E7 ENGINE OVERHAUL AUGUST 1997 ENGINE 5-101
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E7 ENGINE OVERHAUL MARCH 2006 2.5M (REP.) AUGUST 1997 10M © MACK TRUCKS, INC.
front.fr5 Page ii Friday, March 17, 2006 11:04 AM ATTENTION The information in this manual is not all inclusive and cannot take into account all unique situations. Note that some illustrations are typical and may not reflect the exact arrangement of every component installed on a specific chassis. The information, specifications, and illustrations in this publication are based on information that was current at the time of publication.
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front.fr5 Page iv Friday, March 17, 2006 11:04 AM 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 render it unsafe.
front.fr5 Page v Friday, March 17, 2006 11:04 AM SAFETY INFORMATION 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.
front.fr5 Page vi Friday, March 17, 2006 11:04 AM SAFETY INFORMATION Mack Trucks, Inc. cannot anticipate every possible occurrence that may involve a potential hazard. Accidents can be avoided by recognizing potentially hazardous situations and taking necessary precautions. Performing service procedures correctly is critical to technician safety and safe, reliable vehicle operation.
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front.fr5 Page viii Friday, March 17, 2006 11:04 AM EXPLANATION OF NUMERICAL CODE EXPLANATION OF 3-DIGIT NUMERICAL CODE The organization of MACK service manuals has been upgraded to standardize manual content according to a reference system based on component identification.
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front.fr5 Page x Friday, March 17, 2006 11:04 AM ABOUT THIS MANUAL CHANGES FROM THE EXISTING E7 MANUAL Mack Trucks, Inc. has made many major improvements to this E7 Service Manual, with changes to both content and organization. The specifications have been revised to reflect changes and improvements in E7 engines. All specifications and torque values are given in English and metric measurements.
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front.fr5 Page xii Friday, March 17, 2006 11:04 AM TABLE OF CONTENTS SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Advisory Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv Service Procedures and Tool Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
front.fr5 Page xiii Friday, March 17, 2006 11:04 AM TABLE OF CONTENTS [231 PB] FUEL FILTER ADAPTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 [215 LD] COOLANT CONDITIONER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 [215 NU] THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 [214 HD] AIR INLET MANIFOLD . . . . . . . . . . . . . . . . . . . . .
front.fr5 Page xiv Friday, March 17, 2006 11:04 AM TABLE OF CONTENTS [212 NP] PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . .
front.fr5 Page xv Friday, March 17, 2006 11:04 AM TABLE OF CONTENTS Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56 [215 SW] WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57 [219 MU] OIL PUMP . .
front.fr5 Page xvi Friday, March 17, 2006 11:04 AM TABLE OF CONTENTS [212 NP & 212 LP] PISTONS AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
front.fr5 Page xvii Friday, March 17, 2006 11:04 AM TABLE OF CONTENTS [213 EV] CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [222 KG] NOZZLE HOLDER ASSEMBLY . .
front.fr5 Page xviii Friday, March 17, 2006 11:04 AM TABLE OF CONTENTS [271 CB] ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80 Fan Belt(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
front.fr5 Page xix Friday, March 17, 2006 11:04 AM TABLE OF CONTENTS [233 FA] CHASSIS-MOUNTED CHARGE AIR COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Special Tool Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 CMCAC Troubleshooting . . . . . . . . . . . . . . . .
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5-101.bk Page 2 Friday, March 17, 2006 11:05 AM 200 GENERAL INFORMATION INTRODUCTION This manual is intended to assist the technician in properly overhauling MACK E7 engines. The manual is divided into nine major sections. Working on the E7 engine is not difficult, but like most present-day precision equipment, it requires proper tools and knowledge. The overhaul procedures are separated into three sections: engine disassembly, bench procedures and engine assembly.
5-101.bk Page 3 Friday, March 17, 2006 11:05 AM 200 GENERAL INFORMATION ENGINE MODEL IDENTIFICATION For some current MACK engines, the engine information plate also includes pertinent emissions characteristics of NOx and particulates unique to that engine. Engine Information Plate All engines are identified by an engine information plate located on the front valve cover of the engine. This plate indicates the engine’s 11GBA number, emission standards, serial number and various engine adjustments.
5-101.bk Page 4 Friday, March 17, 2006 11:05 AM 200 GENERAL INFORMATION Block 3 — ADR Regulations Block 6 — California Family 앫 An “X” in block three means the engine has been certified to meet Australian emissions regulations. 앫 앫 Two dashes in block three means the engine does not meet Australian emissions regulations. If the engine meets California emissions regulations, the same two-digit numeral stamped in the Federal Family block is stamped in the California block.
5-101.bk Page 5 Friday, March 17, 2006 11:05 AM 200 GENERAL INFORMATION LUBRICANTS AND SEALANTS Use only the following recommended sealing compounds and lubricants. All genuine MACK cylinder head gaskets are precoated and do not require any type of sealing compound. Before installing new gaskets, degrease both gasket sealing surfaces to avoid leaks.
5-101.bk Page 6 Friday, March 17, 2006 11:05 AM 200 GENERAL INFORMATION OVERHAUL PART REPLACEMENT Use genuine MACK parts at all times.
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5-101.bk Page 2 Friday, March 17, 2006 11:05 AM 200 SPECIFICATIONS SPECIFICATIONS Improved Design Compared to earlier designs, the E7 engines include improvements required to accommodate higher horsepower ratings and future emission standards. These changes require increased displacement, higher peak cylinder pressures and a superior engine cooling system. This was all accomplished without a substantial change in engine weight.
5-101.bk Page 3 Friday, March 17, 2006 11:05 AM 200 SPECIFICATIONS Engine Features (Cont.) Component Description Connecting rods Forged steel, I-beam with tapered pin end, 35-degree cap angle, 10.4 inches (26.42 cm) center-to-center length Crankshaft Drop-forged, medium carbon steel, elotherm hardened journals and fillets, eight integral counterweights, 3.25 inch (8.26 cm) piston journal diameter, 4.5 inch (11.
5-101.bk Page 4 Friday, March 17, 2006 11:05 AM 200 SPECIFICATIONS Good Shop Practice — Fasteners Make sure that all components are clean and free from foreign material or corrosion. Use suitable tools and assembly procedures to prevent permanent damage to the engine components. For additional information on tune-up specifications for 1992 and 1993 E7 V-MAC engines, refer to 1992 MACK Engine Tune-Up Specifications No. 5-304ID92 and V-MAC Service Manual No. 8-201.
5-101.bk Page 5 Friday, March 17, 2006 11:05 AM 200 SPECIFICATIONS FASTENER TORQUE Fastener Selection and Installation Selection and correct installation of threaded fasteners are essential parts of any assembly or rebuild procedure. Fasteners hold much of a vehicle together. If a fastener fails to do its job properly, it can cause a minor problem such as a loose mirror, or a large problem, such as loss of steering control.
5-101.bk Page 6 Friday, March 17, 2006 11:05 AM 200 SPECIFICATIONS Fastener Sizes and Types The first and most important fact that the mechanic must know about a fastener is whether it is a U.S. (Inch System) or a metric thread. Next, the size of the fastener, which is usually determined by the diameter of the shank, the length of the fastener, which is usually measured from the bottom of the head to the end of the thread, and the pitch of the threads. The pitch of U.S.
5-101.bk Page 7 Friday, March 17, 2006 11:05 AM 200 SPECIFICATIONS TORQUE SPECIFICATIONS This section includes specifications for torquing all critical and standard non-critical fasteners.
5-101.bk Page 8 Friday, March 17, 2006 11:05 AM 200 SPECIFICATIONS Torque Specifications for Critical Fasteners (Cont.
5-101.bk Page 9 Friday, March 17, 2006 11:05 AM 200 SPECIFICATIONS Torque Specifications for Critical Fasteners (Cont.
5-101.bk Page 10 Friday, March 17, 2006 11:05 AM 200 SPECIFICATIONS Torque Specifications for Critical Fasteners (Cont.
5-101.bk Page 11 Friday, March 17, 2006 11:05 AM 200 SPECIFICATIONS Torque Specifications for Pipe Plugs Torque Pipe Plugs Lb-Ft N•m 1/8 NPT 6 8 1/4 NPT 18 24.4 3/8 NPT 23 31 1/2 NPT 23 31 3/4 NPT 28 38 1 NPT 43 58 1-1/2 NPT 75 102 ® NOTE: All pipe plugs which are not new plugs with preapplied thread sealer must be sealed using Loctite PST pipe thread sealant with Teflon or equivalent. Torque Specifications for Non-Critical Fasteners PROPERTY CLASS 8.
5-101.bk Page 12 Friday, March 17, 2006 11:05 AM 200 SPECIFICATIONS Torque Specifications for Non-Critical Fasteners (Cont.) PROPERTY CLASS 8.8 (Cont.) Size (mm) Pitch 30 Tightening Torques Lb-Ft N•m 3.50 838 1136 33 2.00 1250 1695 33 3.50 1140 1546 36 3.00 1551 2103 36 4.00 1465 1986 PROPERTY CLASS 9.8 Page 2-12 Size (mm) Pitch 6 Tightening Torques Lb-Ft N•m 0.75 7 10 6 1.00 6 8 8 1.00 16 22 8 1.25 15 20 10 1.25 33 45 10 1.50 31 42 12 1.
5-101.bk Page 13 Friday, March 17, 2006 11:05 AM 200 SPECIFICATIONS Torque Specifications for Non-Critical Fasteners (Cont.) PROPERTY CLASS 10.9 Size (mm) Pitch 6 Tightening Torques Lb-Ft N•m 0.75 9 12 6 1.00 8 11 8 1.00 21 29 8 1.25 20 27 10 1.25 42 57 10 1.50 40 54 12 1.25 76 103 12 1.75 69 94 14 1.50 120 163 14 2.00 111 151 16 1.50 184 250 16 2.00 172 233 18 1.50 268 363 18 2.50 239 324 20 1.50 374 507 20 2.50 337 457 22 1.
SECT2.FR5 Page 14 Tuesday, March 21, 2006 12:43 PM 200 SPECIFICATIONS FITS AND LIMITS The specifications listed are for new parts. Good judgement, experience and sound shop practice must be used when determining whether to reuse or replace service parts. Fits and Limits Component Standard Size or Fit English Metric 2.064–2.068 in. 52.426–52.527 mm — presized OD (front and rear) 2.3140–2.3155 in. 58.7756–58.8137 mm — bore in block (front and rear) 2.311–2.312 in. 58.699–58.
SECT2.FR5 Page 15 Tuesday, March 21, 2006 12:43 PM 200 SPECIFICATIONS Fits and Limits (Cont.) Component Standard Size or Fit English Metric 0.007–0.014 in. 0.1778–0.3556 mm Twist within 12 inches (30.48 cm) 0.010 in. 0.254 mm Bend within 12 inches (30.48 cm) 0.004 in. 0.1016 mm Crankpin journal OD 3.248–3.247 in. 82.4992–82.4738 mm End play at No. 4 main 0.004–0.013 in. 0.1016–0.3302 mm 4.4974–4.4964 in. 114.2340–114.2086 mm 0.00035 in. 0.00889 mm 0.007 in. 0.178 mm 0.002 in. 0.
5-101.bk Page 16 Friday, March 17, 2006 11:05 AM 200 SPECIFICATIONS Fits and Limits (Cont.) Standard Size or Fit Component English Metric 0.001–0.003 in. tight 0.0254–0.0762 mm 0.0015–.004 in. tight 0.0381–0.1016 mm 0.9360–0.9375 in. 23.7744–23.8125 mm 0.904–0.906 in. 22.962–23.012 mm — upper and intermediate 0.9390–0.9385 in. 23.8506–23.8379 mm — lower 1/2 inch (12.7 mm) 0.9080–0.9075 in. 23.0632–23.0505 mm Fire ring groove — width 0.030–0.036 in. 0.762–0.914 mm — depth 0.005–0.
5-101.bk Page 17 Friday, March 17, 2006 11:05 AM 200 SPECIFICATIONS Fits and Limits (Cont.) Component Standard Size or Fit English Metric 0.6259–0.6263 in. 15.8979–15.9080 mm 0.6831–0.6835 in. 17.3507–17.3609 mm 0.6251–0.6253 in. 15.8775–15.8826 mm Cylinder block end 0.6251–0.6253 in. 15.8775–15.8826 mm Flywheel housing end 0.6820–0.6825 in. 17.3228–17.3355 mm Crankshaft seal mounting bore 6.748–6.752 in. 171.3992–171.5008 mm Flywheel housing transmission mounting face runout 0.008 in.
5-101.bk Page 18 Friday, March 17, 2006 11:05 AM 200 SPECIFICATIONS Fits and Limits (Cont.) Component Standard Size or Fit English Metric 4.912 in. 124.765 mm Compression rings — No. 349GC3101 0.016–0.028 in. 0.406–0.711 mm Compression rings — No. 349GC3102 0.013–0.025 in. 0.330–0.635 mm Oil control ring — No. 350GC340 0.013–0.028 in. 0.330–0.711 mm Piston ring side clearance (new) 0.0016–0.0030 in. 0.0406–0.0762 mm Piston ring side clearance (used) Maximum 0.0045 in. Maximum 0.
5-101.bk Page 19 Friday, March 17, 2006 11:05 AM 200 SPECIFICATIONS Fits and Limits (Cont.) Standard Size or Fit Component English Metric Shaft end play 0.003–0.006 in. 0.0762–0.1524 mm Bearing radial check (measured at bearings) 0.018–0.030 in. 0.4572–0.7620 mm (0.018–0.025) in (0.4572–0.6350 mm) Shaft end play 0.003–0.006 in. 0.0762–0.1524 mm Bearing radial check (measured at bearings) 0.018–0.029 in. 0.4572–0.7366 mm — inlet + 0.0425 ± 0.007 in. +1.0795 ± 0.
5-101.bk Page 20 Friday, March 17, 2006 11:05 AM 200 SPECIFICATIONS METRIC MISMATCH Inch Nuts Certain metric/English fastener thread combinations are incompatible and may result in mismatch conditions. These conditions can cause thread stripping and/or assembly weaknesses which may lead to service failure, rendering a vehicle inoperative or unsafe for operation. Inch Thread vs.
5-101.bk Page 21 Friday, March 17, 2006 11:05 AM 200 SPECIFICATIONS Inch Thread vs. Metric Thread Fastener Combinations Contributing to Assembly Weakness The following inch/metric screw and nut (or tapped hole) combinations can be fully tightened, but the resulting assembly will be 25% to 60% weaker than required. Service failure of the assembly is probable. Inch Screws *4-48 Metric Nuts M3 x 0.5 Incompatible Metric vs.
5-101.bk Page 22 Friday, March 17, 2006 11:05 AM 200 SPECIFICATIONS SPECIAL TOOLS Special Tool List Tool No. Description 814 Midget Seal Tool 022001 Jacobs Thickness Gauge, 0.060 inch (1.52 mm) 018781 Jacobs Thickness Gauge, 0.080 inch (2.03 mm) 014177 Jacobs Thickness Gauge, 0.085 inch (2.16 mm) 021327 Jacobs Thickness Gauge, 0.100 inch (2.
5-101.bk Page 23 Friday, March 17, 2006 11:05 AM 200 SPECIFICATIONS Special Tool List (Cont.) Tool No.
5-101.bk Page 24 Friday, March 17, 2006 11:05 AM 200 SPECIFICATIONS Special Tool List (Cont.) Tool No. Description PT6435 Cylinder Liner/Sleeve Puller (lubricate with extreme pressure lubricant J 23444-A) PT6570-11 Dowelout, Extractor (7/16 inch) PT6575 Basic Heavy-Duty Dowelout Kit PT6587 Piston Ring Expander PT7070-A Piston Ring Compressor V-MAC Tools Tool No.
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5-101.bk Page 2 Friday, March 17, 2006 11:05 AM 200 ENGINE REMOVAL GENERAL 3. Details of the engine removal procedure vary from one vehicle to another. This section provides general guidelines for removing the engine from the vehicle. Using an appropriate filter wrench, remove the oil filters, fuel filters and coolant conditioner. 4. Loosen clamps that secure the air intake tube to the turbocharger and air filter. Remove the intake tube. 5.
5-101.bk Page 3 Friday, March 17, 2006 11:05 AM 200 ENGINE REMOVAL 17. Disconnect the heater hoses and A/C refrigerant lines, if applicable, from connections at the lower dash panel behind the engine. 18. Disconnect the tube connecting the turbocharger to the air cleaner assembly. 19. Remove all coolant tubes, ground straps, air lines, fuel lines, hydraulic hoses or tubes, throttle linkage and electrical wiring harnesses that are attached to the engine and would prevent its removal. 20.
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5-101.bk Page 2 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY GENERAL This section includes step-by-step procedures for complete disassembly of the MACK E7 engine upon removal from the vehicle. Major components are removed as assemblies and overhauled in the BENCH PROCEDURES section of this manual. 1 10 Failure to follow the sequence of operations listed below may result in damage to components or personal injury.
5-101.bk Page 3 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY MOUNTING ENGINE IN STAND The engine is heavy (approximately 2,300 lbs. [1043 kg] wet). Stay out from under the engine when it is being lifted. Failure of the lifting device could result in serious injury or death. Make sure to use lifting equipment that is rated at a capacity greater than the weight of the engine.
5-101.bk Page 4 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY 1 2 3 4 2 Figure 4-2 — Mount Engine in Stand 1. Adapter plate J 38048 2. Capscrews Page 4-4 3. Engine stand J 29109 4.
5-101.bk Page 5 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY [271 CB] ALTERNATOR [215 HB] FAN ASSEMBLY Refer to Figure 4-3. Refer to Figure 4-4. 1. Loosen adjusting capscrew (2) and mounting nuts (6). 1. Loosen eight fan assembly mounting nuts (2) and capscrews (1). 2. Remove drive belts (1) and tag belts for reassembly. 2. While supporting fan assembly (3), remove nuts (2) from capscrews (1) and remove fan assembly. 3. Disconnect and tag electrical wires by removing mounting hardware. 4.
5-101.bk Page 6 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY [231 PB] FUEL FILTER ADAPTER ASSEMBLY Refer to Figure 4-6 1. Disconnect three fuel lines from fittings (2, 3 and 5) on fuel filter adapter assembly (1). Tag and cap all lines. 2. Remove three capscrews (4) from the top of the fuel filter adapter assembly. 3. Remove fuel filter adapter assembly from the air inlet manifold (7). Figure 4-5 — Viscous Fan Drive Assembly Storage Figure 4-6 — Fuel Filter Adapter Assembly Removal 1.
5-101.bk Page 7 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY [215 LD] COOLANT CONDITIONER ELEMENT Refer to Figure 4-8. 3. Place a suitable container below the coolant filter area to catch any spilled coolant. Refer to Figure 4-7. 1. Cut the plastic tie wrap (1) securing coolant conditioner supply tube (2) to cylinder head manifold overflow line. 2. Disconnect fittings (3) from both ends of the coolant conditioner supply tube. Remove tube (2). 4.
5-101.bk Page 8 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY [215 NU] THERMOSTAT Refer to Figure 4-8. 1. With the coolant conditioner element removed, remove two capscrews (13) that secure the thermostat housing (5) to coolant manifold (9). 2. Loosen two hose clamps (10) on the coupling (12) that connects the oil cooler supply tube (11) to the thermostat housing. 3. Taking care to prevent the thermostat (7) from falling, remove the thermostat housing (5) and thermostat. Discard gasket (8).
5-101.bk Page 9 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY [214 HD] AIR INLET MANIFOLD [215 NK] COOLANT MANIFOLD Refer to Figure 4-9. Refer to Figure 4-9. 1. Support the air inlet manifold sections and remove 12 capscrews (9) that secure the manifold sections (6 and 8) to the cylinder heads. 1. Support the coolant manifold sections and remove 12 capscrews (5) retaining the manifold sections (1 and 4) to the cylinder heads. 2. Remove air inlet manifold.
5-101.bk Page 10 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY [215 DW & 219 EP] OIL COOLER AND OIL FILTER HOUSING ASSEMBLY Refer to Figure 4-10. 1. Disconnect turbocharger lubrication supply hose (6) from the oil filter/cooler assembly (5). Unless it is necessary to repair any portion of the oil cooler or oil filter housing, remove the units as an assembly. The assembly can be disassembled later if necessary. Refer to Oil Cooler Disassembly in the BENCH PROCEDURES section. 2.
5-101.bk Page 11 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY [215 SW] WATER PUMP [214 SD] TURBOCHARGER Refer to Figure 4-11. Refer to Figure 4-12. 1. Disconnect coolant return hose to air compressor (1) at fitting. 2. Remove three mounting capscrews (3) and remove water pump (2). 1. Remove two capscrews (3) securing turbocharger lubrication drain tube (4) to turbocharger (1). 2. Loosen hose clamp (5) securing drain tube to oil fill tube. Remove drain tube (4). 3.
5-101.bk Page 12 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY [222 KD] FUEL NOZZLE INLET TUBE ASSEMBLY 2. Loosen brackets (3 and 5) by removing retaining hardware. 3. Loosen tube sleeve nuts (1) and tube clamping screws at the cylinder heads and remove front (4) and rear (2) tube assemblies. Cap all lines and fittings to prevent contaminants from entering the system. Refer to Figure 4-13. 1. Loosen six tube sleeve nuts (6) at the injection pump.
5-101.bk Page 13 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY Refer to Figure 4-14. 4. If necessary, separate fuel inlet tubes (4) from bracket assembly. Remove nuts (6) from capscrews (1) and remove clamp plate (2), insulators (3) and bracket (5). [213 JB] VALVE COVER AND RISER If engine is equipped with a Jake Brake®, a riser is installed under the valve cover. Longer capscrews are used to secure the valve cover and riser to the cylinder head. 1 2 . Refer to Figure 4-16. 1.
5-101.bk Page 14 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY [213 LP, NV & LH] ROCKER ARM, VALVE YOKE AND PUSH ROD 5 4 3 Refer to Figure 4-16. If equipped with a Jake Brake, perform the following: 6 1. Remove three capscrews (6) from each actuator assembly (15). 2. Remove actuator assemblies from cylinder heads (one actuator assembly per head). 2 1 16 15 If a Jake Brake was not installed, there will be six capscrews per rocker arm assembly.
5-101.bk Page 15 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY [222 KG] NOZZLE HOLDER 1 Special Tool Required 앫 2 Injection Nozzle Puller J 37093 12 After removing the nozzles, it is a good practice to label or tag them for reinstallation into the same cylinders. After removal, place nozzles on a clean surface. Refer to Figure 4-17. 3 11 4 10 1. Remove nozzle holder retainer (2). 5 2. Assemble injection nozzle puller J 37093 as follows: a. b.
5-101.bk Page 16 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY [213 EV] CYLINDER HEAD ASSEMBLY REMOVAL Refer to Figure 4-18. 1. Remove fuel return tube (3) from between the cylinder head assemblies (4) by loosening the tube sleeve nuts from each end. Cylinder head assemblies are heavy. Lifting a cylinder head requires the help of an assistant or suitable lifting device. Attempting to lift a cylinder head without assistance may result in severe personal injury. 2.
5-101.bk Page 17 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY [212 RB & RH] VIBRATION DAMPER AND CRANKSHAFT HUB Refer to Figure 4-19. 1. Remove six mounting capscrews (4) and turnover bracket, if equipped. [261 CK] AIR COMPRESSOR Refer to Figure 4-20. Disconnect two coolant lines (1 and 4) from the air compressor head (2) at the fittings. Tag and cap lines. 2. Remove vibration damper (3) and fan belt drive pulley (1) together. 2 1 3.
5-101.bk Page 18 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY Refer to Figure 4-21. 2. Taking care not to damage or lose the lubrication oil supply tube (2), remove the air compressor by pulling it rearward out of the mounting flange. Discard gasket. 1. Remove three mounting capscrews (5) securing air compressor (1) to auxiliary driveshaft housing (3). 1 2 5 4 3 200360a Figure 4-21 — Air Compressor Removal 1. Air compressor 2. Oil supply tube 3. Auxiliary driveshaft Page 4-18 4.
5-101.bk Page 19 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY [221 GP] INJECTION PUMP Refer to Figure 4-22. 1. Disconnect lubrication supply line (6) at both fittings. Tag and cap fittings. 2. Disconnect fuel lines (1, 3, 4, and 5) at the fittings. Tag and cap all lines. Remove lines from the engine by removing clamp retaining capscrew. Set fuel lines on a clean surface. If the fuel injection pump does not require servicing, set pump-to-engine timing before removal.
5-101.bk Page 20 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY [221 CD] ECONOVANCE 3 V-MAC Equipped Engines Refer to Figure 4-23. 4 5 2 1 1. Working from front of engine, remove four capscrews securing the injection pump drive gear. Remove gear. 6 200364a Figure 4-24 — Econovance Housing Removal (Pre-1992 Style Shown) 1. Mounting capscrew 2. Injection pump adapter 3. Drive coupling 4. Capscrew 5. Econovance 6.
5-101.bk Page 21 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY Figure 4-25 — Oil Pan Bolt Locations 1. Studs and nuts at timing gear cover 2. Studs and nuts at flywheel housing 3.
5-101.bk Page 22 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY [219 MU] OIL PUMP Refer to Figure 4-26. If the oil pump must be disassembled for any reason, it will be easier to loosen the housing cover retaining capscrews (2), the screen capscrews (5), the sump capscrews (3), the cover plate capscrews (9), and the relief valve cap (8) while the pump is still secured in position. Do so before loosening the three retaining capscrews (1).
5-101.bk Page 23 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY [211 RP] TIMING GEAR COVER 3 2 1 Do not attempt to remove timing gear cover without removing oil pan. Doing so may result in damage to the isolating oil pan gasket. 14 Refer to Figure 4-27. 1. Remove front engine mount pedestal (4) by removing six retaining capscrews (7 and 9). 2. Remove auxiliary pump and connecting hardware, if equipped. Discard O-ring seal. 13 12 11 10 8 3.
5-101.bk Page 24 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY [212 CV] AUXILIARY DRIVESHAFT 1 2 Refer to Figure 4-28. 3 1. Remove auxiliary driveshaft gear retaining nut (1). 4 2. Using a hub puller such as J 21834-4A, remove auxiliary driveshaft gear (2) from the splines (5) on the end of shaft. 3. Remove two retaining capscrews (3) from auxiliary driveshaft captured thrust washer (4). Remove washer. 5 200362a Figure 4-29 — Auxiliary Driveshaft Removal 2 3 1. Rear bushing 2.
5-101.bk Page 25 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY 4. Taking care not to damage camshaft or bushings, pull camshaft out of the front of the engine. Carefully guide rear of shaft through the journals. If shaft does not come out freely, ensure all valve lifters are clear of camshaft cams and journals. 1 5. Remove valve lifters. 2 Valve lifters have established wear patterns and should be reinstalled in same locations.
5-101.bk Page 26 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY Refer to Figure 4-32. Refer to Figure 4-33. 3. Using a sharp knife, carefully remove any carbon at the top of the sleeves. Remove any remaining carbon using crocus cloth or fine sandpaper, then wipe inside of sleeves with a clean cloth. 4. Rotate crankshaft so that pistons 1 and 6 are at bottom dead center. Remove connecting rod capscrews and rod bearing caps. Figure 4-32 — Carbon Removal from Cylinder Sleeves .
5-101.bk Page 27 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY [212 UC] FLYWHEEL Refer to Figure 4-34. 1. With engine stand rotated so that engine is inverted (crankshaft horizontal), loosen all six flywheel retaining capscrews. 2. Remove two of the flywheel retaining capscrews that are opposite each other. Install two longer capscrews or studs to allow flywheel to be safely removed from the crankshaft. 3. Remove remaining capscrews. 4.
5-101.bk Page 28 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY [211 HD] FLYWHEEL HOUSING [211 JA] MAIN BEARING CAP Refer to Figure 4-35. 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. Before removing main bearing caps, ensure they are marked so they can be reinstalled on the same journals.
5-101.bk Page 29 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY Figure 4-36 — Buttress Capscrew Installation 1. Main bearing cap capscrews 2. Buttress capscrews, 80 mm 3. Buttress capscrews, 110 mm 4. Main bearing caps 5.
5-101.bk Page 30 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY [212 HP] CRANKSHAFT Refer to Figure 4-37. 1. Using a suitable lifting device, secure a sling or crankshaft support tool around the crankshaft and lifting device hook. Ensure crankshaft is evenly balanced when lifted from the engine block. [219 RV] PISTON COOLING SPRAY NOZZLE To avoid damaging spray nozzles, remove them before removing sleeves. 2.
5-101.bk Page 31 Friday, March 17, 2006 11:05 AM 200 ENGINE DISASSEMBLY [212 NC] CYLINDER SLEEVE Special Tool Required 앫 Cylinder Liner/Sleeve Puller PT6435 6. Remove puller from sleeve. 7. Remove crevice seal (1) from sleeve. 8. Repeat steps 2 through 7 to remove remaining cylinder sleeves. Refer to Figures 39 and 40. 1 1. Rotate engine in stand so that it is upright (deck surface upward). 2. Use puller PT6435, or equivalent, to remove cylinder sleeve (2) from cylinder block (4). 2 3.
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5-101.bk Page 2 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES [211 DB] CYLINDER BLOCK Cylinder Sleeve Counterbore SPECIAL TOOLS REQUIRED: 앫 Counterbore Tool PT2210 앫 Counterbore Cutter Plate PT2210-3A 앫 Universal Dial Depth Gauge PT5025 앫 Stylus Extension (3-Inch) PT5052-11 앫 Hex Key Wrench PT2210-14 INSPECTION AND REPAIR If the cylinder block deck is resurfaced, the cylinder sleeve counterbore depth must be recut to specification.
5-101.bk Page 3 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES When the entire block must be counterbored, cut the deepest bores first. This way, the tool can be adjusted to the lowest depth and used for all cylinders, ensuring uniform depth on all cylinder counterbores. 3. Position the tool in the cylinder bore by backing the depth-set collars (5 and 16) off and lowering the cutter plate (13) into the counterbore to center the tool. 4.
5-101.bk Page 4 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES 3 2 1 4 5 6 7 3 17 16 8 4 3 3 18 9 10 9 4 15 13 13 12 11 14 200328a Figure 5-1 — Counterbore Ledge Tool Installation 1. 2. 3. 4. 5. 6. 7. 8. 9. Cutter plate holder T-handle Capscrews, M16 x 2 x 90 Special washers Upper depth-set collar Lower thumbscrew Oil fill tube Main housing Hold-down capscrews Page 5-4 10. 11. 12. 13. 14. 15. 16. 17. 18.
5-101.bk Page 5 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES CUTTING THE COUNTERBORE Refer back to Figure 5-1. 1. Fill the oil fill tube (7) with 30W nondetergent oil to maintain lubrication during use. 2. Back off the lower depth-set collar (16) two increments or less, and tighten the thumbscrew (6) securely. 3. Cut the counterbore by turning the T-handle clockwise while maintaining constant downward pressure on the tool.
5-101.bk Page 6 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES BEFORE MID 1992 (367GC4243M) SINCE MID 1992 (367GC4255M) CONTOUR MACHINING FLAT MACHINING 200282a Figure 5-2 — Connecting Rod Identification Refer to Figure 5-3. A redesigned connecting rod assembly with an added alignment sleeve feature was introduced into E7 production engines in April 1995.
5-101.bk Page 7 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES Special Tools Required During initial production, part numbers were stamped onto the through hole of the connecting rod bearing cap. In later production, the part number was forged into the I-beam of the rod.
5-101.bk Page 8 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES Refer to Figure 5-5. 3. Position rod assembly in press with piston pin burnishing broach J 37718. Figure 5-4 — Wrist Pin Bushing Removal WRIST PIN BUSHING INSTALLATION Figure 5-5 — Burnishing Wrist Pin Bushing The wrist pin bushing has a lubrication hole through it. This hole MUST be aligned with rifledrilled hole in rod to allow oil flow to wrist pin. If holes are not aligned, wrist pin, piston, and connecting rod failure will result.
5-101.bk Page 9 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES important for engine timing. The flywheel is mounted to a flange at rear of crankshaft. Two seals, one at the front and one at the rear, prevent engine lubricating oil from leaking around ends of the crankshaft. Bearing caps are furnished with the crankcase and support the crankshaft in true alignment. Webs integral to the crankcase provide upper half of main bearing supports. Removable caps provide lower support.
5-101.bk Page 10 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES Inspection If crankshaft journals are worn, out of round, or tapered, order a new crankshaft or exchange kit through the MACK parts system. New and exchange crankshafts are available through MACK distribution centers. When ordering an E7 crankshaft, be sure to note V-MAC or non V-MAC application, since crankshafts are not the same. 1. Inspect crankshaft journals for straightness, out-of-round, taper, and surface finish. 2.
5-101.bk Page 11 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES All new service replacement crankshafts, short blocks or basic engines will have a dowel pin in the crankshaft rear flange. In nearly all cases, the flywheel will already have a hole in it to accept the dowel pin. If, in an earlier version, the flywheel or torque converter drive flange does not have a hole in it for a dowel pin, it must be reworked.
5-101.bk Page 12 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES [212 HV] Crankshaft Gear INSPECTION After inspecting the crankshaft and determining that it is serviceable, inspect crankshaft gear for cracks and broken, worn or chipped teeth. If crankshaft gear is defective, it must be replaced. REPLACEMENT Refer to Figure 5-9. 1. Using a suitable puller such as J 21834-4A, remove gear and key. Take care not to damage gear teeth while seating gear. 5.
5-101.bk Page 13 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES CLUTCH PILOT FLYWHEEL FRICTION FACE UNDERCUT 200735a Figure 5-10 — Flywheel Resurfacing [212 UB] FLYWHEEL 1. Inspect the flywheel to determine if it requires resurfacing. The wear areas should be measured using a straightedge across the friction face and a thickness gauge. If the wear measurement is 0.020 inch (0.508 mm) or less, the flywheel does NOT need to be machined when operated against ceramic clutch facings. 2.
5-101.bk Page 14 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES The two-piece piston design incorporates two compression ring grooves and one oil ring groove. A plasma-faced, keystone-type ring is used in the top ring location. A tapered chrome, rectangular-type ring is used in the second ring groove. The oil control ring is located in the third (or lower) groove, nearest the piston pin bore. New piston rings are designed to further improve oil control, especially relating to particulates control.
5-101.bk Page 15 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES Inspection Keystone Ring Groove Check Inspect piston ring grooves, lands, piston skirt and combustion bowl for wear, scuffing, cracks or blow-by. Pistons are NOT repairable. Discard piston if it is damaged. Refer to Figure 5-12. Keystone piston-ring groove gauge J 29510 consists of two 0.120-inch (3.048 mm) diameter pins (1) connected at ends by two springs (2). 1 Do not stamp or engrave on TOP of piston.
5-101.bk Page 16 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES POSITION GAUGE IN RING GROOVE WITH GAUGE PINS ALIGNED WITH WRIST-PIN BORE. For a new ring and piston, oil ring side clearance is 0.0016–0.0030 inch (0.0406–0.0762 mm). For an old ring and piston, the clearance should not exceed 0.0045 inch (0.1143 mm). 6. Perform step 5 on each piston. MEASURE DISTANCE ACROSS PISTON AT GAUGE PINS (PARALLEL TO WRIST-PIN BORE).
5-101.bk Page 17 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES Ring Installation Refer to Figure 5-16. 2. Stagger piston rings so that no ring gap is directly over wrist pin bore, and no ring end gaps are aligned over each other. Identification markings on rings should face top of piston. The keystone ring goes in the top ring groove. Follow the directions on each piston ring packet. Refer to Figure 5-15. 1.
5-101.bk Page 18 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES [213 CH] CAMSHAFT The piston crown, skirt and rod are marked FRONT. Be sure that rod, piston crown and skirt are properly aligned. Description The gear-driven carbon steel E7 camshaft, with its large journal bearing diameter of 2.689 inches (68.301 mm), provides excellent bearing unit loading and allows the use of large, durable camshaft lobes. E7 engine camshaft gears are pressed onto the camshaft.
5-101.bk Page 19 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES Make sure there is enough clearance between the end of the camshaft and the floor while removing the gears. Do not let camshaft fall or strike the floor when pressed from the gears. The camshaft can be bent easily, and the bend may go unnoticed. Installing a bent camshaft in the engine could result in cam bushing failure. 4. Remove the thrust washer.
SECT5.FR5 Page 20 Tuesday, March 21, 2006 12:49 PM 200 BENCH PROCEDURES Inspection Assembly Refer to Figure 5-19. Two methods can be used to assemble camshaft gears on a camshaft. 1. Thoroughly clean camshaft (3). Use magnaflux (PT7190) inspection procedure to detect cracks. 2. Inspect camshaft lobes and journals for evidence of cracks, pitting, scoring or severe wear. If any of these conditions exist, replace camshaft. 3.
5-101.bk Page 21 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES Wear protective gloves when handling heated gears. Refer to Figure 5-20. 4. Using an oven (not a torch), heat new camshaft gear and new injection pump driving gear to 400°F (205°C). Do not exceed 400°F (205°C) and do not heat for more than one to two hours. Do not exceed two hours. Position camshaft gear with timing marks facing out, and align keyway with key. 7.
5-101.bk Page 22 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES is being pressed on. As the gear seats, allow the pressure to climb to, but not exceed, 10 tons (9.1 MT). This will ensure that gear is seated firmly on shaft. The gear should be flush with the end of the shaft when fully seated. Figure 5-21 — Camshaft Gear Installation 9. Using a suitable press cup, press the gear onto the shaft until it is fully seated. The pressure gauge on the press should read approximately 5 tons (4.
5-101.bk Page 23 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES 1989/1990 E7 COMBUSTION SYSTEM ORIGINAL SWIRL LEVEL 6-HOLE NOZZLE TIPS 1991 AND LATER E7 COMBUSTION SYSTEM INCREASED SWIRL LEVEL 8-HOLE VCO NOZZLE TIPS 200285a Figure 5-23 — Combustion Chamber Design Refer to Figure 5-24. The cast iron cylinder head is constructed using a special iron alloy.
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5-101.bk Page 25 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES [213 NB] Inlet and Exhaust Valve Removal VALVE STEM SEALS Refer to Figure 5-25. A new valve stem seal was introduced into E7 engine production on 11/1/96, beginning with engine serial number 6S2657. The older valve stem seal has a single sealing lip, while the newstyle seal incorporates a second lip that significantly reduces crankcase blowby.
5-101.bk Page 26 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES Figure 5-26 — New Valve Stem Seal This new seal is recommended for all E7 engines. The single lip seal has been terminated, and as service stock is depleted, only the new seal will be available. This new seal can be used on the old-style valve guides. Part Number Description 4. With valve spring keepers (1) removed, remove upper washer (2), valve spring (3), oil seal (4), lower washer (Roto-Coil) (5) and valve (6).
5-101.bk Page 27 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES 1 When the deck is resurfaced, fire ring groove and valve seat insert dimensions must be reestablished. Correct dimensions are shown in this section. 2 3 4 5 [213 EH] Fire Ring Groove 6 DESCRIPTION 200483a Figure 5-27 — Valve Assembly 1. 2. 3. 4. Valve spring keepers Upper washer Valve spring Oil seal 5. Lower washer (Roto-Coil) 6.
5-101.bk Page 28 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES FIRE RING GROOVE CUTTING PROCEDURE Refer to Figure 5-29. 1. Place cutter base (1) on cylinder head (2). Insert hold-down capscrews into appropriate mounting holes (per application) until holddown capscrews bottom out in mounting holes. 1 Refer to Figure 5-30. 2. Position cylinder head so threaded section of hold-down capscrews can be reached. Install spacer (3), washer (2) and wing nut (1). Lightly tighten wing nut.
5-101.bk Page 29 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES Refer to Figure 5-31. Refer to Figure 5-32. 3. Place alignment fixture (1) over the cutter base (2) to ensure proper positioning. With fixture in place, tighten wing nuts on holddown capscrews. Remove alignment fixture. 1 The desired finished fire ring groove depth is 0.008 inch (0.203 mm). 4. Install cutter head J 37719 (1) on cutter base (4). a.
5-101.bk Page 30 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES [213 EP] Valve Guides Refer to Figure 5-33. 6. Install a socket (1) and T-handle (2) on cutter head (3). Using T-handle, rotate cutter head in a clockwise direction only, applying an even downward pressure to cut fire ring groove. 2 INLET AND EXHAUST VALVE GUIDE DIMENSIONS Refer to Figure 5-34. 앫 Valve guide ID (3) — 3/8 inch (9.53 mm) 앫 Top end of guide to valve spring seat (4) — 0.959 ± 0.040 inch (24.36 ± 1.
5-101.bk Page 31 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES INSPECTION Refer to Figure 5-36. 3. Use a depth gauge to check valve guide extension. Worn valve guides may result in poor valve-toseat contact, valve damage or oil consumption. 1. Inspect valve guides for wear, damage, cracks and looseness. Refer to Figure 5-35. 2. Use a small bore gauge (1) to obtain an accurate valve guide bore (2) measurement.
5-101.bk Page 32 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES Figure 5-38 — Checking Valve Guide Extension 1 Refer to Figure 5-39. 2 5. Using valve guide reamer J 37481 (1), ream new valve guide (2) to dimension. 200295a Figure 5-37 — Valve Guide Remover J 37482 1. Valve guide remover J 37482 2. Cylinder head 1 2. Press out old valve guides from cylinder head. 3. Check valve guide bore in the cylinder head for wear, cracks or other damage.
5-101.bk Page 33 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES 6. Thoroughly clean all metal debris from valve guide and surrounding area. 7. Install valves in cylinder head and check for binding, looseness and other conditions that may result in premature valve or valve guide failure. [213 FB] Inlet and Exhaust Valve Seat Inserts INLET AND EXHAUST VALVE SEAT INSERT DIMENSIONS Refer to Figure 5-40.
5-101.bk Page 34 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES INSPECTION Visually inspect valve seat inserts for looseness, cracks or other conditions that may result in improper operation. Replace as necessary. Collet PT6390-4 is not included in basic kit PT6391. VALVE SEAT INSERT REMOVAL Refer to Figure 5-41. Valve seat extractor kit PT6391 and collet PT6390-4 are used to remove inlet and exhaust seat inserts. 2 5 1 4 3 6 7 9 8 200298a Figure 5-41 — Valve Seat Extractor Kit PT6391 1. 2.
5-101.bk Page 35 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES Refer to Figure 5-42. 1. Using depth measurement tool (1), measure distance from cylinder head surface (2) to point on insert where groove will be ground. This point should be approximately 0.060 inch (1.524 mm) below any angular face on valve seat insert. 4. Grind a groove around inside circumference of valve seat insert. This groove should be approximately 0.030 inch (0.762 mm) deep.
5-101.bk Page 36 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES VALVE SEAT INSERT COUNTERBORE Refer to Figure 5-45. 앫 Valve seat at counterbore depth (3): — Exhaust: 0.376–0.372 inch (9.55–9.449 mm) — Inlet: 0.364–0.360 inch (9.246–9.144 mm) 앫 Inlet valve seat insert counterbore diameter (4): 1.8295–1.8285 inches (46.4693–46.4439 mm) 앫 Exhaust valve seat counterbore diameter (5): 1.6885–1.6875 inches (42.8879–42.8625 mm) 1 2. Check surface finish for smoothness.
5-101.bk Page 37 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES If valve seat insert widths exceed specifications when grinding inserts, use a 15-degree angle grinding stone to obtain correct width. Refer to Figure 5-48. 4. After grinding is completed, thoroughly clean valve seat insert. 5. Determine concentricity of each valve seat insert relative to valve guide. Valve seat runout is to be held within 0.001 (0.
5-101.bk Page 38 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES 1 Figure 5-49 — Checking Valve Spring Tension 2 200304a 1. Spring tester J 22738-02 2. Valve spring Figure 5-48 — Checking Valve Seat Runout 1. Arbor 2. Valve guides [213 MB] Valve Springs 1. Visually inspect inside surfaces of coils. Also, feel inside surfaces of spring for any indication of roughness or grooving. If any of these conditions exist, replace spring. Refer to Figure 5-49. 2.
5-101.bk Page 39 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES 1 2 200306a Figure 5-50 — Removing Injection Nozzle Holder Insert 1. Slide hammer J 2619-01 2. Sleeve puller J 29880 INJECTION NOZZLE HOLDER INSERT INSTALLATION 1. Thoroughly clean insert bore and surrounding area before installing insert. 2. Apply Loctite 620 completely around the center of all three sealing diameters of the new insert. Refer to Figure 5-51. Figure 5-51 — Injection Nozzle Holder Insert Installation 1. Insert 2.
5-101.bk Page 40 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES VALVE YOKE GUIDE PIN REMOVAL VALVE YOKE GUIDE PIN INSTALLATION Refer to Figure 5-52. Refer to Figure 5-53. 1. To remove pin, use valve yoke guide pin puller kit PT6575 and extractor PT6570-11 (7/16 inch). 2. Install extractor over guide pin and position extractor lock over extractor. If new pin is required, use valve guide pin installer J 37809 to drive pin into cylinder head.
5-101.bk Page 41 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES [213 FP] Cylinder Head Cup Plugs DESCRIPTION The cylinder head has two different-size cup plugs: 13/16 inch (20.64 mm) and 1-1/16 inch (26.99 mm). CYLINDER HEAD CUP PLUG INSTALLATION 1. Clean cup bore thoroughly. 2. Use Loctite 277 sealer, or equivalent, and apply to cup plug and cup plug bore in head. Refer to Figure 5-54. 3.
5-101.bk Page 42 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES Cylinder Head Pipe Plugs CYLINDER HEAD PIPE PLUG INSTALLATION 1. Apply dry pipe thread sealant to pipe plug and pipe plug bore in head. Refer to Figure 5-55. 2. Install a 1/8-inch pipe plug in top of rear cylinder head. 3. Install two 3/4-inch core hole pipe plugs in cylinder head. Torque to 28 lb-ft (38 N•m). Figure 5-55 — Cylinder Head Pipe Plug Locations 1. 1-1/16 inch cup plug 2. 3/4-inch NPT plug 3.
5-101.bk Page 43 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES [213 NB] INLET AND EXHAUST VALVES Inspection Refer to Figure 5-56. Visually inspect valves for cracks, pits or other conditions that may cause improper operation. Check valve seat angle. Also check stem length, diameter and condition. Figure 5-56 — Valve Dimensions (Through September 1996 Production) Valve Identification The Pyromet exhaust valve cannot be used on E7 engines equipped with a Dynatard engine brake.
5-101.bk Page 44 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES New cylinder heads have been produced in November 1996 which have 20-degree intake valves and seats. These valves and seats replace the 30-degree intake valves and seats in all E7 cylinder heads. The 20-degree valves and seats are 100% interchangeable with the 30-degree valves and seats, provided the seat matches the valve (20-degree seat with 20-degree valve, 30-degree seat with 30-degree valve).
5-101.bk Page 45 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES Refer to Figures 5-57 and 5-58. The following (Figures 5-57 and 5-58) show a remanufactured cylinder head assembly ID and 20-degree intake valve ID. Inlet and Exhaust Valve Installation The inlet and exhaust valve head diameters are nearly the same size. It is important, therefore, that extra care be taken when assembling these valves.
5-101.bk Page 46 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES 1. Lubricate the valve guides and valve stems with engine oil prior to installation. 2. Install valve spring lower washer (Roto-Coil), over valve guide. 3. Lubricate valve stem seals with engine oil and install seals using valve seal installer J 42453. 4. Install valve into cylinder head. 5. Check valve stem tip for nicks or burrs that may damage valve seal upon installation. 6. Install valve spring, upper washer and keepers.
5-101.bk Page 47 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES If dimensions are not within specification, machine valve seat insert and/or valve face as necessary. Refer back to Valve Seat Insert Installation (page 36 in this section) for detailed specifications. [213 LV] VALVE ROCKER ARM SHAFT There is a shouldered rocker arm mounting capscrew at one end of each rocker arm assembly to ensure proper alignment.
5-101.bk Page 48 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES 6. Assemble rocker arm retaining (coil) spring (6) on shaft. 12. Assemble rocker arm retaining (coil) spring (6) on shaft. 7. Lubricate exhaust rocker arm (5) and install on rocker arm shaft. 13. Lubricate exhaust rocker arm (5) and install on shaft. 8. Lubricate valve rocker arm adjusting screw and nut, and install into exhaust rocker arm. 14. Place last (third) rocker arm shaft bracket (4) and shaft on a flat surface.
5-101.bk Page 49 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES Figure 5-62 — Valve Rocker Arm Shaft Assembly (Without Engine Brake) 1. 2. 3. 4. 5. 6. Snap ring Flat spring Inlet rocker arm Brackets Exhaust rocker arm Spring 7. 8. 9. 10. 11. 12. Locating screw and lock washer Bracket with center threaded hole Standard adjusting screws and jam nuts Capscrews Washers Shaft 19. Install flat spring (2) and snap ring (1) on end of shaft.
5-101.bk Page 50 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES 4. Thread oil supply screw and O-ring (7) into bracket and torque to 5 lb-ft (7 N•m) using torque wrench J 24405 or equivalent. 5. Lubricate inlet rocker arm (3) and install on rocker arm shaft. 6. Lubricate valve rocker arm adjusting screw and nut, and install into inlet rocker arm. 7. Assemble rocker arm retaining (coil) spring (6) on shaft. 10. Place center (second) rocker arm shaft bracket (4) and shaft (11) on a flat surface.
5-101.bk Page 51 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES At this point, a used or scrapped cylinder head can be used as a template for proper bracket alignment and to ensure mounting surfaces of each bracket are parallel. 12. Lubricate inlet rocker arm (3) and install on shaft. 13. Assemble rocker arm retaining (coil) spring (6) on shaft. 14. Lubricate exhaust rocker arm (5) and install on shaft. 15. Place last (third) rocker arm shaft bracket (4) and shaft on a flat surface.
5-101.bk Page 52 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES pressure relay switch and related hardware. Its purpose is to protect the Dynatard exhaust push rod from overload and from possibly bending during the transition from power mode to braking mode. An overload condition occurs when the turbocharger boost pressure in the inlet manifold is greater than 25 psi (172.4 kPa).
5-101.bk Page 53 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES 18. Connect jumper wire to Dynatard engine brake harness connection. 19. Attach wire tie around jumper wire and Dynatard switch bracket. 20. Test engine brake and check for leaks. INSTALLATION (V-MAC APPLICATIONS) 1. Connect engine brake wiring harness to connection located on right-hand side engine harness. 2. Secure connection to air compressor coolant line with wire tie. 3.
5-101.bk Page 54 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES 7. Remove the 0.008-inch (0.203 mm) thickness gauge and insert a 0.014-inch (0.356 mm) thickness gauge. There must be NO continuity with the 0.014-inch thickness gauge. [215 DW] OIL COOLER ASSEMBLY 8. Apply locking compound to the switch assembly nut after adjustment is correct. The oil cooler assembly is located near the left front of the engine.
5-101.bk Page 55 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES 13 12 15 14 11 10 9 8 16 7 6 18 17 5 1 2 3 4 19 20 24 27 23 22 21 25 26 200556a Figure 5-67 — Oil Cooler Assembly 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Gasket Coolant outlet end cap O-ring Mounting flange Clamps Coupler Gasket or O-ring Washer Capscrew Oil outlet tube O-ring Capscrew Washer Oil supply head Disassembly Refer to Figure 5-67. 1. Remove coolant inlet end cap (20) by removing six capscrews (19).
5-101.bk Page 56 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES Inspection Refer back to Figure 5-67. 1. Visually inspect housing (24) for cracks which may cause a leak. Replace housing if damaged. 2. Check oil cooler bundle (22) for leaks by pressurizing with air to 80 psi (552 kPa) and submerging it in water. If a leak is detected, replace with new bundle. 12. Torque coolant outlet end-cap capscrews to 20 lb-ft (27 N•m) using torque wrench J 24406 or equivalent. Refer to Figure 5-68. 13.
5-101.bk Page 57 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES When pressure-testing complete oil cooler assembly using an in-line pressure regulator, apply pressure at 2–5 psi (14–34 kPa) maximum. Then gradually increase pressure, checking for leaks until 80 psi (552 kPa) is reached. During engine operation, the impeller spins in proportion to engine speed. The spinning impeller blades create a negative pressure (suction) at the water pump inlet port and a positive pressure at the outlet port.
5-101.bk Page 58 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES 6 5 7 8 4 10 3 1 9 10 2 14 11 12 13 200345a Figure 5-70 — Lubrication Oil Pump 1. 2. 3. 4. 5. 6. 7. Self-locking nut Washer Drive gear Housing Key Pumping gear and shaft assembly Oil pump housing cover Inspection Refer to Figure 5-70. 1. Clean and inspect oil pump housing (4) for scoring, cracks or other damage. If any of these conditions exist, replace oil pump. 2.
5-101.bk Page 59 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES 6. Insert pumping gear in housing and check for free play by spinning. If any binding occurs, check housing and gear teeth for burrs, nicks, or other damage. Replace as necessary. Before proceeding with assembly, check end clearance, side clearance, and backlash of drive gears as follows. END CLEARANCE CHECK Refer to Figure 5-71. 1. Low Limit — Place a straightedge across face of gears and run a 0.001-inch (0.
5-101.bk Page 60 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES SIDE CLEARANCE CHECK BACKLASH CHECK Refer to Figure 5-72. Refer to Figure 5-73. 1. Low Limit — Insert a 0.002-inch (0.051 mm) thickness gauge between side of gears and housing. Gauge should pass between gears and housing without drag. If it drags, check housing and gears for nicks or burrs. Replace as necessary. 1. Check backlash between driving gear (3) and driven gear (2) with thickness gauge (1). 2. High Limit — Insert a 0.
5-101.bk Page 61 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES Improved “Fast Ratio” Auxiliary Driveshaft An improved “fast ratio” auxiliary driveshaft assembly and oil pump assembly are in current production engines (effective February 27, 1992, serial No. 2E1233) and are available for service. These arrangements increase operating oil pressure by approximately 25%. 앫 앫 Refer to Figure 5-74. 1. Obtain a 1.5 fast ratio oil pump driving shaft gear (683GB284). 2.
5-101.bk Page 62 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES Assembly Refer back to Figure 5-70. 1. Install oil pressure relief valve plunger (11) in relief valve housing (4). 2. Install oil pressure relief valve spring (12) in relief valve housing. 3. Clean oil pressure relief cap (13) and install in relief valve housing. 7. Install cover (7) on pump and secure with capscrews. Torque to 15 lb-ft (20 N•m). 8. Install key (5) in driving shaft and gear assembly (6). 9.
5-101.bk Page 63 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES Econovance Disassembly 3. Remove inner shaft assembly from rear of Econovance housing by manually guiding gear assembly outward. Refer to Figure 5-75. 1. Place scalloped drive hub (5) in a vise equipped with brass jaws. Remove drivehub retaining capscrew (10) and washer (9) while holding inner shaft assembly (2) at rear of Econovance. This will prevent assembly from dropping out of housing when retaining capscrew is removed. 4.
5-101.bk Page 64 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES Cleaning and Inspection 1. Thoroughly clean inner sleeve and inner shaft with solvent and dry with compressed air. 2. Inspect inner sleeve and inner shaft for extreme wear, cracks or other damage. Replace as necessary. 3. Inspect outer shaft drive hub and seals. 4. Inspect Econovance housing. Econovance Assembly 1. Using clean engine oil, lubricate all gear surfaces. 2. Install Econovance spring (3) on inner shaft assembly (2).
5-101.bk Page 65 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES Cleaning Degrease tapered surfaces of injection pump camshaft and drive hub with Stoddard No. 303 or Loctite 75559, or an equivalent degreasing agent. Failure to degrease drive components prior to assembly may result in drive hub slippage. Installation of Drive Hub (Mechanically Governed Engines) Refer to Figure 5-77. 1. Place injection pump into pump holding fixture J 37078.
5-101.bk Page 66 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES Installation of Drive Hub (V-MAC Engines) Refer to Figure 5-81. 3. Using a suitable two- or three-jaw puller, remove the inner hub from the injection pump camshaft. DRIVE COUPLING REMOVAL A metal two-piece style drive coupling was introduced into production on certified E7 V-MAC engines built after July 1, 1992 — beginning with serial No. 2P and above.
5-101.bk Page 67 Friday, March 17, 2006 11:05 AM 200 BENCH PROCEDURES [222 KG] INJECTOR NOZZLES Nozzle Cleaning 1991 and later MACK E7 engines require different fuel injection nozzles, nozzle holders and nozzle holder assemblies than previous E7 engines. When servicing nozzle holder assemblies, cleaning of nozzle tips may be necessary. Special care must be taken when cleaning nozzle tips to avoid damaging nozzle spray holes.
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5-101.bk Page 2 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY GENERAL This section includes step-by-step procedures for complete assembly of the MACK E7 engine. Major components that were overhauled in the BENCH PROCEDURES section of this manual are reinstalled here as assemblies. Failure to follow the sequence of operations listed may result in damage to components or personal injury. After cleaning the components, properly store them where they will remain clean until needed for assembly.
5-101.bk Page 3 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY 2. Using a wire brush or rotary wheel, remove any rust, corrosion or other debris from the block. 3. Clean all other block surfaces with mineral spirits or other suitable solvent. 4. Using due care and caution, clean and dry the block with compressed air. INSPECTION If the cylinder block is determined to be serviceable after thorough cleaning and inspection, reassemble the engine.
5-101.bk Page 4 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Pipe Plug Replacement Any rust around a pipe plug is an indication of a leak and the plug should be replaced. REMOVAL 1. Using an appropriate wrench, remove the plug. 2. Clean the threads in the block by running a tap into the hole, just far enough to remove any rust on the threads without expanding the diameter of the hole. Use compressed air to remove any chips from the block. It is best to replace a leaking pipe plug.
5-101.bk Page 5 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [213 CC] Camshaft Bushings DESCRIPTION Lubrication oil is pumped into the cylinder block main oil gallery. Oil from the gallery flows to each main bearing bushing bore and then on to the respective camshaft bushing bore, providing lubrication for both the crankshaft and camshaft bushings. Camshaft bushing bores No. 1, 2 and 5 are grooved to supply oil to other components as well. Oil from the No.
5-101.bk Page 6 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY INSTALLATION Refer to Figure 6-6. Each camshaft bushing is located at set distances from the thrust washer mounting surface to the forward edge of the bushings. Correct installation of each camshaft bushing is very important.
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5-101.bk Page 8 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Refer to Figure 6-8. 1. Position a replacement bushing (2) against the side of the block at the No. 7 (rear) bushing bore. Align the oil hole in the bushing (1) with the oil passage (7) in the block. 2. Using a dark-colored felt-tip marker, mark the block and the bushing with a line (5) to facilitate correct alignment at installation. 3. Clean the surfaces of the bushing and the bore. Dry both surfaces with compressed air.
5-101.bk Page 9 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [212 CB] Auxiliary Driveshaft Bushing Replacement DESCRIPTION The front and rear auxiliary driveshaft bushings are identical. Engine lubrication oil passing through the No. 1 camshaft bushing supplies oil to the front auxiliary driveshaft bushing. Oil passing through the No. 4 camshaft bushing supplies oil to the rear auxiliary driveshaft bushing.
5-101.bk Page 10 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY 5. Check the bushing surface for burrs caused by installation. 1 Refer to the Fits and Limits chart in this manual for correct bushing ID dimensions. 2 6. Using an inside micrometer or telescope gauge, measure the ID of the bushing to ensure against using an undersize bushing. An undersize bushing may cause the auxiliary driveshaft to seize in the bushing during installation.
5-101.bk Page 11 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [212 NC] CYLINDER SLEEVE Description The cylinder sleeve works with the piston, piston rings, cylinder head, and cylinder head gasket to seal combustion pressure. It transfers combustion heat to engine coolant and guides piston travel during engine operation. Correct extension of sleeve flange above top deck and uniform cylinder block counterbore are essential for satisfactory sleeve life and head gasket seal.
5-101.bk Page 12 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY 2 Clean any RTV from around the bottom of the cylinder sleeve and the block which may have been pressed between the block and sleeve during installation. 1 3 4 6 7. After the cylinder sleeve is fully seated, use depth gauge J 26948 or equivalent to check flange height above the deck dimensions. The specified flange height above-deck dimension is 0.022–0.027 inch (0.559–0.686 mm).
5-101.bk Page 13 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Refer to Figure 6-13. 8. Using dial bore gauge J 5347-B or equivalent, check the cylinder sleeve for outof-round and taper limit. Take readings in two directions, 90 degrees apart, at each of three levels. Cylinder sleeve ID maximum: 4.877 inches (123.876 mm). Cylinder sleeve ID minimum: 4.875 inches (123.825 mm), cylinder sleeve ID may be minimum 4.872 inches (123.749 mm) due to close-in from press fit.
5-101.bk Page 14 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [219 RV] PISTON COOLING SPRAY NOZZLE Special Tools Required Description 앫 Refer to Figure 6-14. The piston cooling system consists of an oil pump, oil passages drilled in the cylinder block, and an oil spray-nozzle assembly for each piston. The piston cooling nozzles are attached to the main oil gallery. Oil is discharged through the nozzles and into the underside of each piston. This spray provides additional piston cooling.
5-101.bk Page 15 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Piston Cooling Nozzle Spray Positioning Refer to Figure 6-16. The piston cooling oil spray location on the underside of the piston is important; it ensures adequate heat dissipation from the piston and makes certain that the crankshaft counterweights of the connecting rods do not strike the nozzles. Always replace a badly deformed spray nozzle. Do not attempt to realign it.
5-101.bk Page 16 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Refer to Figure 6-17. 1. Using piston cooling nozzle spray position set J 37721-A (pre-1991) or J 39045 (1991 and later), check the direction of the spray from the nozzles. 1 2 3 4 2. Position rod (6) in end of spray nozzle (7). 3. Place the applicable plastic target (1) on the cylinder block (2) over the cylinder to be tested. 5 4.
5-101.bk Page 17 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [211 HA] CYLINDER BLOCK DOWEL PINS Description The diamond locating dowel pins used to install the front timing gear cover, flywheel and flywheel housing, have been replaced in production by blade-style locating dowel pins. The diamond pins were dual-diameter type pins with a smaller diameter at the round end that goes into the cylinder block. The blade-style pins are the same diameter at the round end and the blade end.
5-101.bk Page 18 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY DIAMOND-SHAPED DOWEL PIN INSTALLATION BLADE-TYPE DOWEL PIN INSTALLATION Refer to Figure 6-19. 1. Position the two alignment studs (3) in the threaded holes (2) nearest the right dowel location hole (6) in the cylinder block (1). 2. Position the diamond-shaped dowel pin (5) in the diamond dowel aligner J 37711 (4). 3. Position the diamond dowel aligner with the pin in position on the two alignment studs (3). 4.
5-101.bk Page 19 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [212 HP] CRANKSHAFT Installation 1. Clean the crankshaft and crankcase area. 2. Thoroughly clean each main bearing bore and the back of each bearing insert before installation. The inserts must be installed dry. 3. Place the upper half of the bearing insert in the block bore, making sure that the locating tab fits into the notch provided. 4. Repeat above step to install the remaining upper inserts.
5-101.bk Page 20 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Due to the considerable weight of the crankshaft, extreme care must be observed during installation. No nicks, scratches, burrs, or any other kinds of distress are acceptable on the main bearing and/or crankshaft journals and fillets. 6. Using a suitable lifting device, position the crankshaft in the crankcase. [212 HH] MAIN BEARING CAP Unfinished main bearing caps are available for servicing of E7 engines.
5-101.bk Page 21 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY The thickness of the thrust washers used in the bearing cap must match the thickness of the thrust washers in the block. Be sure to put the bearing surface of the thrust washer against the crankshaft when installing thrust washers. 16. Install the center main bearing cap, with bearing insert and the correct thrust washer sections in place, and torque the bearing capscrews to specification. 17.
5-101.bk Page 22 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Refer to Figure 6-22. 5. Remove capscrews and cap, and check the bearing running clearance. 1. Use Plastigage to check the main bearing clearance. Check each bearing, one at a time, by placing a piece of Plastigage on the journal and tightening the cap in place. The bearing clearance is determined by measuring the width of the crushed Plastigage with the supplied gauge. 6. Check width of the Plastigage using a Plastigage width chart.
5-101.bk Page 23 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY RIGHT SIDE OF ENGINE 2 1 110 mm FRONT OF VEHICLE 80 mm 80 mm 1 1 80 mm BOTTOM VIEW 200340a Figure 6-23 — Buttress Capscrew Locations 1. 80-mm buttress capscrews After obtaining proper main bearing clearance: 1. Check torque of main bearing capscrews: 210 lb-ft (285 N폷m) using torque wrench J 24407 or equivalent. 2. Torque the buttress capscrews to 90 lb-ft (122 N폷m) using torque wrench J 24407 or equivalent.
5-101.bk Page 24 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Installation Refer to Figure 6-24. 1. Rotate crankshaft so that the journals for the No. 1 and No. 6 cylinders are at bottom dead center. 2. Place piston, marked No. 1, on a clean, flat surface. Rest the piston and rod assembly on the piston crown with the rod upward. MACK E7 6-cylinder engines use a special type of connecting rod bearing. Each bearing half has a different thickness.
5-101.bk Page 25 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY CHECKING RUNNING CLEARANCE Do not force the piston. This indicates an incorrectly aligned ring. Remove piston, correct the problem, and reinstall. Before pushing piston all the way down in the sleeve, check to see if piston cooling nozzle is aligned with the nozzle clearance notch provided in the lower end of the piston skirt. If it is not aligned, damage to piston or spray nozzle may result. 13.
5-101.bk Page 26 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Refer to Figure 6-25. 9. Check rod side clearance by installing a thickness gauge between rod and side of journal at the entire parting line area. [211 HD] FLYWHEEL HOUSING Description Beginning in 1991, flywheel and flywheel housings for E7 engines equipped with standard transmissions incorporate engine timing and engine turnover features.
5-101.bk Page 27 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Capscrews (Flywheel Housing) A variety of lengths of flywheel housing-tocylinder block capscrews are used. Also, different sized flat washers are used depending upon whether a ductile iron or aluminum flywheel housing is being installed. The following illustrations show where the different length capscrews should be installed in various flywheel housings. Refer to Figure 6-26. On flywheel housing-to-cylinder block capscrew, No.
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5-101.bk Page 29 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Installation 1. Remove the rear crankshaft oil seal from the flywheel housing by drilling two 3-mm holes 180 degrees apart into the outer edge of the seal. Remove the seal with a slide hammer fitted with a No. 10 sheet-metal screw. Thread it into each of the holes alternately and work the seal free. 4. Apply an even coat of Silastic (approximately a 1/16-inch [2 mm] bead) to the flywheel housing mounting surface of the cylinder block.
5-101.bk Page 30 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY 6. Install the exposed flywheel mounting capscrews and tighten them finger tight. 7. Torque all flywheel housing capscrews to 170 lb-ft (231 N폷m) using torque wrench J 24407 or equivalent. Refer to Figure 6-30. Figure 6-30 — Torquing Flywheel Housing Capscrews Runout With the machined dowel method of installation, flywheel housing runout is well within the old service specification of 0.010 inch (0.
5-101.bk Page 31 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [212 JH] CRANKSHAFT WEAR RING When the service oil seal is to be replaced and the crankshaft flange is worn, the crankshaft can be salvaged by installing a crankshaft wear ring. An oil seal with a larger inside diameter is used with this wear ring.
5-101.bk Page 32 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY 1. Position wear ring in the spring clips of the wear ring installer J 38880 with the arrow pointing away from the installer tool. Do not heat the wear ring with a torch. This type of heat source will not heat the ring evenly. 2. Heat the wear ring and wear ring installer together in a temperature-controlled oven or on a hotplate, with the wear ring on the bottom and installed in the spring clips of the installer.
5-101.bk Page 33 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY 7. Tighten the hex nut until a positive stop is felt. At that point, the oil seal and wear ring are properly installed on the crankshaft flange. 8. Remove the installation tool. Special handling precautions must be taken while installing Teflon seals. Do not lubricate the lips of a Teflon seal before installation. Teflon seals function most effectively when installed dry. 1. Thoroughly clean the surface of the crankshaft flange. 2.
5-101.bk Page 34 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY 4. Determine the seal and wear ring installation depth: 앫 New seal on new crankshaft — Install to initial production depth of 0.339–0.349 inch (8.611–8.865 mm). 앫 New seal on service crankshaft — Install to service depth of 0.245–0.255 inch (6.223–6.477 mm). 앫 Wear ring installation depth — 0.15–0.220 inch (5.461–5.588 mm). 앫 Service oil seal installation depth with new wear ring — 0.339–0.349 inch (8.611–8.865 mm).
5-101.bk Page 35 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [212 VC] FLYWHEEL (E7 ENGINE WITHOUT POINTER ON TIMING COVER) Description The flywheel has a stamped timing scale of TDC to 45 degrees of engine travel for setting and checking injection pump to engine timing. It also has three stamped locations, 120 degrees apart, for valve settings.
5-101.bk Page 36 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Installation 4. Torque the capscrews to 185 lb-ft (251 N폷m), alternating from opposite sides to apply even pressure to the flywheel (use torque wrench J 24407 or equivalent). After resurfacing, any flywheel with drilled balance holes on the clutch side requires rebalancing by a machine shop. When installing the flywheel, insert two alignment studs into the flywheel mounting holes to aid in installation. Refer to Figure 6-41. 1.
5-101.bk Page 37 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [213 CH] CAMSHAFT Special Tools Required 앫 Description 앫 Refer to Figure 6-42. Tappet Holders J 37720-B Camshaft Removal/Installation Tool J 41461 Inspection The E7 camshaft design uses large journals to decrease bearing loading and to allow for larger, more durable cam lobes. In addition, the profile of the exhaust lobes has been changed (with part No. 5205) to increase the duration of exhaust valve opening.
5-101.bk Page 38 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Installation (Engine in Stand) 1. With the cylinder block in the stand, rotate the stand so that the crankcase is upward (engine inverted). 2. Rotate the crankshaft so that the drive gear timing mark is aligned with the camshaft opening. Refer to Figure 6-44. 4. Lubricate the camshaft journals and the camshaft bearing surfaces with clean engine oil. Refer to Figure 6-45. 5.
5-101.bk Page 39 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Installation (Engine in Chassis) J 37720-B In order to use the valve lifter tool to hold the valve lifters in position, the cylinder heads must be installed on the engine. Arrange valve lifters so that they can be identified and reinstalled into the same hole from which they came. 1. Rotate the crankshaft so that the drive gear timing mark on the drive gear is aligned with the camshaft opening. Refer back to Figure 6-44. 2.
5-101.bk Page 40 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY 7. Lubricate camshaft journals and camshaft bearing surfaces (in cylinder block) with clean engine oil. Do not rotate camshaft with the installation tool in position on the shaft. The tool must remain on the bottom of the shaft (6 o’clock position) or it will not function properly. Refer to Figure 6-48. 9. Secure camshaft captured thrust washer to the block using the two patch-lock 12-point capscrews (3) and hardened washers.
5-101.bk Page 41 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [212 CV] AUXILIARY DRIVESHAFT Installation 앫 앫 Current production engines (effective February 27, 1992, serial No. 2E1233) feature an improved “fast ratio” auxiliary driveshaft assembly and oil pump assembly. This arrangement increases operating oil pressure by approximately 25% and creates a change in the oil pump speed. Do not mix ratios. Refer to Oil Pump assembly procedures in this section for part number information. Inspection 1.
5-101.bk Page 42 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [219 MU] OIL PUMP Refer to Figure 6-50. 3. Install thrust washer (4) and secure it in position with the patch-lock capscrews (3) and hardened washers. 4. Torque the thrust washer retaining patchlock capscrews to 15 lb-ft (20 N폷m) using torque wrench J 24406 or equivalent. 5. Install auxiliary driveshaft gear (2) on shaft splines (5). The auxiliary driveshaft and nut threads must be clean and dry before assembly.
5-101.bk Page 43 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Installation Refer to Figure 6-51. 1. Position the oil pump (1) on the cylinder block (3). 1 2. Secure the pump in position using the mounting capscrews (2). Torque the mounting capscrews to 40 lb-ft (54 N폷m) using torque wrench J 24407 or equivalent. 2 2 3 2 200653a Figure 6-51 — Oil Pump Installation 1. Lubrication oil pump 2. Mounting capscrews 3.
5-101.bk Page 44 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [211 RP] TIMING GEAR COVER Apply Loctite 271 to all capscrews used to assemble the oil pump. 3.
5-101.bk Page 45 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [211 SB] TIMING GEAR COVER SEAL [221 GP] FUEL INJECTION PUMP INSTALLATION Special Tool Required Refer to SETUP AND ADJUSTMENTS section under Fuel Injection Fixed-Timing Procedures for pump installation procedure. 앫 Crankshaft Front Seal Installer J 37715-A Installation [212 RH] CRANKSHAFT HUB Refer to Figure 6-52. 1. To install the lip-type seal, use crankshaft front seal installer J 37715-A.
5-101.bk Page 46 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Inspection Inspect the vibration damper for dents, nicks or fluid leaks in the outer housing. If any of the above are evident, the vibration damper must be replaced. Due to the close clearances between the damper housing and its internal flywheel, dents or nicks may cause contact between the two components. Fluid loss will deteriorate the dampening effect of the damper. Installation Figure 6-53 — Crankshaft Hub/Vibration Damper 1.
5-101.bk Page 47 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Other changes include the use of new shouldered oil pan bolts which bottom on the cylinder block rather than the oil pan, and rubber isolators installed between the heads of the pan bolts and the oil pan. Together, these isolators and the isolating gasket eliminate metal-to-metal contact between the bolts and the oil pan, significantly reducing the amount of engine vibration transmitted to the pan.
5-101.bk Page 48 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY With the new isolating oil pan gasket arrangement, the mounting holes tapped into the cylinder block, timing gear cover, and flywheel housing are now 8 mm rather than 10 mm. The illustration below, Figure 6-55, shows the newer production arrangement. The fiber oil pan gasket can be used on engines with either 8-mm or 10-mm tapped mounting holes. The isolating oil pan gasket may only be used on cylinder blocks with 8-mm tapped holes.
5-101.bk Page 49 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY The isolating oil pan gasket contains 12 integral locating/retaining cones which lock into holes drilled through the oil pan rails, and two large rectangular tabs located directly across from each other on the inner perimeter of the gasket. The cones keep the gasket properly located during oil pan installation, and the rectangular tabs serve as a starting point for locating the gasket on the oil pan rail.
5-101.bk Page 50 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Oil Pan Installation 1. Clean any oil from the cylinder block mounting surface and the oil pan rail. The oil pan must be installed dry. 1 Oil on the surface of the gasket or the rails of the cylinder block and oil pan during oil pan installation can cause the gasket to bulge out between any two bolts, particularly those at the mid-section corners. This condition may not occur immediately, but can do so at any time after installation.
5-101.bk Page 51 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY OIL PAN INSTALLATION WITH NEW E7 TIMING GEAR COVER AND FLYWHEEL HOUSING 앫 A new timing gear cover with 8-mm holes for oil pan mounting was introduced with the 1994 certified E7-427 and E7-454 engines. This timing cover is used in conjunction with the isolating oil pan arrangement, but is also the service replacement for timing covers with 10-mm tapped holes for oil pan mounting. The new style timing gear cover part No. is 333GB285AM.
5-101.bk Page 52 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Installation Ensure that the cylinder heads are in acceptable condition. Refer to the cylinder head inspection procedures in the BENCH PROCEDURES section in this manual. All MACK head gaskets are precoated and do not require any type of additional sealing compound. Refer to Figure 6-58. 1. Place the head gaskets in position on the locating pins in the cylinder block deck. 2.
5-101.bk Page 53 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Several of the head mounting capscrews have threaded holes drilled in the heads for bracketmounting purposes. The drilled capscrews must be located in the correct positions for proper bracket installation. Do not install painted capscrews at locations that are under the valve cover. There are two cylinder-head capscrew lengths: 198.0 mm and 225.0 mm. 5.
5-101.bk Page 54 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Refer to Figure 6-60. 6. Torque all head mounting capscrews in three stages to the specified torque. a. Torque all head mounting capscrews in sequence to 50 lb-ft (68 N폷m) using torque wrench J 24407 or equivalent. b. Torque all head mounting capscrews in sequence to 125 lb-ft (170 N폷m) using torque wrench J 24407 or equivalent. c.
5-101.bk Page 55 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [222 KG] NOZZLE HOLDER ASSEMBLY Description 2. Lubricate the nozzle holder surface and install O-ring on the nozzle holder. 3. Thread injection nozzle puller J 37093 into the top of nozzle holder. Refer to Figure 6-62. Each cylinder has a nozzle to ensure proper delivery of fuel that is metered and timed by the injection pump. The nozzle is positioned at the lower end of the nozzle holder.
5-101.bk Page 56 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY 4. Insert nozzle holder in the nozzle holder hole. Be sure to align the locator ball in the nozzle holder with the socket in the cylinder head to ensure inlet tube alignment. Refer to Figure 6-63. 앫 앫 If the gauge block is too high, it may indicate that there are two gaskets installed under the nozzle holder, or the nozzle holder has not been fully inserted.
5-101.bk Page 57 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [213 LH] VALVE LIFTER PUSH RODS Inspection Check the push rods. Replace any push rods that have loose ends, are bent, or show signs of excessive wear. Identification Refer to Figure 6-67. The current E7 valve lifter has no hole in the center of the stem. In conjunction with this change, the E7 inlet and exhaust (nonbrake engine) push rods have a 0.060-inch (1.524 mm) maximum flat or dimple on the ball end.
5-101.bk Page 58 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY All E7 production engines starting with serial No. 2X0000 and above, feature valve lifters with no hole as well as inlet and nonbrake push rods with 0.060 inch (1.524 mm) maximum flat or dimple on the push rod ball end. Installation Used push rods have established wear patterns. Push rods being returned to service should be installed in the same position from which they were removed. 1.
5-101.bk Page 59 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [213 LP] ROCKER ARMS Description The valve rockers pivot on a shaft supported by three brackets per cylinder head. Two capscrews secure each bracket to the cylinder head. The rocker arms are operated by a camshaft through valve lifters and push rods extending through the cylinder heads. A coil spring returns each valve to the closed position, holding the rocker arm in contact with the push rod.
5-101.bk Page 60 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY 2. Check that all push rods are in their sockets and rocker adjusting screws are backed out to prevent piston damage or bent rods. 3. Start at the center and tighten each bracket hold-down screw in two steps: 앫 Torque to 20 lb-ft (27 N•m). 앫 Retorque to 40 lb-ft (54 N•m). 4. Lubricate and install O-rings in the groove in the Jacobs oil supply screws. Install the screws into the rocker brackets and tighten to 5 lb-ft (7 N•m).
5-101.bk Page 61 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [213 JB] VALVE COVER Description Valve cover mounting capscrews have undergone a manufacturing change. The existing mounting capscrews require two different sockets for cover installation. The new capscrews require only one socket. Note the capscrews used on your engine and replace with the same capscrews, if required. Cylinder head cover (No.
5-101.bk Page 62 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY 6. Lubricate threads of the capscrews (2) and secure the valve covers with the lubricated capscrews. Torque capscrews to 16 lb-ft (22 N폷m). 1 2 If replacing an existing manifold (on engines manufactured before March 1995) with a lowboss exhaust manifold and reusing the long studs (103 mm long), each stud requires a spacer.
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5-101.bk Page 64 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [215 NK] COOLANT MANIFOLD 3. Place couple (2) in position on the couple mounting flange. Place two clamps (3) over the couple. Inspection 4. Insert the rear manifold section (4) in the couple. Check the coolant manifold sections for restrictions, cracks and flange wear. The manifold cannot be repaired. Replace if any signs of damage are present. 5.
5-101.bk Page 65 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [261 CK] AIR COMPRESSOR Installation If the oil supply tube is lost, the air compressor will fail from lack of oil. Refer to Figure 6-75. 1. Install a new gasket on the air compressor mounting flange. 3. Install the three mounting capscrews (5) and torque to 70 lb-ft (95 N폷m) using torque wrench J 24407 or equivalent. 2.
5-101.bk Page 66 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [221 CD] ECONOVANCE [221 GP] FUEL INJECTION PUMP Installation Installation Refer to Figure 6-76. 1. Lubricate with clean engine oil and then install O-ring in groove on front of Econovance assembly (5). This procedure is described and illustrated with pump-to-Econovance adapter installed on pump. 2. Position the Econovance assembly (5) on the mounting surface of the engine front flange.
5-101.bk Page 67 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY 3. Loosen the two upper support bracket-tofuel injection pump capscrews. 200441a Figure 6-78 — Installing Outer Coupling 2. Loosen the three injection pump rear support bracket-to-cylinder block capscrews. Then hand tighten the capscrews until snug, and loosen 1/4 turn. The lower support bracket should move freely from side to side.
5-101.bk Page 68 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY 5. With the fuel injection pump positioned over the alignment dowels, in one motion, lift the rear of the pump and slightly rotate the Econovance hub. Slide the pump forward into position. 7. Install and torque the remaining fuel injection pump adapter mounting capscrews to 40 lb-ft (54 N폷m) using torque wrench J 24407 or equivalent. 8.
5-101.bk Page 69 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY 9. Torque the three lower support bracket-tocylinder block capscrews to 40 lb-ft (54 N폷m) using torque wrench J 24407 or equivalent. 10. Torque the two upper support bracket-to-fuel injection pump capscrews to 15 lb-ft (20 N폷m) using torque wrench J 24407 or equivalent. Loosen and then retorque the capscrews to 40 lb-ft (54 N폷m).
5-101.bk Page 70 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [222 KD] FUEL NOZZLE INLET TUBE ASSEMBLY 5. Tighten all fuel inlet tube assembly clamping screws to 35 lb-ft (48 N폷m) torque using torque wrench J 24407 or equivalent. Installation Refer to Figure 6-88. 1. Install the fuel nozzle inlet tube assemblies (1) into the front and rear cylinder heads. Lubricate the nozzle inlet tube clamping screw threads before installing. 2.
5-101.bk Page 71 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY 2 1 3 2 1 3 1 1 11 4 5 10 9 6 5 8 7 200353a Figure 6-88 — Fuel Nozzle Inlet Tube Assembly Installation 1. Nozzle fuel inlet tube and sleeve nut 2. Rear fuel inlet tube assembly 3. Bracket/insulator (tube clamp) 4. Front fuel inlet tube assembly 5. Bracket/insulator (tube clamp) 6. Sleeve nut 7. 8. 9. 10. 11.
5-101.bk Page 72 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [214 SC] TURBOCHARGER Installation (Includes Pre-Lubing Procedures) Refer to Figure 6-89. 1. Inspect the intake and exhaust systems leading to and from the turbocharger to ensure absence of foreign material, including burrs and loose lining fragments. retaining nuts to 90 lb-in (10 N폷m) using torque wrench J 5853-C or equivalent. Then make certain that all ducting aligns closely with the turbocharger.
5-101.bk Page 73 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [215 NU, NG & LD] THERMOSTAT, THERMOSTAT HOUSING, THERMOSTAT SEAL AND COOLANT CONDITIONER Refer to Figure 6-90. 1. When replacing a seal for any reason, examine the surface of the thermostat sleeve, the bore area and the seal to prevent premature failure of the new seal. A sealing lip that has been turned back, cut or otherwise damaged will leak and must be replaced. The lip faces the front of the engine. 2.
5-101.bk Page 74 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Figure 6-90 — Thermostat Housing Installation 1. Capscrew 2. Coolant conditioner head assembly 3. Check valve 4. O-ring 5. Thermostat housing 6. Thermostat seal 7. Thermostat Page 6-74 8. Gasket 9. Coolant manifold 10. Clamps 11. Oil cooler supply tube 12. Coupling (hose) 13. Capscrew 14.
5-101.bk Page 75 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [214 HD] AIR INLET MANIFOLD Refer back to Figure 6-74. 1. Place the front air inlet manifold section (8) into position on the cylinder head and insert the 12-point capscrews (9) and washers. 2. Torque capscrews to 40 lb-ft (54 N폷m) using torque wrench J 24407 or equivalent. 3. Place the coupling on the rear of the front air inlet section (8). Assemble two clamps on the coupling and install the rear air inlet section (6). 4.
5-101.bk Page 76 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [215 SW] WATER PUMP Installation Refer to Figure 6-92. 1 Water pump-to-housing mounting capscrews should not be lubricated before installation. Instead, apply thread sealing compound to all water pump-to-water pump housing capscrews. Also apply thread sealing compound to water pump housing (pump outlet) to block capscrews. 2 3 1. Position a gasket on the water pump mounting flange. 2. Secure pump with three mounting capscrews (3). 3.
5-101.bk Page 77 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [215 DW & 219 EP] OIL COOLER AND OIL FILTER HEAD Assembling a New Oil Filter Adapter The oil filter head does not come as a complete assembly, so the fittings, nipples, spuds, etc., must be installed before installing the filter head onto the engine. Perform the following procedures before installing the threaded spuds into the filter head. Refer to Figure 6-93. 1.
5-101.bk Page 78 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY Installation Refer to Figure 6-94. 1. Lubricate the oil cooler supply tube (5) with Vaseline® or equivalent. 2. Position coupling (4) over the lubricated tube. 3. Place two clamps (3) over the coupling. 4. Place a gasket on the oil supply mounting flange (11). 5. Position the oil cooler and oil filter head assembly on the engine. Slide the coupling (4) over the thermostat housing flange.
5-101.bk Page 79 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY 4 3 6 5 2 7 1 9 13 12 11 8 10 200654a Figure 6-94 — Oil Cooler and Oil Filter Head Installation 1. Capscrew 2. Water pump mounting flange 3. Clamps 4. Coupling 5. Oil cooler supply tube (water bypass tube) 6. Centri-Max™ filter breather hose 7. Breather hose fitting (MR chassis with Jake Brake use breather assembly) 8. Oil hose 9. Fitting 10. Capscrew 11. Oil supply mounting flange 12. Sending unit 13.
5-101.bk Page 80 Friday, March 17, 2006 11:05 AM 200 ENGINE ASSEMBLY [271 CB] ALTERNATOR Fan Belt(s) Installation ADJUSTMENT Refer to Figure 6-95. 1. Install the alternator plate (5) and mounting hardware (4). 2. Position the alternator (7) on the plate and install capscrews (3), washers and mounting nuts (6). 3. Connect the electrical wires as tagged during disassembly. 4. Install drive belt(s) (1). 5.
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5-101.bk Page 2 Friday, March 17, 2006 11:05 AM 200 SETUP AND ADJUSTMENTS [213 NB] VALVE YOKE AND VALVE LASH ADJUSTMENTS (NON-JAKE BRAKE ENGINE AND DYNATARD EQUIPPED) Description Yoke and valve adjustments are done in two stages on E7 engines. Adjust the yoke clearance first, then adjust the valve lash. Make sure both adjustments are done in firing order sequence.
5-101.bk Page 3 Friday, March 17, 2006 11:05 AM 200 SETUP AND ADJUSTMENTS After verifying that there is a clutch mounting bolt/ bolt hole in line with the TC mark, the next step is to locate the three locations where the valve adjustment marks should be. Put a temporary (chalk, grease pencil, paint, etc.) mark at each of the three locations. Proceed as follows: 1.
5-101.bk Page 4 Friday, March 17, 2006 11:05 AM 200 SETUP AND ADJUSTMENTS Figure 7-2 — Flywheel Marks 2. Back off the valve rocker adjusting screws. 3. Loosen the No. 1 cylinder yoke adjusting screw locknuts. 4. Exert moderate force on the yoke by pressing on the rocker arm slipper end. Turn down the yoke adjusting screw until it makes solid contact with the outboard valve stem tip, as sensed by a light drag on the adjusting screw. 5. Turn adjusting screw an additional 1/6 turn (60 degrees) clockwise.
5-101.bk Page 5 Friday, March 17, 2006 11:05 AM 200 SETUP AND ADJUSTMENTS CHECKING YOKE ADJUSTMENT Refer to Figure 7-4. 1. Insert a 0.010-inch (0.254 mm) thickness gauge between the yoke and valve stem, at both the inboard and outboard locations. 2. Exert moderate force on the yoke by pressing on the rocker arm slipper end. An equal drag should be felt on both thickness gauges. If drag is unequal, readjust the yoke adjusting screw, as required. Figure 7-5 — Inlet Valve Adjustment 1. Thickness gauge 2.
5-101.bk Page 6 Friday, March 17, 2006 11:05 AM 200 SETUP AND ADJUSTMENTS 3. Continue adjusting yoke and valve lash for the remaining cylinders, in firing order. Rotate crankshaft to place each piston 30 degrees past TDC. Figure 7-6 — Exhaust Valve Adjustment 1. Thickness gauge 2. Adjusting wrench J 37092 Continuation of Adjustments Refer to Figure 7-7. 1.
5-101.bk Page 7 Friday, March 17, 2006 11:05 AM 200 SETUP AND ADJUSTMENTS Some E7 engines are equipped with a pointer marked VALVE on the timing gear cover. When aligned with the TC mark on the vibration damper, it provides the 30 degrees after Top Dead Center (TDC) damper relationship for valve lash adjustment. Make all adjustments in firing order sequence. SPIRALOCKTM YOKE THREADS WEDGE RAMP YOKE E7 engine firing order is 1 - 5 - 3 - 6 - 2 - 4.
5-101.bk Page 8 Friday, March 17, 2006 11:05 AM 200 SETUP AND ADJUSTMENTS Special Tools Required Jacobs feeler gauges: 앫 0.060 inch (1.52 mm) No. 022001 앫 0.080 inch (2.03 mm) No. 018781 앫 0.085 inch (2.16 mm) No. 014177 앫 0.100 inch (2.54 mm) No. 021327 Valve Yoke Jacobs yokes must be installed on the exhaust yoke guide pins. Lubricate the guide pin and the pallet of the yoke with engine oil. Install yoke with the adjustment screw outboard (toward the intake manifold side of the engine).
5-101.bk Page 9 Friday, March 17, 2006 11:05 AM 200 SETUP AND ADJUSTMENTS Slave Piston, Inlet Valve and Exhaust Valve Lash Adjustments Make the following adjustments with the engine shut down. Coolant temperature must be below 100!F (38!C) to ensure proper adjustment. Exhaust Valve Adjustment Exhaust valve lash clearance is 0.024 inch (0.610 mm) or 0.028 inch (0.711 mm) for V-MAC II or mechanically governed engines equipped with camshafts effective April 1996. 1.
5-101.bk Page 10 Friday, March 17, 2006 11:05 AM 200 SETUP AND ADJUSTMENTS Slave Piston Adjustment Engine and Turbocharger Model, and Camshaft Part No. 454GC — Engine Brake Slave Lash Adjusting Tool Part No. 1996/1997 E7 with 5205 Jake Brake camshaft and plus Extarder S300 or S400 Turbocharger 0.085" 014177 1996/1997 E7 with 5205 camshaft and S300 or S400 Turbocharger Jake Brake Only 0.060" 022001 1996 E7 with 583(A), 5142 camshaft and S3B or S4D Turbocharger Jake Brake Only 0.
5-101.bk Page 11 Friday, March 17, 2006 11:05 AM 200 SETUP AND ADJUSTMENTS Continuation of Adjustments 1. Using engine barring socket J 38587-A, manually rotate engine in normal rotation direction 120 degrees until pointer in flywheel housing aligns with the “5” mark on the flywheel. The No. 5 piston will be on the compression stroke.
5-101.bk Page 12 Friday, March 17, 2006 11:05 AM 200 SETUP AND ADJUSTMENTS 앫 On all P7100 non V-MAC mechanically controlled fuel-injection systems, injection timing is referenced to the No. 1 cylinder. The engine must be timed during the compression stroke of cylinder No. 1. 앫 On all P7100 V-MAC electronically controlled fuel-injection systems, injection timing is referenced to the No. 6 cylinder. The engine must be timed during the compression stroke of cylinder No. 6.
5-101.bk Page 13 Friday, March 17, 2006 11:05 AM 200 SETUP AND ADJUSTMENTS Accurately setting the injection pump timing is the best way to ensure optimum fuel economy, engine durability, and maintain engine exhaust within established EPA limits.
5-101.bk Page 14 Friday, March 17, 2006 11:05 AM 200 SETUP AND ADJUSTMENTS 3. Clean the J 37077 tool sensor probe points with compressed air before using. This helps prevent metallic contamination between the sensor probe points. J 37077 200405a Figure 7-17 — Installing J 37077 Tool 5. Slowly turn the knurled surface clockwise to lock the tool into place. Check to make sure tool is seated by applying pressure to the end of the tool and checking for any movement.
5-101.bk Page 15 Friday, March 17, 2006 11:05 AM 200 SETUP AND ADJUSTMENTS 7. To continue the procedures for setting the timing, refer to the following applications for an engine with front timing indicator or with rear timing indicator. Fuel Injection Pump Driven Gear Installation To install the fuel injection pump gear: 1. Verify crankshaft is set to correct BTDC position for pump timing.
5-101.bk Page 16 Friday, March 17, 2006 11:05 AM 200 SETUP AND ADJUSTMENTS 3. Install two pump drive gear alignment dowels, J 37085, to ease alignment of drive gear to timing gear hub. 5. Install two driven gear capscrews in the open holes. Install capscrews snugly to remove clearance but allow relative motion between hub and gear. J 37085 200453a 200455a Figure 7-21 — Installing Drive Alignment Dowels Figure 7-23 — Installing Driven Gear Capscrews 4.
5-101.bk Page 17 Friday, March 17, 2006 11:05 AM 200 SETUP AND ADJUSTMENTS J 38740 7 707 J3 WE PO PO R ION SIT SE NS OR B RE OO -M NT KE A 200458a Figure 7-24 — Rotating Timing Gear Hub Counterclockwise 8. Rotate timing gear hub clockwise until both A and B lamps are lit. There is only a very small band of rotation for which both lamps are lit.
5-101.bk Page 18 Friday, March 17, 2006 11:05 AM 200 SETUP AND ADJUSTMENTS Checking Pump-to-Engine Timing Fuel Injection Pump Access Cover Installation To install the fuel injection pump access cover: Using hub bolt to rotate engine backward may change bolt torque. Check torque of hub bolt after completing timing procedure. 1. Lubricate the access cover O-ring with Lubrizol OS-50044 or equivalent. 1. Rotate engine crankshaft counterclockwise to a minimum of 45 degrees before TDC.
5-101.bk Page 19 Friday, March 17, 2006 11:05 AM 200 SETUP AND ADJUSTMENTS 200465a Figure 7-29 — Installing Access Cover Seal 5. Using Midget sealing tool 814 or equivalent, compress the lead seal. 6. Reconnect fuel injection pump oil supply line. Fuel Injection Pump Pre-Lubrication To pre-lubricate the P8500/RE30 fuel injection pump and governor, add 12 ounces (0.4 liter) of clean engine oil through the Timing Event Marker (TEM) port located in the RE30 governor housing.
5-101.bk Page 20 Friday, March 17, 2006 11:05 AM 200 SETUP AND ADJUSTMENTS Timing Event Marker (TEM) Installation To install the TEM: 1. Thoroughly clean all oil residue from the TEM and timing access window. 2. Completely back off the TEM jam nut (toward the sensor pigtail). 3. Apply a 1/8- to 1/4-inch bead of Silastic (MACK part No. 342SX32 or equivalent) around the sensor threads at the jam nut. Figure 7-35 — Torquing TEM Sensor Jam Nut 7. Wipe the excess Silastic with a dry cloth.
5-101.bk Page 21 Friday, March 17, 2006 11:05 AM 200 SETUP AND ADJUSTMENTS [212 NP] LOCATING PISTON TOP DEAD CENTER (TDC) 6. Rotate engine in direction opposite to normal rotation until a reading of 0.060 inch (1.524 mm) is obtained on the dial indicator. E7 Series Engines with Front Timing Indicators 7. Rotate engine in normal rotation direction until dial indicator reads exactly 0.035 inch (0.889 mm). During timing inspection, if timing is found to be incorrect, check piston TDC and retime engine.
5-101.bk Page 22 Friday, March 17, 2006 11:05 AM 200 SETUP AND ADJUSTMENTS 10. Rotate engine in direction opposite to normal rotation until a reading of exactly 0.035 inch (0.889 mm) is indicated on dial indicator. 11. Place a mark on the masking tape on the vibration damper to align with pump timing pointer. 12. Measure distance between the two marks just made on the masking tape and place a third mark exactly at the midpoint between the first two marks. 13.
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5-101.bk Page 2 Friday, March 17, 2006 11:05 AM 200 ENGINE INSTALLATION & TESTING INSTALLATION Engine Installation into Vehicle Description Engine installation details vary from vehicle to vehicle. The following procedure provides general installation guidelines for MACK E7 engines. It is good practice to steam-clean road grime, grease, and oil from the engine before service. Steam-cleaning the engine and engine compartment permits more detailed inspection and improved workmanship.
5-101.bk Page 3 Friday, March 17, 2006 11:05 AM 200 ENGINE INSTALLATION & TESTING A new S3B turbocharger with a 3.5-inch push-on compressor discharge has replaced the earlier S3B turbocharger with cast elbow required for V-band connection. You will need to know which type turbocharger is used on your engine when ordering replacement parts. 11. Connect tube to turbocharger and air cleaner assembly. 12.
5-101.bk Page 4 Friday, March 17, 2006 11:05 AM 200 ENGINE INSTALLATION & TESTING 5. Prime the SECONDARY fuel filter element (green) by filling with clean No. 2 fuel oil. Do not fill filter through center hole; it must be filled using outer holes. Lubricate gasket with oil and install filter. FINAL PREPARATION Lubrication A lubricating oil film coats rotating parts and bearings of an overhauled engine, but this may not provide sufficient lubrication when engine is started for the first time.
5-101.bk Page 5 Friday, March 17, 2006 11:05 AM 200 ENGINE INSTALLATION & TESTING FUEL SYSTEM 1. Check fuel system to ensure that all connections are tight. 2. Remove any trapped air by operating manual priming pump, if equipped, located on the side of injection pump (V-MAC only). Prime the fuel system with clean, Grade 2D diesel fuel (DF-A). 3. Check injection pump timing. Injection pump-to-engine timing must be set for the specific engine.
5-101.bk Page 6 Friday, March 17, 2006 11:05 AM 200 ENGINE INSTALLATION & TESTING [233 FA] CHASSIS-MOUNTED CHARGE AIR COOLING Description The Chassis-Mounted Charge Air Cooling (CMCAC) system cools hot turbocharged air before it enters the engine intake manifold. The CMCAC system uses ambient air as a cooling medium by allowing it to pass through a core equipped with heat-exchanging fins. Hot turbocharged air, varying in pressure from 0.0–25 psi (0.
5-101.bk Page 7 Friday, March 17, 2006 11:05 AM 200 ENGINE INSTALLATION & TESTING CMCAC Pressure Test 6. Pressurize system to 30 psi (207 kPa). 1. Remove air ducting from core. 2. Plug core inlet opening. 3. Insert a plug with an air-line adapter in core outlet opening. 4. Connect a safety chain to both plugs. Use air charge cooler pressure fixture J 41473 on coolers with flange connections. Stand clear of plug area when system is pressurized. 7. Shut off air source.
5-101.bk Page 8 Friday, March 17, 2006 11:05 AM 200 ENGINE INSTALLATION & TESTING Restriction Pressure Test Perform restriction pressure test at maximum, full-load condition. A restriction in the internal portion of cooler may interfere with proper airflow, and can result in excessively high pyrometer readings. To perform a restriction pressure test, use the following procedure: 1. Units are equipped with connections on the inward sides of inlet and outlet charge cooler tubes.
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5-101.bk Page 2 Friday, March 17, 2006 11:05 AM 200 TROUBLESHOOTING ENGINE WILL NOT CRANK Possible Cause Correction 1. Batteries have low output. 1. Check the batteries. Charge or replace as required. 2. Loose or corroded battery connections. 2. Clean and tighten battery connections. 3. Broken or corroded wires. 3. Check voltage at the following connections: — Switch to starter — Battery to starter Replace as required. 4. Faulty starter or starter solenoid. 4.
5-101.bk Page 3 Friday, March 17, 2006 11:05 AM 200 TROUBLESHOOTING ENGINE MISFIRES Possible Cause Correction 1. Poor quality fuel, or water or dirt in the fuel. 1. Drain fuel from tanks. Replace fuel filters and fill tank with MACKspecified diesel fuel. 2. Air in fuel system. 2. Check fuel system for air leaks. Repair as necessary. (Air generally gets into the fuel system on the suction side of the fuel pump.) 3. Broken or leaking high-pressure fuel lines. 3. Check for fuel leaks.
5-101.bk Page 4 Friday, March 17, 2006 11:05 AM 200 TROUBLESHOOTING ERRATIC ENGINE SPEED Possible Cause Correction 1. Air leaks in fuel suction line. 1. Check for air leaks. Repair as necessary. 2. Throttle linkage loose or out of adjustment. 2. Check throttle linkage. Repair or adjust as necessary. 3. Injection pump governor failure. 3.
5-101.bk Page 5 Friday, March 17, 2006 11:05 AM 200 TROUBLESHOOTING ENGINE WILL NOT ACHIEVE NO-LOAD GOVERNED RPM Possible Cause Correction 1. Air in fuel system. 1. Check system for air leaks and correct as required. Air will generally enter the fuel system on the suction side of the fuel transfer pump. 2. Accelerator linkage loose or out of adjustment. 2. Check linkage. Make necessary adjustments. 3. Restricted fuel lines or stuck overflow valve. 3. Check flow in fuel lines.
5-101.bk Page 6 Friday, March 17, 2006 11:05 AM 200 TROUBLESHOOTING EXCESSIVE BLUE OR WHITE SMOKE Possible Cause Correction 1. Engine lubricating oil level too high. 1. 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. 2. Turbocharger oil seal failure. 2.
5-101.bk Page 7 Friday, March 17, 2006 11:05 AM 200 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. Adjust belt tension or replace belts as required. 3. Restricted airflow through radiator. 3. Remove any restrictions from the outer surface of the radiator. 4. Defective radiator pressure cap. 4.
5-101.bk Page 8 Friday, March 17, 2006 11:05 AM 200 TROUBLESHOOTING HIGH EXHAUST TEMPERATURE Possible Cause Correction 1. Operating chassis in wrong gear ratio for load, grade and/or altitude. 1. Instruct operator on correct gear selection for load and grade conditions. 2. Restrictions in the air induction system. 2. Inspect air induction system. Remove restrictions and/or replace defective parts. 3. Air leaks in the air induction system. 3. Check pressure in the air intake manifold.
5-101.bk Page 9 Friday, March 17, 2006 11:05 AM 200 TROUBLESHOOTING LOW ENGINE OIL PRESSURE Possible Cause Correction 1. Oil level insufficient. Oil leaking from oil line, gasket, etc. 1. Check engine oil level. Add oil if necessary. Check for oil leaks. Repair as required. 2. Incorrect oil viscosity. 2. Drain oil, change oil filters, and fill with the proper grade oil meeting MACK specifications. 3. Defective oil pressure gauge. 3. Check the operation of the oil pressure gauge.
5-101.bk Page 10 Friday, March 17, 2006 11:05 AM 200 TROUBLESHOOTING CAMSHAFT TIMING CHECK Correct camshaft timing is essential for proper engine performance. Incorrect camshaft timing may be suspected if soon after engine overhaul, lack of performance, unusual noise or excessive smoke are reported. Camshaft timing can be checked using either cylinder No. 3 or No. 4 inlet valve. For example purposes, No. 3 cylinder will be used in the steps below. 1. Remove cylinder head cover over cylinder No. 3. 2.
5-101.bk Page 11 Friday, March 17, 2006 11:05 AM 200 TROUBLESHOOTING PROPER FIRE RING/CYLINDER SLEEVE-TOP COMBINATIONS General Information Two types of cylinder head gasket/fire ring kits are available for E7 engines: a flat fire-ring kit and a stepped fire-ring kit. Both kits include instructions. Two sleeve-top configurations are also available. Use the correct fire ring and cylinder sleeve combination to ensure full contact support and improved combustion sealing.
5-101.bk Page 12 Friday, March 17, 2006 11:05 AM 200 TROUBLESHOOTING If replacing less than a full set of six sleeves, use the same original production sleeve. For each sleeve replaced, use a new crevice seal and apply Silastic at the cylinder block sleeve seat. Depending on their condition, new piston ring sets may also be needed. O-rings are no longer used in the cylinder block groove below the sleeve seats.
5-101.bk Page 13 Friday, March 17, 2006 11:05 AM 200 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. Before proceeding with the following tests, make sure leakage is not from the oil cooler or air compressor.
5-101.bk Page 14 Friday, March 17, 2006 11:05 AM 200 TROUBLESHOOTING CYLINDER BLOCK/CYLINDER HEAD COOLANT PASSAGES LEAK CHECK — IN CHASSIS Refer to Figure 9-4. Do not exceed 50 psi (345 kPa) air pressure. Damage to seals or cup plugs may result. 1. Drain coolant from the engine. 2. Remove the engine oil pan and valve lifter covers. 3. Remove the water pump assembly and use a suitable plate and gasket to seal opening. 4. Remove the upper and lower hoses from the thermostat housing.
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5-101.bk Page 16 Friday, March 17, 2006 11:05 AM 200 TROUBLESHOOTING CYLINDER HEAD OIL PASSAGE LEAK CHECK — OUT OF CHASSIS Refer to Figure 9-5. 1. Remove cylinder head from the engine. 2. Install a suitable plug to seal the rocker arm oil passage at deck side of head. There are two ways to plug the hole: 앫 Drill and tap the oil passage to accept a pipe plug. 앫 Insert a suitable rubber plug and clamp the plug in position with a C-clamp. 3.
5-101.bk Page 17 Friday, March 17, 2006 11:05 AM 200 TROUBLESHOOTING CYLINDER HEAD COOLANT PASSAGE LEAK CHECK — OUT OF CHASSIS Refer to Figure 9-6. 1. Remove cylinder head from engine. 2. Fabricate a suitable 3/4-inch-thick (19.1 mm) steel plate and a 1/4-inch (6.4 mm) rubber gasket. The plate must have cutouts for the entire combustion chamber. Position plate and gasket assembly on underside of head and secure with C-clamps. 3. Use suitable plate and gasket to seal water manifold openings.
5-101.bk Page 18 Friday, March 17, 2006 11:05 AM 200 TROUBLESHOOTING CYLINDER BLOCK COOLANT PASSAGE LEAK CHECK — OUT OF CHASSIS Refer to Figure 9-7. 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. Use a 1/4-inch (6.4 mm) rubber gasket as a seal. Install the plates onto the cylinder head.
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5-101.bk Page 2 Friday, March 17, 2006 11:05 AM 200 APPENDIX E7 ENGINE SERIAL NUMBERS, JACOBS BRAKE APPLICATION The following is a list of selected 1990 E7 engine serial numbers requiring 0.080-inch (2.03 mm) Jacobs thickness gauge 017099 for Jacobs Brake slave piston adjustment. Refer to the Slave Piston Adjustment procedure in the SETUP AND ADJUSTMENTS section of this manual.
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INDEX.
INDEX.FR5 Page 2 Friday, March 17, 2006 11:04 AM INDEX A ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . ix ADJUSTMENT (E7 MECHANICALLY GOVERNED ENGINE WITH ENGINE BRAKE) . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53 AIR COMPRESSOR, INSTALLATION . . . . 6-65 AIR COMPRESSOR, REMOVAL . . . . . . . . 4-17 AIR INLET MANIFOLD, INSTALLATION . . . . . . . . . . . . . . . . . . . . 6-75 AIR INLET MANIFOLD, REMOVAL . . . . . . . 4-9 ALTERNATOR, INSTALLATION . . . . . . . . .
INDEX.FR5 Page 3 Friday, March 17, 2006 11:04 AM INDEX E E7 COOLING SYSTEM . . . . . . . . . . . . . . . . 10-4 E7 ENGINE SERIAL NUMBERS, JACOBS BRAKE APPLICATION . . . . . . . 10-2 E7 LUBRICATION SYSTEM . . . . . . . . . . . . 10-3 E7 SERIES ENGINES WITH FRONT TIMING INDICATORS . . . . . . . . . . . . . . . 7-21 ECONOVANCE, INSTALLATION. . . . . . . . . 6-66 ECONOVANCE, REMOVAL. . . . . . . . . . . . . 4-20 ECONOVANCE ASSEMBLY . . . . . . . . . . . . 5-64 ECONOVANCE CONTROL VALVE ASSEMBLY . . . . . . . .
INDEX.FR5 Page 4 Friday, March 17, 2006 11:04 AM INDEX INJECTION PUMP FIXED-TIMING PROCEDURES . . . . . . . . . . . . . . . . . . . . 7-11 INJECTION PUMP DRIVE HUB . . . . . . . . . 5-64 INJECTOR NOZZLES . . . . . . . . . . . . . . . . . 5-67 INLET AND EXHAUST VALVE INSTALLATION . . . . . . . . . . . . . . . . . . . . 5-45 INLET AND EXHAUST VALVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 5-25 INLET AND EXHAUST VALVES . . . . . . . . . 5-43 INLET AND EXHAUST VALVE SEAT INSERTS . . . . . . . .
INDEX.FR5 Page 5 Friday, March 17, 2006 11:04 AM INDEX RING INSTALLATION . . . . . . . . . . . . . . . . . 5-17 ROCKER ARM, VALVE YOKE AND PUSH ROD . . . . . . . . . . . . . . . . . . . . . . . 4-14 ROCKER ARMS, INSTALLATION . . . . . . . . 6-59 ROCKER ARMS, SERVICE . . . . . . . . . . . . . 5-47 RUN-IN CHECK . . . . . . . . . . . . . . . . . . . . . . . 8-5 S SAFETY INFORMATION . . . . . . . . . . . . . . . . . iii SETTING STATIC FUEL INJECTION PUMP TIMING . . . . . . . . . . . . . . . . . . . . .
INDEX.
E7 ENGINE OVERHAUL PRINTED IN U.S.A. ENGINE 5-101 © MACK TRUCKS, INC.
