User Manual

Page 6-2
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.
The purpose of component inspection is to
determine which parts can be reused and which
parts must be replaced. Use considerable
judgment to make this determination.
[211 DB] CYLINDER BLOCK
Special Tools Required
앫 Camshaft Bushing Installation/Removal Kit
J 37713
앫 Camshaft Bushing Remover/Installer
J 21428-01
앫 Counterbore Tool PT2210
앫 Counterbore Cutter Plate PT2210-3A
앫 Hex Key Wrench PT2210-14
앫 Universal Dial Depth Gauge PT5025
앫 3-Inch Stylus Extension PT5025-11
Cleaning and Inspection
The engine should have been thoroughly steam
cleaned prior to component removal and the
block should be relatively clean. If heavy
accumulations of dirt and grease are still present,
steam clean the block as thoroughly as possible
before attempting to clean with solvents.
Cleaning solvent is flammable and toxic to the
eyes, skin and respiratory tract. Skin and eye
protection is required. Avoid repeated or
prolonged contact. Use only in well-ventilated
area.
Compressed air used for cleaning can create
airborne particles that may enter the eyes or
irritate the skin. Pressure must not exceed
30 psi (207 kPa). Eye protection is required.
Use only with effective chip guarding and
personal protective equipment (goggles/
shield, gloves, etc.).
Cleaning the cylinder block is important. While
cleaning the cylinder block, carefully inspect the
areas around the cup plugs and the coolant
jacket. If cup plugs or pipe plugs show signs of
leaking, they should be replaced.
Cleaning the cylinder block is a good time to
inspect it for cracks or other possible defects
that may be reason for rejection. Refer to
TROUBLESHOOTING section of this manual for
information on testing for leaks in the cylinder
head and cylinder block. If damage is not found
until after the engine is assembled, the engine
must be disassembled and rebuilt again.
SOLVENT TANK CLEANING
Use a cleaning tank large enough to
accommodate the largest component to be
cleaned. Fill the tank with a suitable solvent and
always use caution while cleaning parts. Parts
may be dried with compressed air.
1. Scrape any remaining gasket material from
the block.
5-101.bk Page 2 Friday, March 17, 2006 11:05 AM