oil Filter 3. Apply the gasket onto the block over the previously installed alternator stud. Mounting Bracket Assembly 4. If not previously done, install the cooler-to- Installation water pipe hose onto the water pump inlet pipe and slide completely onto the pipe to...
Page 299 5_106_00.bk Page 283 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 312 — Plate-Type Oil Cooler and Oil Filter Mounting Bracket Installation 1. Oil Supply Port for Mechanical Oil Pressure Dashboard 5. Oil Temperature Sensor Port Gauge 6. Oil Pressure Sensor 2.
Page 300: Engine Installation
Engine installation details vary from vehicle to transmission. vehicle. The following procedure provides 4. Install the clutch linkage and bracket- general installation guidelines for MACK retaining capscrews. E-Tech™ engines. 5. Install power steering hoses and reservoir, if Before beginning, make sure all equipment has applicable.
Page 301 5_106repair.fm Page 285 Monday, August 7, 2000 2:04 PM REPAIR INSTRUCTIONS 17. Install the retaining capscrews to the 25. If the vehicle is equipped with air radiator support rods. conditioning: 18. Position the fan clutch air solenoid valve, if Connect the A/C refrigerant low- so equipped, on the radiator support and pressure cutout switch to the wiring install the retaining fastener.
Page 302: In-Chassis Part/Component Procedures
5_106_00.bk Page 286 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS IN-CHASSIS PART/ 3. On chassis with inlet manifold-mounted fuel filters, remove both the inlet and outlet fuel COMPONENT PROCEDURES hoses from the secondary fuel filter. This allows additional fuel to drain from the hose, This section presents four standalone through the cylinder block, and out of the replacement operations which can be done in-...
Page 303 5_106_00.bk Page 287 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 11. Remove roller tappet from the EUP bore by hand. Do not use a tool as it could damage the bore. Place the roller tappet in a clean A small amount of scuffing or foreign particle area and cover it to prevent the entry of dirt scoring in a lifter bore can inhibit static-free and other contaminants.
Page 304: Camshaft Replacement (Engine In Chassis)
5_106_00.bk Page 288 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS UNIT PUMP INSTALLATION 5. Reinstall the wire terminals and tighten to specification, 9 lb-in (1 N•m). Do not bend 1. Install two new O-rings on the replacement wire terminals down after installation. EUP in the upper and lower O-ring grooves.
Page 305 5_106_00.bk Page 289 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 1. Insert the tappet holder in the lifter bore so that the magnetic head of the tool holds the lifter in position. Check to see if the tool has captured the valve lifter by drawing upward on the tool.
Page 306 5_106_00.bk Page 290 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 5. Taking care not to damage camshaft or 2. Install a lifter into the lifter bore by aligning bushings, pull the camshaft out of the front the lifter flats with the H-ring flats. As the of the engine.
Page 307 5_106_00.bk Page 291 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS [213] CAMSHAFT IDLER GEAR INSTALLATION Before installing the idler gear/hub assembly, The camshaft is heavy, approximately 90 pounds determine which is the top mounting hole on the with the gear. The installation guide allows the hub.
Page 308 5_106_00.bk Page 292 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 2. Align the timing marks. First look at the 4. Position idler gear timing marks so they align timing marks on both the camshaft and with the crankshaft and camshaft gear crankshaft gears.
Page 309: Engine Brake Control Valve Replacement
J-Tech™ control valve for Jacobs 690 (J-Tech™) engine brake is components have been redesigned to available through the MACK Parts System. The incorporate a new-style collar (which replaces the kit includes all the necessary components to old-style valve stop spacer), an outer spring and replace all six control valves on the engine.
Page 310 5_106_00.bk Page 294 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS The control valve stop spacer used with the previous (non-current) control valve assembly has been terminated and is no longer available. Additionally, the new-style collar and outer spring are not compatible with the non-current control valves.
Page 311: Valve Lifter H-Ring Installation Check
5_106_00.bk Page 295 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS INSPECTION AND REPAIR Valve Lifter H-Ring Installation Check Remove the cylinder head valve covers and check the control valve bores in each J-Tech™ assembly (Figure 320) for a dislodged or broken snap ring(s).
Page 312 5_106_00.bk Page 296 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 3. Place a straightedge on the cylinder head 6. Place a long screwdriver or long piece of drill top rail surface, in contact with the welding rod on the H-ring top surface and using a rod.
Page 313: Engine Setup And Adjustments
5_106_00.bk Page 297 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS ENGINE SETUP AND ADJUSTMENTS Engine firing order is 1-5-3-6-2-4. Fuel Injection Timing There is no longer a need to set injection pump- SPECIAL TOOL REQUIRED to-engine timing. Consequently, the timing pointer Engine Barring Socket J 38587-A on the engine front cover is eliminated.
Page 314 5_106_00.bk Page 298 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Figure 325 — Flywheel Marks There are 12 clutch mounting bolt holes in the 1. Beginning with the TC mark aligned with the flywheel, but only 8 of these holes are used to timing pointer, rotate the engine in the mount the clutch.
Page 315 5_106_00.bk Page 299 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 5. Permanently mark the flywheel at this Refer to Figure 326 and Figure 327. location for cylinders 1 and 6. To gain 1. Using engine barring socket J 38587-A, access, rotate the engine slightly so that the manually rotate engine in normal rotation area to be marked is either to the right or left...
Page 316 5_106_00.bk Page 300 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 2. Back off the valve rocker adjusting screws. 3. Loosen the No. 1 cylinder yoke adjusting screw jam nuts for the inlet and exhaust valves. 4. Exert moderate force on the yoke by pressing on the rocker arm slipper end.
Page 317 5_106_00.bk Page 301 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS 3. After setting adjustment screw, tighten jam nut to specification, 40 lb-ft (54 N•m), using torque wrench J 24407, or equivalent. Do not allow the adjustment screw to turn. 4.
Page 318 5_106_00.bk Page 302 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS EXHAUST VALVE ADJUSTMENT Refer to Figure 330. The J-Tech™ exhaust rocker arm adjusting screw Exhaust valve clearance is 0.024 inch spherical jam nut is a through-hardened nut. (0.610 mm). When tightening these nuts, be aware of the following: Always use the proper 20-mm size wrench.
Page 319 5_106_00.bk Page 303 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS ENGINE BRAKE ADJUSTMENT (IF EQUIPPED) [213] It may be necessary to back off the adjusting screw slightly to remove the thickness gauge. Refer to Figure 331. However, be sure to return the adjusting screw to the proper position.
Page 320: Engine Speed And Position Sensors Installation And Adjustment
CONTINUATION OF ADJUSTMENTS FOR 3. Make sure that the Jacobs electrical REMAINING CYLINDERS connector, MACK part No. 4559-17366, is installed in each of the engine brake cylinder 1. Using the barring socket, manually rotate head cover spacers. Install one valve cover...
Page 321: Electronic Unit Pump (Eup) Calibration
EUPs. For later-production EUPs, the calibration code is still found in the same location on the data plate (next to the word MACK), only the identification letters “CAL” have been eliminated to provide room for larger bar codes.
Page 322: Engine Final Preparation And Operational Check
The following briefly describes the recommended procedure for All filters and coolant conditioners must meet ensuring proper lubrication. MACK specifications. Prime oil filters before installation using the correct specification engine oil. Do not mix brands or types of lubricants.
Page 323: Cooling System
5_106_00.bk Page 307 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS Cooling System 1. Check the cooling system. Make sure all Excessive hand-priming after fuel is seen at the plugs are installed and tight. Make sure the fitting may make the engine difficult to start. thermostat is installed.
Page 324: Rebuilt Engine Run-In Procedures
5_106_00.bk Page 308 Friday, August 4, 2000 11:17 AM REPAIR INSTRUCTIONS REBUILT ENGINE RUN-IN The operator must be observant throughout the entire run-in procedure, in order to detect any PROCEDURES problems that develop. Constantly monitor the instrumentation displaying functions of the engine General Instructions and support systems, and record all readings.
Page 325: Specifications
5_106_00.bk Page 309 Friday, August 4, 2000 11:17 AM SPECIFICATIONS SPECIFICATIONS Page 309 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 326: E-Tech™ Engine Mechanical Specifications
5_106_00.bk Page 310 Friday, August 4, 2000 11:17 AM SPECIFICATIONS E-TECH™ ENGINE E7-310/330 E-TECH™ MECHANICAL Power at Governed Speed — 310 hp (231 kW) at 1800 rpm SPECIFICATIONS Peak Power — 330 hp (246 kW) at Performance Specifications 1500 rpm Maximum Torque —...
Page 327: Material And Dimensional Data
5_106_00.bk Page 311 Friday, August 4, 2000 11:17 AM SPECIFICATIONS E7-400 E-TECH™ Torque Rise — 25 percent Power at Governed Speed — 400 hp Engine Brake Retarding Power — 360 hp (298 kW) at 1800 rpm (251 kW) at 2100 rpm Maximum Torque —...
Page 328 Lubrication system Full pressure, wet sump, 28-quart (26.5 L) capacity, 25,000-mile (40 000-km) highway/300-hour stop-and-go change interval; MACK-approved EO-M oil. If application meets Line Haul 1 requirements, it qualifies for extended service interval with MACK-approved EO-M Plus oil. Valve seat inserts Pressed-in head, replaceable Manifold —...
Page 329 5_106_00.bk Page 313 Friday, August 4, 2000 11:17 AM SPECIFICATIONS FITS AND LIMITS good judgment, experience and sound shop practice. The specifications as listed are for new parts, and therefore, maximum wear must be established by Tolerances Are Shown Low to High Standard Size or Fit Component English...
Page 330 5_106_00.bk Page 314 Friday, August 4, 2000 11:17 AM SPECIFICATIONS Tolerances Are Shown Low to High Standard Size or Fit Component English Metric Bearing ID (in place) 2.9993–3.0013 in. 76.1822–76.2330 mm Twist (within 12 in./30.48 cm) 0.010 in. 0.254 mm Bend (within 12 in./30.48 cm) 0.004 in.
Page 331 5_106_00.bk Page 315 Friday, August 4, 2000 11:17 AM SPECIFICATIONS Tolerances Are Shown Low to High Standard Size or Fit Component English Metric Valve Roller Follower Bore 1.1245–1.1255 in. 28.562–28.588 mm Valve Roller Follower OD 1.122–1.123 in. 28.499–28.524 mm Valve Roller Follower-to-Bore Clearance 0.0015–0.0035 in.
Page 332 5_106_00.bk Page 316 Friday, August 4, 2000 11:17 AM SPECIFICATIONS Tolerances Are Shown Low to High Standard Size or Fit Component English Metric FLYWHEEL AND HOUSING Dowel Pin Hole, Flywheel Housing (round pin, LH) 0.6259–0.6263 in. 15.8979–15.9080 mm Dowel Pin Hole, Flywheel Housing (blade pin, RH) 0.6831–0.6835 in.
Page 333 Note: End gap checked in 4.875 gauge diameter. For every 0.001-inch (0.0254-mm) increase in gauge diameter, ring gap will increase by 0.003 inch (0.076 mm). Refer to a MACK branch or dealer for specifications for piston ring part numbers not listed above.
Page 334 5_106_00.bk Page 318 Friday, August 4, 2000 11:17 AM SPECIFICATIONS Tolerances Are Shown Low to High Standard Size or Fit Component English Metric Inlet (acceptable range for interim checks) 0.012–0.020 in. 0.305–0.508 mm Exhaust (adjustment at scheduled intervals) 0.024 in. 0.601 mm Exhaust (acceptable range for interim checks) 0.020–0.028 in.
Page 335: E-Tech™ Component Torque Specifications
5_106_00.bk Page 319 Friday, August 4, 2000 11:17 AM SPECIFICATIONS E-Tech™ Component Torque Specifications All components are to be clean and free from foreign material or corrosion. Assemblies are to be made using suitable tools and procedures so that no permanent damage will occur as a result of the assembly.
Page 336 5_106_00.bk Page 320 Friday, August 4, 2000 11:17 AM SPECIFICATIONS Torque Fastener Name Lb-Ft N•m CRANKSHAFT Vibration Damper Hub to Crank Screw Vibration Damper to Hub Screw CYLINDER BLOCK Main Bearing Capscrew (See “NOTE 2 — MAIN BEARING CAP INSTALLATION” on page 328.) Cylinder Block Main Brg.
Page 337 5_106_00.bk Page 321 Friday, August 4, 2000 11:17 AM SPECIFICATIONS Torque Fastener Name Lb-Ft N•m Oil Cooler Water Inlet and Water Outlet Ftg. to Oil Cooler Screw OIL COOLER – Plate-Type Oil Cooler Tube to Water Pump (MR Model Stud) Oil Cooler Tube to Water Pump Oil Cooler to Brkt.
Page 338 5_106_00.bk Page 322 Friday, August 4, 2000 11:17 AM SPECIFICATIONS Torque Fastener Name Lb-Ft N•m Timing Cover to Cyl. Block Screw TURBO AND EXHAUST MANIFOLD Turbo to Exhaust Manifold Stud Nut Turbo Oil Inlet Tube to Turbo Screw Turbo Oil Drain Tube to Turbo Screw ®...
Page 339 5_106_00.bk Page 323 Friday, August 4, 2000 11:17 AM SPECIFICATIONS TORQUE SPECIFICATIONS FOR HOSE CLAMPS HOSE CLAMPS (SEE “NOTE 6 — HOSE CLAMP INSTALLATION POSITIONING INFORMATION” ON PAGE 328) Torque Fastener Name Lb-In N•m For Standard SAE J536 Type F Hose Clamps Air Inlet Systems Oil Drain Systems Water or Coolant Systems...
Page 340 5_106_00.bk Page 324 Friday, August 4, 2000 11:17 AM SPECIFICATIONS TORQUE SPECIFICATIONS FOR ENGINE-MOUNTED SENSORS E-TECH™ ENGINE-MOUNTED SENSORS Description Sensor and Sensor Mounting Hardware Sensor Threads Mounting Torque V-MAC III Engine Speed 64MT348M sensor and 505GC28 P15 and None 7 lb-ft (10 N•m) Sensor P30 shims, as required.
Page 341 5_106_00.bk Page 325 Friday, August 4, 2000 11:17 AM SPECIFICATIONS TORQUE SPECIFICATIONS FOR NON-CRITICAL FASTENERS PROPERTY CLASS 8.8 Tightening Torques Size (mm) Pitch Lb-Ft N•m 0.75 1.00 1.00 1.25 1.25 1.50 1.25 1.75 1.50 2.00 1.50 2.00 1.50 2.50 1.50 2.50 1.50 2.50...
Page 342 5_106_00.bk Page 326 Friday, August 4, 2000 11:17 AM SPECIFICATIONS PROPERTY CLASS 9.8 Tightening Torques Size (mm) Pitch Lb-Ft N•m 0.75 1.00 1.00 1.25 1.25 1.50 1.25 1.75 1.50 2.00 1.50 2.00 1.50 2.50 1.50 2.50 1.50 2.50 2.00 3.00 2.00 3.00 2.00...
Page 343 5_106_00.bk Page 327 Friday, August 4, 2000 11:17 AM SPECIFICATIONS PROPERTY CLASS 10.9 Tightening Torques Size (mm) Pitch Lb-Ft N•m 0.75 1.00 1.00 1.25 1.25 1.50 1.25 1.75 1.50 2.00 1.50 2.00 1.50 2.50 1.50 2.50 1.50 2.50 2.00 3.00 2.00 1250 3.00...
Page 344: Specification Footnotes
5_106_00.bk Page 328 Friday, August 4, 2000 11:17 AM SPECIFICATIONS SPECIFICATION FOOTNOTES NOTE 4 — EXHAUST MANIFOLD TORQUING Torque exhaust manifold nuts to 35 lb-ft (47 N•m) NOTE 1 — AUXILIARY SHAFT GEAR in a top-to-bottom sequence. Retorque to 80 lb-ft RETAINING NUT INSTALLATION (109 N•m) following the same top-to-bottom A new nut has pre-applied thread locker.
Page 345: E-Tech™ Engine Lubricant And Sealant Specifications
Dow Corning No. 1200 primer, Dow Corning RTV 734 adhesive (clear), and naphtha solvent or equivalent Cylinder sleeve seat MACK Silastic (RTV Silicone Adhesive Sealant) part No. 342SX32 Oil filter sealing gasket Clean engine oil ® Holding metal parts in place MACK MG-C grease or petroleum jelly (Vaseline ®...
Page 346: Fastener Torque
5_106_00.bk Page 330 Friday, August 4, 2000 11:17 AM SPECIFICATIONS FASTENER TORQUE Proper installation is as important as the selection of the correct fastener. Improperly installing a Fastener Selection and Installation correct fastener is just as bad as using an incorrect one.
Page 347: Fastener Sizes And Types
5_106_00.bk Page 331 Friday, August 4, 2000 11:17 AM SPECIFICATIONS Fastener Sizes and Types The pitch of metric fasteners is measured by determining the millimeters per thread. For The first and most important fact that the example, a bolt with 0.8 pitch would have 125 mechanic must know about a fastener is whether complete threads in a 100-millimeter section it is a U.S.
Page 348 5_106_00.bk Page 332 Friday, August 4, 2000 11:17 AM NOTES Page 332 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 349: Schematics & Diagrams
5_106_00.bk Page 333 Friday, August 4, 2000 11:17 AM SCHEMATICS & DIAGRAMS SCHEMATICS & DIAGRAMS Page 333 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 350: Engine System Schematics (Fluids Flow)
5_106_00.bk Page 334 Friday, August 4, 2000 11:17 AM SCHEMATICS & DIAGRAMS ENGINE SYSTEM SCHEMATICS (FLUIDS FLOW) Cooling System Flow Diagram Figure 338 — E-Tech™ Cooling Circuit Page 334 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 351: Lubrication System Flow Diagram
5_106_00.bk Page 335 Friday, August 4, 2000 11:17 AM SCHEMATICS & DIAGRAMS Lubrication System Flow Diagram Figure 339 — E-Tech™ Oil Flow Schematic Page 335 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 352: Fuel System Flow Diagram
5_106_00.bk Page 336 Friday, August 4, 2000 11:17 AM SCHEMATICS & DIAGRAMS Fuel System Flow Diagram Figure 340 — E-Tech™ Fuel System Page 336 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 353: Special Tools & Equipment
5_106_00.bk Page 337 Friday, August 4, 2000 11:17 AM SPECIAL TOOLS & EQUIPMENT SPECIAL TOOLS & EQUIPMENT Page 337 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 354: E-Tech™ Engine Special Tools
5_106_00.bk Page 338 Friday, August 4, 2000 11:17 AM SPECIAL TOOLS & EQUIPMENT E-TECH™ ENGINE SPECIAL TOOLS Special Tools for Engine Overhaul Tool No. Description Midget Seal Tool 00-18238 Jacobs Slave Piston Tool 014177 Jacobs Thickness Gauge, 0.085 inch (2.16 mm) 018781 Jacobs Thickness Gauge, 0.080 inch (2.03 mm) 021327...
Page 355 5_106_00.bk Page 339 Friday, August 4, 2000 11:17 AM SPECIAL TOOLS & EQUIPMENT Tool No. Description J 29600-C Fire Ring Groove Cutter J 29653-A Ultrasonic Nozzle Cleaner J 29880 Nozzle Sleeve Extractor J 34046-A Compression Gauge Adapter Set J 34046-5 Compression Tester Metric Adapter (used with J 34046-A) J 34684 Cylinder Head Core Plug Installer (13/16 inch)
Page 356 5_106_00.bk Page 340 Friday, August 4, 2000 11:17 AM SPECIAL TOOLS & EQUIPMENT Tool No. Description J 42426 Valve Roller Follower H-Ring Remover (use with J 6125-1B Slide Hammer) J 42453 Valve Seal Installer J 42490 Camshaft Cup Plug Installer (use with J 8092 Driver Handle) J 42595 Fuel Injection Nozzle Sleeve Installer J 42639...
Page 357: V-Mac Iii Special Tools
5_106_00.bk Page 341 Friday, August 4, 2000 11:17 AM SPECIAL TOOLS & EQUIPMENT V-MAC III Special Tools Tool No. Description J 37490 Diesel Electronic Connector Replacement Kit J 38351-B Serial Link Adapter Assembly J 38480 Portable Printer (use with J 38500-1) J 38500-1 Pro-Link Diagnostic Scan Tool J 38500-60A...
Page 358 5_106_00.bk Page 342 Friday, August 4, 2000 11:17 AM NOTES Page 342 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 359: Index
Index.fm Page 343 Friday, August 4, 2000 11:16 AM INDEX INDEX Page 343 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 360 Index.fm Page 344 Friday, August 4, 2000 11:16 AM INDEX CHASSIS-MOUNTED CHARGE AIR COOLING TESTS ....67 ABOUT THE E-TECH™ ENGINE AND ITS CLEANING AND INSPECTION .
Page 361 Index.fm Page 345 Friday, August 4, 2000 11:16 AM INDEX CYLINDER HEAD ..... .41 ENGINE FINAL PREPARATION AND CYLINDER HEAD AND CYLINDER BLOCK OPERATIONAL CHECK .
Page 362 Index.fm Page 346 Friday, August 4, 2000 11:16 AM INDEX FRONT COVER INSTALLATION ..247 FRONT COVER REMOVAL ... . .126 LOW-PRESSURE FUEL SYSTEM ..32 FUEL FILTER ADAPTER ASSEMBLY LUBRICATION SYSTEM .
Page 363 Index.fm Page 347 Friday, August 4, 2000 11:16 AM INDEX PISTON COOLING SPRAY NOZZLE INSTALLATION ....157 VALVE COVER AND SPACER PISTON COOLING SPRAY NOZZLE INSTALLATION .
Page 364 Index.fm Page 348 Friday, August 4, 2000 11:16 AM NOTES Page 348 BDC for engine manuals and specs https://barringtondieselclub.co.za/...
Page 365 SERVICE MANUAL PRINTED IN U.S.A. S IN . 000 5-106 BDC for engine manuals and specs https://barringtondieselclub.co.za/...

Mack E-TECH SB-210-034 Service Manual

Introduction

Identification

Description & Operation

Troubleshooting

Maintenance

Repair Instructions

Specifications

Schematics & Diagrams

Special Tools & Equipment

Index

Quick Links

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for Mack E-TECH SB-210-034