General; Vehicle Preparation; 200 Engine Removal - Mack E7 Service Manual

5-101.bk Page 2 Friday, March 17, 2006 11:05 AM

GENERAL

Details of the engine removal procedure vary
from one vehicle to another. This section
provides general guidelines for removing the
engine from the vehicle.
Before beginning engine removal, make sure all
equipment is available for use and has been
inspected for safety.

Vehicle Preparation

It is good practice to steam-clean the engine to
remove road grime, grease and oil before starting
work. Steam cleaning the engine and engine area
allows more detailed inspection and improved
workmanship.
Care must be used to keep moisture from
entering the air intake system. If moisture does
enter the system, make sure it is removed (dried
out) before the engine is reinstalled.
1. Position vehicle on a flat and level surface in
an area with ample work space in and
around the vehicle. Ensure that a suitable
lifting device is available.
2. Apply the parking brake and block the
vehicle wheels to prevent vehicle from
moving. Observe all safety precautions.
3. Disconnect the battery negative (ground)
cable.
4. Drain the air tanks.
Engine Removal
1. Remove the hood and position it away
from the work area to prevent accidents or
hood damage. Refer to Hood Removal
procedures in the appropriate vehicle
manual.
2. Place a suitable container beneath the
engine and drain engine oil and coolant.
Open the coolant drain valves in the block,
if applicable.
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200 ENGINE REMOVAL

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10. Disconnect the chassis-mounted charge air
11. Locate the engine coolant temperature
12. Remove fastener from the bracket that
13. Remove the retaining bolts from the radiator
14. Obtain a lifting device (chain fall or engine
15. Remove the retaining bolts from the radiator
16. Remove the radiator from the vehicle using
Using an appropriate filter wrench, remove
the oil filters, fuel filters and coolant
conditioner.
Loosen clamps that secure the air intake
tube to the turbocharger and air filter.
Remove the intake tube.
If vehicle is equipped with air conditioning:
a. Using A/C refrigerant recovery and
recycling equipment, recover the A/C
system refrigerant.
b. Disconnect the A/C compressor
discharge hose at connection near the
radiator support.
c. Disconnect the A/C line at the
receiver/dryer.
d. Locate and disengage the electrical
connector from binary pressure switch
on the receiver/dryer.
e. Locate and disengage the electrical
connector from the low-pressure cutout
switch in the A/C refrigerant line.
Disconnect the upper radiator hose from the
engine coolant outlet fitting.
Disconnect the lower radiator hose from the
coolant inlet of the oil cooler assembly.
Remove the clamps that retain the coolant
overflow tank. Remove tank.
Disconnect the chassis-mounted charge air
cooler inlet hose at the cooler.
cooler outlet hose at the cooler.
sensor and disengage the electrical
connector, if applicable. Remove sensor
harness from the radiator support.
secures the radiator fan air clutch solenoid
valve to the radiator support. Set the
solenoid valve aside.
support rods at the radiator support.
hoist) and support the radiator.
support mounts.
a lifting device and an assistant, if required.