MACK E7, E7 Overhaul Service Manual

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E7 ENGINE

OVERHAUL

AUGUST 1997

ENGINE 5-101

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Manual: _______________________________ Publication Number: _______

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E7 ENGINE

OVERHAUL

MARCH 2006 2.5M (REP.) AUGUST 1997 10M

ENGINE 5-101

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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.

No part of this publication may be reproduced, stored in a retrieval system, or be transmitted in any form by any means including electronic, mechanical, photocopying, recording, or otherwise without prior written permission of Mack Trucks, Inc.

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SAFETY INFORMATION

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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. Additional Notes and Service Hints are utilized to emphasize areas of procedural importance and provide suggestions for ease of repair. The following definitions indicate the use of these advisory labels as they appear throughout the manual:

Directs attention to unsafe practices which could result in damage to equipment and possible subsequent personal injury or death if proper precautions are not taken.

Directs attention to unsafe practices which could result in personal injury or death if proper precautions are not taken.

Directs attention to unsafe practices and/or existing hazards which will result in personal injury or death if proper precautions are not taken.

An operating procedure, practice, condition, etc., which is essential to emphasize.

A helpful suggestion which will make it quicker and/or easier to perform a certain procedure, while possibly reducing overhaul cost.

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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.

Also note that particular service procedures may require the use of a special tool(s) designed for a specific purpose. These special tools must be used in the manner described, whenever specified in the instructions.

1. Before starting a vehicle, always be seated in the driver’s seat, place the transmission in neutral, be sure that parking brakes are set, and disengage the clutch.

SAFETY INFORMATION

2. Before working on a vehicle, place the transmission in neutral, set the parking brakes, and block the wheels.

3. Before towing the vehicle, place the transmission in neutral and lift the rear wheels off the ground, or disconnect the driveline to avoid damage to the transmission during towing.

REMEMBER,

SAFETY . . . IS NO ACCIDENT!

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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.

The following list of general shop safety practices can help technicians avoid potentially hazardous situations and reduce the risk of personal injury. DO NOT perform any services, maintenance procedures or lubrications until this manual has been read and understood.

앫 Perform all service work on a flat, level

surface. Block wheels to prevent vehicle from rolling.

앫 DO NOT wear loose fitting or torn clothing.

Remove any jewelry before servicing vehicle.

앫 ALWAYS wear safety glasses and protective

shoes. Avoid injury by being aware of sharp corners and jagged edges.

앫 Use hoists or jacks to lift or move heavy

objects.

앫 NEVER run engine indoors unless exhaust

fumes are adequately vented to the outside.

앫 Be aware of hot surfaces. Allow engine to

cool sufficiently before performing any service or tests in the vicinity of the engine.

앫 Keep work area clean and orderly. Clean up

any spilled oil, grease, fuel, hydraulic fluid, etc.

앫 Only use tools that are in good condition,

and always use accurately calibrated torque wrenches to tighten all fasteners to their specified torques. In instances where procedures require the use of special tools which are designed for a specific purpose, use only in the manner described in the instructions.

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EXPLANATION OF NUMERICAL CODE

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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. The new reference system will help link the information contained in this publication with related information included in other MACK service/warranty publications, such as associated service bulletins, warranty manuals, and the TS477 Service Labor Time Standards Manual.

The system is based on a numerical code first digit of which identifies the general component grouping as listed here:

GROUP 000 — INSPECTIONS GROUP 100 — CHASSIS GROUP 200 — ENGINE GROUP 300 — CLUTCH, TRANSMISSION,

TRANSFER CASE AND PTO

, the

GROUP 400 — STEERING, AXLES, WHEELS

AND TIRES, DRIVELINE

GROUP 500 — BRAKES, AUXILIARY

SYSTEMS GROUP 600 — CAB, TRUCK BODY GROUP 700 — ELECTRICAL

The second two digits of the 3-digit code are used to identify the system, assembly or subassembly, as appropriate, within each of the groupings. The codes applicable to this publication are shown at the TOP OF EACH PAGE and at SECTION HEADINGS, as necessary, and may also appear in the TABLE OF CONTENTS, to guide you to specific component information.

Additionally, a two-character alpha code (i.e. [NV] RINGS, PISTON) is shown with each operation. This alpha code, in combination with the three-digit Group number, identifies the specific assembly, subassembly or part, and directly relates to the first five positions of the operation code listed in the Service Labor Time Standards Manual, TS477.

Examples:

Base Operation

Cylinder Block Moving Parts

Rings, Piston

MACK E7

Replace (one piston)

212 NV 2J 53

200976a

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ABOUT THIS MANUAL

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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. Torque values are also included in the text, eliminating the need to refer to the Fits and Limits chart each time a specified torque value is required. The Special Tools list has been revised to include new special tools. Warnings, cautions, notes and service hints help the technician service the engine safely and efficiently.

The ENGINE DISASSEMBLY section shows how to remove components in an order that requires the least amount of handling. It includes brief component descriptions and information needed to properly service that component.

The BENCH PROCEDURES section guides the technician in disassembly, cleaning, inspection and assembly of each component. It also helps in determining if the part is serviceable or should be replaced. This section alerts the user to component upgrades and helps the technician to decide whether to use the latest available parts or reinstall existing parts. Precise descriptions aid in component identification.

The ENGINE ASSEMBLY section includes stepby-step procedures for reassembling the engine. This helps to ensure proper installation and longer service life.

The SETUP AND ADJUSTMENTS section has the latest setup information, complete with charts showing necessary data for adjusting all E7 engine models. Engines perform best and conserve fuel most efficiently when adjusted properly.

Two additional sections are included as guides for removing and reinstalling the engine. Both sections are generic in nature. E7 engine installation procedures vary from one vehicle style to another. These procedures are intended as a checklist to remind the technician of all necessary tasks.

While troubleshooting procedures are similar for most diesel engines, this manual includes only those that pertain to the E7 engine. The TROUBLESHOOTING section contains questions to help the technician consider all possible problem sources.

This service manual has been revised to include all applicable active service bulletins and service letters since publication of the earlier E7 Service Manual (October 1992).

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TABLE OF CONTENTS

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TABLE OF CONTENTS

SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Advisory Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv

Service Procedures and Tool Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

EXPLANATION OF NUMERICAL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

EXPLANATION OF 3-DIGIT NUMERICAL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ix

200 GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

ENGINE MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Engine Information Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

LUBRICANTS AND SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

OVERHAUL PART REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

200 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Improved Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Engine General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Engine Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Good Shop Practice — Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Performance Specifications (Oil Pressure and Intake Manifold Temperature) . . . . . . . . . . . . 2-4

FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Fastener Selection and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Fastener Sizes and Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Torque Specifications for Critical Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Torque Specifications for Hose Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Torque Specifications for Pipe Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Torque Specifications for Non-Critical Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

FITS AND LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Fits and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

METRIC MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Inch Thread vs. Metric Thread Fastener Combinations Contributing to

Thread Stripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Inch Thread vs. Metric Thread Fastener Combinations Contributing to

Assembly Weakness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Incompatible Metric vs. Metric Fastener Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Special Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

V-MAC Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

200 ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Vehicle Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

200 ENGINE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

[219 EV] CENTRI-MAX™ AND SPIN-ON FILTER ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

MOUNTING ENGINE IN STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

[271 CB] ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

[215 HB] FAN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

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[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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

[215 NK] COOLANT MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

[215 DW & 219 EP] OIL COOLER AND OIL FILTER HOUSING ASSEMBLY . . . . . . . . . . . . . . 4-10

[215 SW] WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

[214 SD] TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

[222 KD] FUEL NOZZLE INLET TUBE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

[214 EG] EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

[213 JB] VALVE COVER AND RISER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

[213 LP, NV & LH] ROCKER ARM, VALVE YOKE AND PUSH ROD . . . . . . . . . . . . . . . . . . . . . 4-14

[222 KG] NOZZLE HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Special Tool Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

[213 EV] CYLINDER HEAD ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

[212 RB & RH] VIBRATION DAMPER AND CRANKSHAFT HUB . . . . . . . . . . . . . . . . . . . . . . . 4-17

[261 CK] AIR COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

[221 GP] INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

[221 CD] ECONOVANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

V-MAC Equipped Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

[211 NB] OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

[219 MU] OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

[211 RP] TIMING GEAR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

[212 CV] AUXILIARY DRIVESHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

[213 CH] CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

[212 NP & LQ] PISTON AND CONNECTING ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 4-25

[212 UC] FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

[211 HD] FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

[211 JA] MAIN BEARING CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

[212 HP] CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

[219 RV] PISTON COOLING SPRAY NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

[212 NC] CYLINDER SLEEVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

Special Tool Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

200 BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

[211 DB] CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Cylinder Sleeve Counterbore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

[212 CV] AUXILIARY DRIVESHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

[212 LP] CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Wrist Pin Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

[212 HP] CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

[212 HA] Crankshaft Dowel Pin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

[212 HV] Crankshaft Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

[212 UB] FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

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[212 NP] PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

[212 NV] PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Keystone Ring Groove Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

[212 LP & NP] CONNECTING ROD ASSEMBLY TO PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

[213 CH] CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

[213 EV] CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

[213 NB] Inlet and Exhaust Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

[213 EX] Cylinder Head Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

[213 EH] Fire Ring Groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

[213 EP] Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

[213 FB] Inlet and Exhaust Valve Seat Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

[213 MB] Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

[213 GB] Injection Nozzle Holder Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

[213 FH] Valve Yoke Guide Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

[213 FP] Cylinder Head Cup Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

Cylinder Head Pipe Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

[213 NB] INLET AND EXHAUST VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

Valve Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

Inlet and Exhaust Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45

[213 LV] VALVE ROCKER ARM SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

Valve Rocker Arm Shaft Assembly (Except Jacobs Engine Brake) . . . . . . . . . . . . . . . . . . . . 5-47

Valve Rocker Arm Shaft Assembly (with Jacobs Engine Brake) . . . . . . . . . . . . . . . . . . . . . . 5-49

Dynatard Engine Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51

[266 KD] DYNATARD ENGINE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51

Dynatard Overload Protection (E7 Engines with Dynatard) . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51

Dynatard Overload Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

[266] JACOBS쏐 ENGINE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

[266] ENGINE BRAKE SWITCH AND BRACKET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

Adjustment (E7 Mechanically Governed Engine with Engine Brake) . . . . . . . . . . . . . . . . . . 5-53

[215 DW] OIL COOLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55

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Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

[215 SW] WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57

[219 MU] OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58

Improved “Fast Ratio” Auxiliary Driveshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62

[221 CD] ECONOVANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62

Econovance Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62

Econovance Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64

Econovance Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64

[221 KU] INJECTION PUMP DRIVE HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64

Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65

Installation of Drive Hub (Mechanically Governed Engines) . . . . . . . . . . . . . . . . . . . . . . . . . 5-65

Installation of Drive Hub (V-MAC Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66

[222 KG] INJECTOR NOZZLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67

Nozzle Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67

200 ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

[211 DB] CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Cup Plug Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Pipe Plug Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

[213 CC] Camshaft Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

[212 CB] Auxiliary Driveshaft Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

[212 NC] CYLINDER SLEEVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

[219 RV] PISTON COOLING SPRAY NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Piston Cooling Nozzle Spray Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

[211 HA] CYLINDER BLOCK DOWEL PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

[212 HP] CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

[212 HH] MAIN BEARING CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Special Tool Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

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[212 NP & 212 LP] PISTONS AND CONNECTING RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

[211 HD] FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

Dowel Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

Capscrews (Flywheel Housing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

[212 JH] CRANKSHAFT WEAR RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

Wear Ring with Double-Lip Teflon Seal (Automatic Transmission) . . . . . . . . . . . . . . . . . . . . 6-32

[212 JH] CRANKSHAFT REAR OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

[212 VC] FLYWHEEL (E7 ENGINE WITHOUT POINTER ON TIMING COVER) . . . . . . . . . . . . 6-35

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

[213 CH] CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

Installation (Engine in Stand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

Installation (Engine in Chassis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39

[212 CV] AUXILIARY DRIVESHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

[219 MU] OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43

[211 RP] TIMING GEAR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

[211 SB] TIMING GEAR COVER SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

Special Tool Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

[221 GP] FUEL INJECTION PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

[212 RH] CRANKSHAFT HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

[212 RB] VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

[211 NB] OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

Description (Isolating Oil Pan Gasket on E7 Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46

Oil Pan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

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[213 EV] CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52

[222 KG] NOZZLE HOLDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55

Special Tool Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55

[213 LH] VALVE LIFTER PUSH RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58

[213 NV] VALVE YOKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58

[213 LP] ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59

Installation (Non-Brake and Dynatard Equipped Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59

Installation (Jake Brake-Equipped Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-59

Brake Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60

[213 JB] VALVE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61

[214 EG] EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62

[215 NK] COOLANT MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64

[261 CK] AIR COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65

[221 CD] ECONOVANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66

[221 GP] FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66

[222 KD] FUEL NOZZLE INLET TUBE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70

[214 SC] TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72

Installation (Includes Pre-Lubing Procedures) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72

[215 NU, NG & LD] THERMOSTAT, THERMOSTAT HOUSING, THERMOSTAT SEAL

AND COOLANT CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73

[214 HD] AIR INLET MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75

[231 PB] FUEL FILTER ADAPTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75

[215 SW] WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76

[215 DW & 219 EP] OIL COOLER AND OIL FILTER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77

Assembling a New Oil Filter Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78

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[271 CB] ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80

Fan Belt(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-80

200 SETUP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

[213 NB] VALVE YOKE AND VALVE LASH ADJUSTMENTS

(NON-JAKE BRAKE ENGINE AND DYNATARD EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Special Tool Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Locating and Marking Flywheel Valve Adjustment Markings . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Valve Yoke Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Inlet Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Exhaust Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Continuation of Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

[213 NB] VALVE YOKE, VALVE LASH AND SLAVE PISTON ADJUSTMENTS

(JACOBS BRAKE ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Housing Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Valve Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Slave Piston, Inlet Valve and Exhaust Valve Lash Adjustments . . . . . . . . . . . . . . . . . . . . . . . 7-9

Inlet Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Exhaust Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Slave Piston Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Continuation of Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

[221 GP] INJECTION PUMP FIXED-TIMING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Setting Static Fuel Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Fuel Injection Pump Driven Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

Checking Pump-to-Engine Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Fuel Injection Pump Access Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Fuel Injection Pump Pre-Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

Timing Event Marker (TEM) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

[212 NP] LOCATING PISTON TOP DEAD CENTER (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

E7 Series Engines with Front Timing Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

Special Tool Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

Locating Piston TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

200 ENGINE INSTALLATION & TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Removing Engine from Engine Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Engine Installation into Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Filter Element Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

FINAL PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Engine Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

REBUILT ENGINE RUN-IN PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Run-In Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

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[233 FA] CHASSIS-MOUNTED CHARGE AIR COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Special Tool Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

CMCAC Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

CMCAC Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Restriction Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Core Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

CMCAC Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

200 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

CAMSHAFT TIMING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

CAMSHAFT LOBE LIFT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

PROPER FIRE RING/CYLINDER SLEEVE-TOP COMBINATIONS . . . . . . . . . . . . . . . . . . . . . . 9-11

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

Engines Built Prior to 1993 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

Engines Built from June 1993 to Present (3L Serial Number and Later) . . . . . . . . . . . . . . . . 9-12

Cylinder Head and Cylinder Block Leak Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13

200 APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

E7 ENGINE SERIAL NUMBERS, JACOBS BRAKE APPLICATION . . . . . . . . . . . . . . . . . . . . . . 10-2

E7 LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

E7 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

TABLE OF CONTENTS

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NOTES

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200 GENERAL INFORMATION

GENERAL INFORMATION

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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. Each section contains detailed procedures that must be followed in the order specified. If a step calls for a procedure that has already been described earlier in the manual, you will be referred to the section where the original procedure appeared. This manual covers the overhaul of an engine once it is removed from the vehicle, but also gives instructions for removing the engine from a nonspecified chassis.

The new E7 is the most fuel-efficient diesel engine MACK has ever produced. This engine provides higher horsepower ratings, better fuel economy, increased durability and improved serviceability. In addition, the E7 still easily meets all applicable emissions standards. All this, coupled with the latest manufacturing techniques and equipment, makes the new E7 the highestquality MACK engine ever made.

Externally, all E7 engine models look the same. However, Mack Trucks, Inc. has made many major internal design changes to comply with current and future EPA emission standards. To properly identify the E7 engine model year, refer to the engine information plate and the following pages of this section for additional engine plate information.

200600a

Figure 1 — 3/4 View E7, Front, Left

Page 1-2

3/4 VIEW E7

200333a

Figure 2 — 3/4 View E7, Front, Right

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200 GENERAL INFORMATION

ENGINE MODEL IDENTIFICATION

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. The engine is also identified by the serial number stamped into the cylinder block above the timing cover on early engines, or on the pad just to the rear of the air compressor on later engines.

For some current MACK engines, the engine information plate also includes pertinent emissions characteristics of NO unique to that engine.

A given MACK engine may meet federal emission regulations in 49 states (excluding California) or an engine may meet emission regulations of all 50 states (including California). To determine which regulations a given engine meets, refer to the engine information plate. If the engine plate has a series of dashes in the long upper-left block, and two dashes in the CALIF. FAMILY block, the engine does not meet California regulations.

and particulates

Figure 3 — Engine Information Plates

New Engine Information Plate

The following explanations are provided to aid in interpreting some of the key information found on the new engine information plate (effective late

1996). Refer to Figure 1-4.

Block 1 — U.S. EPA Regulations

앫 An “X” in block one means the engine meets

United States EPA regulations for the year stamped in block No. four.

앫 Two dashes in block one indicates the

engine does not meet United States EPA regulations for the year stamped in block No. four. This is only permissible with certain export engines. All domestic engines will have an “X” in block one.

Block 2 — California Regulations

앫 An “X” in block two indicates the engine

meets California emissions regulations for the year stamped in block No. four. This engine is referred to as a “50-state” engine and can be sold in any state throughout the U.S.

앫 Two dashes stamped in block two means

the engine does not meet California emissions regulations. If an engine has an “X” in block one and two dashes in block two, it is referred to as a “49-state” engine, meaning it is not certified for sale in California.

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200 GENERAL INFORMATION

Block 3 — ADR Regulations

앫 An “X” in block three means the engine has

been certified to meet Australian emissions regulations.

앫 Two dashes in block three means the engine

does not meet Australian emissions regulations.

Block 4 — Model Year

앫 The four-digit numeral stamped in block four

represents the year in which the engine was certified.

Block 5 — Federal Family

앫 A two-digit numeral stamped in block five

denotes the Federal Family to which the engine belongs, for emissions certification purposes.

앫 All domestic engines will have a two-digit

Federal Family number in block five.

Block 6 — California Family

앫 If the engine meets California emissions

regulations, the same two-digit numeral stamped in the Federal Family block is stamped in the California block.

앫 If the engine does not meet California

emissions regulations, there will be two dashes in block six.

Block 7 — Initial Injection Timing

앫 Block seven indicates the initial setting for

E7 injection timing.

앫 E7 EUP (E-Tech™) engines do not have an

initial injection timing, as this is controlled electronically. E-Tech™ engines have “NA” stamped in block seven.

Block 8 — Engine Brake

앫 This block is only used when the engine is

equipped with a Jake Brake. The stamping in this block indicates the Jake Brake slavepiston lash setting.

Page 1-4

Figure 4 — Engine Information Plate

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LUBRICANTS AND SEALANTS

200 GENERAL INFORMATION

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.

Location Sealant or Lubricant

Cup plugs/threaded plugs Loctite 277 or equivalent/Teflon thread sealer

Injection nozzle holder inserts (upper and lower end) Loctite 620

Camshaft gear assembly Loctite 609

Timing gear cover

Timing event marker with jam nut

Oil filter sealing gasket Clean engine oil

Holding metal parts in place

Valve stems

Engine parts, fasteners (sides and threads), and washers Clean engine oil

Cylinder sleeve upper crevice seal (on sleeve) Ethylene glycol or propylene glycol

Cylinder sleeve seat

Oil cooler assembly Permatex gasket sealer

Oil cooler assembly O-ring Drydene No. 4000

O-rings (except as noted) MACK O-ring lubricant part No. 243SX41

Chassis-mounted charge air cooling system (core sealing)

Engine oil pressure sensor

Intake manifold temperature sensor

Coolant temperature sensor

Coolant level sensor

Fuel injection pump actuator connector

Fuel injection pump driven gear access cover

Econovance

Crankshaft flange and wear ring Loctite 609

Turbocharger mounting nuts Fel Pro C5A

 drive coupling bolt threads Loctite 242

MACK Silastic (RTV Silicone Adhesive Sealant) part No. 342SX32

MACK MG-C grease or petroleum jelly (Vaseline)

MACK Silastic (RTV Silicone Adhesive Sealant) part No. 342SX32

Dow Corning No. 1200 primer, Dow Corning RTV 734 adhesive (clear), and naphtha solvent or equivalent

Sealing compound on threads

O-ring lube Lubrizol No. OS-50044 or equivalent

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200 GENERAL INFORMATION

OVERHAUL PART REPLACEMENT

Use genuine MACK parts at all times. Parts that are typically replaced during an engine overhaul are listed below:

앫 Gaskets and seals

앫 Bearings and bushings

앫 Pistons (aluminum) and piston rings

앫 Cylinder sleeves

앫 Cylinder block cup plugs and cylinder head

cup plugs

앫 Connecting rod capscrews

Steel top pistons should not be replaced without first inspecting them for excessive wear or other damage. Clean, inspect and measure pistons to determine need for replacement.

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200 SPECIFICATIONS

SPECIFICATIONS

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200 SPECIFICATIONS

SPECIFICATIONS

higher horsepower ratings and future emission standards. These changes require increased displacement, higher peak cylinder pressures

Improved Design

Compared to earlier designs, the E7 engines include improvements required to accommodate

and a superior engine cooling system. This was all accomplished without a substantial change in engine weight.

Engine General Specifications

Characteristic Description

Weight (wet*) 2300 lbs. (1043.3 kg)

Weight (dry) 2210 lbs. (1002.5 kg)

Displacement 728 cu. in. (12L)

Bore and stroke 4-7/8 x 6-1/2 in. (123.83 x 165.10 mm)

Engine oil capacity 33.5 qts. (32L)

Coolant capacity 13 qts. (12.3L)

Compression ratio 16.5:1 (up to 375 hp); 15.3:1 (375 hp and above)

Fasteners and threads Metric and English

*Wet includes oil and coolant

Engine Features

Component Description

Cylinder block Alloyed gray cast iron

Main bearing caps Ductile iron, intermediate supported with buttress screws to prevent bulkhead

movement

Flywheel housing Standard — Aluminum, standard SAE No. 1, precision doweled

Optional — Ductile iron

Cylinder sleeves Wet/dry, replaceable, centrifugally cast, alloyed cast iron

Cylinder sleeve seal Teflon-coated AFLAS/EPDM, intolerant of oil (use glycol for installation

Cylinder heads Alloy gray cast iron; four valves per cylinder, two cylinder heads per engine

Cylinder head gaskets

— Body Nonasbestos material with a steel core (two per engine)

— Fire ring Steel, six per engine

Piston assembly Refer to Tune-Up Specifications manual.

Pistons (1989–1990) Aluminum alloy, Ni-resist insert top two grooves, steel insert third groove, oval

Pistons (1991 and later) Two-piece, top crown material steel, aluminum alloy skirt, three-ring piston

Piston rings (1989–1990)

— Compression Chrome, three per cylinder

— Oil control Chrome, one per cylinder

Piston rings (1991 and later)

— Compression Plasma, top ring; chrome, second ring

— Oil control Chrome, one per cylinder

Piston pins Full-floating, 2.25 inch (5.72 cm) diameter, full-pressure lubrication through

lubricant)

and roll burnished pin bores, continuous oil cooling

rifle-drilled holes in connecting rods

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Engine Features (Cont.)

Component Description

Connecting rods Forged steel, I-beam with tapered pin end, 35-degree cap angle, 10.4 inches

Crankshaft Drop-forged, medium carbon steel, elotherm hardened journals and fillets, eight

Bearings

— Main Steel-backed, lead-tin overlay

— Rod Steel-backed, lead-tin overlay deltawall

Vibration damper Viscous fluid filled

Camshaft Carbon steel, carburized journals and lobes, gear driven

Valves

— Inlet 30-degree face angle (before November 1996), 20-degree face angle

— Exhaust 30-degree face angle, poppet with positive rotator, two per cylinder

Valve lifters Mushroom type, durafaced (tungsten carbide)

Oil filters Spin-on, disposable (two); Centri-Max

Oil pan (isolating)

— 240GB5240M Used as either front or rear sump by reversing pan.

— 240GC5240M2 Same as 240GB5240M except for the addition of three bosses located in the

— 240GB5240M3 Same as 240GB5240M2 except it is for a rear sump

— 240GB5420M4 Used as either front or rear sump, includes five bosses to accept all variations

Air compressor Flange mounted, gear driven, engine oil lubricated, water cooled (integral to

Turbocharger Exhaust gas driven, radial flow, engine oil lubricated (Schwitzer or Garrett)

Lubrication system Full pressure, wet sump, 33.5 quart (32 L) capacity, 25,000 mile (40,225 km)

Valve seat inserts Pressed-in cylinder heads (30° inlet seat before November 1996, 20° inlet

Manifolds

— Air inlet Two-piece, six-port

— Exhaust Three-piece, six-port

— Coolant Two-piece, four-port

Injection pump Robert Bosch, P7100 fixed timing, Bosch LDA. V-MAC engines use P8500,

Injection nozzles Refer to Tune-Up Specifications manual.

Fuel filters Spin-on, disposable

Water pump Centrifugal-rotor, belt driven

Coolant conditioner Spin-on, disposable

Thermostat 180°F (82°C), with rubber seated flange seal and caged check ball

200 SPECIFICATIONS

(26.42 cm) center-to-center length

integral counterweights, 3.25 inch (8.26 cm) piston journal diameter, 4.5 inch (11.43 cm) main journal diameter

(November 1996 and later), poppet with positive rotator, two per cylinder

centrifugal filter (one)

front of oil pan, one each for oil temperature sensor, turbocharger unloader and tandem air compressor

engine coolant system) (Bendix or Holset)

highway/300 hour stop-and-go change interval, MACK approved EO-L oil.

seat after November 1996, 30° exhaust seat)

multiple plunger, flange mounted, gear driven, with variable timing by Econovance

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200 SPECIFICATIONS

Good Shop Practice — Fasteners

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. For information on 1993 V-MAC E7 engine, refer to 1993 MACK Engine Tune-Up Specifications No. 5-305ID93.

All 1992 engine models use 1991 injection nozzles except 1992 EM7-300 V-MAC with 20-degree Econovance, No. 710GB51AM. 1992 EM7-300 models with 20-degree Econovance use nozzle holder assembly No. 736GB343P4 and nozzle tip No. 114GC325P3. 1992 EM7-300 V-MAC models with 10-degree Econovance, No. 710GB416CM, use 1991 EM7-300 V-MAC injection nozzles.

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.

Metric fasteners are used on the E7 engine with a few exceptions. The exceptions are fasteners with English threads, as noted in the charts that follow.

Patchlock/Hyloc fasteners follow the same guidelines as standard fasteners.

A calibrated manual torque wrench is required to tighten the fasteners listed in the charts. Threads, washers and underhead of screws or washer face of nuts should be lubricated with engine oil, unless otherwise specified.

Some designs require individual consideration and may deviate from torque guidelines in this manual.

Performance Specifications (Oil Pressure and Intake Manifold Temperature)

Description 650 rpm (idle) 1200 rpm 1750 rpm

Oil pressure

— Cool engine 20 psi (138 kPa) 45 psi (310 kPa) 65 psi (448 kPa) —

— Warm engine 15 psi (103 kPa) 30 psi (207 kPa) 45 psi (310 kPa) —

Intake manifold temperature

*Dependent on outside air temperature and vehicle speed.

Outside air

temperature

——

Full Load

(Peak Torque rpm)

100–140°F*

(38–60°C)

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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.

Because there are so many styles of fasteners, in various sizes and quality grades, a mechanic must have a working familiarity with the fasteners commonly used in vehicles. Only in this way can the correct selection and installation of the proper fastener be ensured. Each fastener is intended to do a particular job, and is selected by the vehicle manufacturer for its suitability for that job.

Proper installation is as important as the selection of the correct fastener. Improperly installing a correct fastener is just as bad as using an incorrect one. Undertightening and overtightening both result in an improperly installed fastener. When threaded fasteners are tightened, a slight stretching of the fastener occurs, and it is this stretching that binds the assembly together. If too little tightening occurs, the slight stretching does not happen, and the joint is not clamped securely. If too much tightening occurs, the fastener will be excessively stretched, causing narrowing of the fastener and possibly breaking. Correct and consistent use of a torque wrench ensures the fasteners are properly tightened, and clamping the pieces of the assembly together.

Figure 2-1 — Fastener Grading System

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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. (Inch System) fasteners is measured by determining the number of threads per inch. The two pitches commonly used in vehicles are coarse thread, officially called Unified National Coarse (UNC), and fine thread, officially called Unified National Fine (UNF).

The pitch of metric fasteners is measured by determining the millimeters per thread. For example, a bolt with 0.8 pitch would have 125 complete threads in a 100-millimeter section (100 mm divided by 125 threads equals 0.8), and a bolt with 1.0 pitch would have 100 threads in a 100-millimeter section. Pitch may be measured directly, using a ruler and counting the threads. Also, thread pitch gauges are available for both U.S. and metric threads, which make it easy to check the pitch of a fastener.

In the U.S. system, a typical designation would be: 7/16-20 x 1. This describes a bolt that is 7/16 inch in diameter, has 20 threads per inch, and is one inch long. The metric system is similar. A typical metric designation would be: 10 x 0.8 x 25 mm. This describes a bolt that is 10 mm in diameter, has a thread pitch of 0.8 (0.8 mm per thread), and is 25 mm long.

Figure 2-2 — Fastener Dimensions

Figure 2-3 — Flanged Capscrew

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TORQUE SPECIFICATIONS

This section includes specifications for torquing all critical and standard non-critical fasteners.

Torque Specifications for Critical Fasteners

200 SPECIFICATIONS

Description

Air compressor-to-cylinder block screw 70 95

Auxiliary driveshaft gear nut (front) 300 dry 407

Auxiliary driveshaft hole cover stud nut 40 54

Auxiliary driveshaft thrust washer-to-block screw 15 20

Brake harness adapter (at cylinder head) 8a 11

Brake (Dynatard)

Brake hydraulic lash adjuster retainer nut 27a 37

Brake solenoid to adapter 8a 11

Brake solenoid adapter to rocker arm shaft 24a 33

Brake (Jacobs)

Cylinder head cover/spacer capscrews 20 27

Electrical connector 57

Engine brake hold-down capscrew 45 61

Oil supply screw 57

Rocker arm adjusting screw jam nut 40 54

Rocker arm bracket hold-down capscrew 40 54

Slave piston adjusting screw nut 17 23

Throttle switch actuating arm 55 (lb-in) 6

Yoke leveling screw jam nut 33 45

Buttress screw 90 122

Camshaft thrust washer-to-block screw 15 20

Centrifugal oil filter drain fitting stud nut 40 54

Clutch cover-to-flywheel screw 40 54

Connecting rod screw 150 203

Coolant conditioner-to-water fitting screw 15 20

Crankcase drain plug 55 75

Cylinder head breather-pipe-to-cylinder-head cover screw 15 20

Cylinder head capscrew 205 278

Cylinder head cover screw 16 22

Econovance assembly-to-cylinder block screw 40b 54b

Econovance control valve and cover plate-to-Econovance screw 180 lb-inb 20b

Econovance diagnostic port cap 125 lb-inb 14 b

Econovance thrust washer retaining screw 150 b 203b

English threads.

V-MAC applications.

Lb-Ft N•m

Torque

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200 SPECIFICATIONS

Torque Specifications for Critical Fasteners (Cont.)

Description

Engine turnover bracket screw 40 54

Exhaust manifold-to-cylinder-head stud nut

10 mm 55 dry 75

12 mm 65 dry 88

Fan drive pulley to hub 40 54

Flywheel housing-to-cylinder block screw 170 231

Flywheel-to-crankshaft screw 185 251

Fuel filter bracket-to-inlet manifold screw 35 48

Hydraulic steering pump-to-timing gear cover stud nut 40 54

Injection line clamp bracket stud nut 40 54

Injection nozzle holder clamping screw (1991 and later) 45 61

Injection nozzle holder clamping screw (1989/1990) 45 61

Injection pump driven gear hub-to-injection pump shaft nut 200 dry 271

Injection pump driven gear-to-hub screw 40 54

Injection pump housing-to-Econovance assembly-to-cylinder block screw 40b 54b

Injection pump housing-to-Econovance assembly screw 40b 54b

Injection pump driven gear-to-Econovance outer shaft 40b 54b

Injection pump mounting stud nut (mechanical pumps) 40 54

Inlet manifold-to-cylinder head screw 40 54

Injection pump access cover capscrews 30 41

Injection pump rear support

Lower bracket-to-cylinder block screw 40 b 54 b

Upper bracket-to-injection pump screw 15b 20 b

Link(s)-to-lower bracket screw 40b 54 b

Link(s)-to-upper bracket screw 40b 54 b

Injection pump-to-adapter housing screw 40b 54b

Main bearing capscrew 210 285

Nozzle fuel inlet tube clamp screw (at cylinder head) 35 47

Nozzle fuel inlet tube nut (at cylinder head) 25 34

Nozzle fuel inlet tube nut (at pump) 25 34

Oil cooler fitting-to-water pump 60 81

Oil cooler oil inlet tube screw 40 54

Oil cooler water inlet fitting screw 20 27

OC/OFT fitting-to-oil filter bracket screw 40 54

English threads.

V-MAC applications.

Lb-Ft N•m

Torque

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Torque Specifications for Critical Fasteners (Cont.)

200 SPECIFICATIONS

Description

Oil fill hole cover screw 15 20

Oil filler/tube drain-to-block screw 15 20

Oil filter bracket-to-cylinder block screw 60 81

Oil filter valve plunger spring cap 100 136

Oil pan-to-cylinder block screw 30 41

Oil pump driven gear retaining nut 60 81

Oil pump-to-cylinder block mounting screw 40 54

Oil pump housing cover screw 15 20

Oil pump inlet fitting-to-pump assembly screw 35 47

Oil pump pressure relief valve cap 80 109

Piston cooling nozzle screw 15 20

Rocker arm adjusting screw nut 40 54

Rocker arm bracket-to-cylinder head screw 40 54

Rocker arm shaft locating screw 23 a 31

Timing gear cover and front support bracket-to-cylinder block screw 70 95

Timing gear cover-to-cylinder block screw 40 54

Timing hole cover screw 40 54

Timing indicator screw 15 20

Torque drive hub retaining capscrew 15 20

Transmission-to-flywheel housing screw 40 54

Turbo oil inlet screw 15 20

Turbo oil drain screw 15 20

Turbo-to-exhaust manifold stud nut 40 54

Valve yoke screw locknut 33 45

Vibration damper hub-to-crank screw 360 488

Vibration damper-to-hub screw 45 61

V-MAC components:

Control valve mounting capscrews 15 20

Drive hub retaining capscrew 150 203

Econovance mounting capscrews 40 54

Econovance drive coupling bolt 150 203

Injection pump mounting capscrews 40 54

Injection pump access cover capscrews 30 41

Injection pump driven gear capscrews 40 54

Link-to-support bracket capscrews 40 54

English threads.

V-MAC applications.

Lb-Ft N•m

Torque

Page 2-9

5-101.bk Page 10 Friday, March 17, 2006 11:05 AM

200 SPECIFICATIONS

Torque Specifications for Critical Fasteners (Cont.)

Description

V-MAC components (cont.)

Lower support bracket-to-cylinder block capscrews 40 54

Upper support bracket-to-injection pump capscrews 15 20

Timing event marker (TEM) 22 30

V-MAC 7-pin pump connector 15 20

Bracket-to-block capscrews 40 54

Hose clamp screw 15 20

RPM/TDC (engine position) sensor (jam nut) 15 20

MPH (road speed) sensor (jam nut) 15 20

Engine oil pressure sensor 6 8

Intake manifold temperature sensor 23 31

Coolant temperature sensor 23 31

Coolant level sensor 23 31

Bulkhead connector (jackscrew) 5 7

V-MAC module connector (jackscrew) 2 3

V-MAC ELAB valve terminal nut 3 4

Fuel injection pump actuator connector 15 20

Electrical equipment panel mounting leg hardware 6 8

Electrical equipment panel accessory studs 2 3

Timing solenoid to Econovance (four bolts) 15 20

Water manifold screw 25 34

Water pump cover-to-water pump housing screw 15 20

Water pump shaft locknut 90 122

Water pump-to-cylinder block screw 60 81

English threads.

V-MAC applications.

Lb-Ft N•m

Torque

Torque Specifications for Hose Clamps

Hose Clamps

Lb-In N•m

SAE J536 Type F

Air inlet systems 38 4

Water or coolant systems 28 3

Oil drain systems 28 3

Hi-torque heavy-duty worm clamp 80 9

T-bolt type hose clamp 50 6

NOTE: The band of any hose clamp in all installations should be a minimum of 0.090 inch (2.290 mm) from the end of the hose

and must be clear of tube bead.

Page 2-10

Torque

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

Torque Specifications for Pipe Plugs

200 SPECIFICATIONS

Pipe Plugs

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

sealant with Teflon or equivalent.

Lb-Ft N•m

Torque Specifications for Non-Critical Fasteners

PROPERTY CLASS 8.8

Size (mm) Pitch

60.7568

61.0068

81.001520

81.251419

10 1.25 30 41

10 1.50 28 38

12 1.25 55 75

12 1.75 50 68

14 1.50 86 117

14 2.00 80 109

16 1.50 133 180

16 2.00 124 168

18 1.50 193 262

18 2.50 172 233

20 1.50 270 366

20 2.50 244 331

22 1.50 365 495

22 2.50 332 450

24 2.00 459 622

24 3.00 421 571

27 2.00 666 903

27 3.00 618 838

30 2.00 928 1258

Tightening Torques

Lb-Ft N•m

Torque

PST pipe thread

Page 2-11

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 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

Size (mm) Pitch

60.75710

61.0068

81.001622

81.251520

10 1.25 33 45

10 1.50 31 42

12 1.25 59 80

12 1.75 54 73

14 1.50 94 127

14 2.00 87 118

16 1.50 144 195

16 2.00 135 183

18 1.50 210 285

18 2.50 187 254

20 1.50 293 397

20 2.50 264 358

22 1.50 395 536

22 2.50 360 488

24 2.00 498 675

24 3.00 456 618

27 2.00 722 979

27 3.00 669 907

30 2.00 1005 1363

30 3.50 908 1231

33 2.00 1355 1837

33 3.50 1235 1674

36 3.00 1681 2279

36 4.00 1587 2152

Tightening Torques

Lb-Ft N•m

Tightening Torques

Lb-Ft N•m

Page 2-12

5-101.bk Page 13 Friday, March 17, 2006 11:05 AM

Torque Specifications for Non-Critical Fasteners (Cont.)

PROPERTY CLASS 10.9

200 SPECIFICATIONS

Size (mm) Pitch

60.75912

61.00811

81.002129

81.252027

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 1.50 505 685

22 2.50 460 624

24 2.00 636 862

24 3.00 583 790

27 2.00 922 1250

27 3.00 855 1159

30 2.00 1284 1741

30 3.50 1159 1571

33 2.00 1730 2346

33 3.50 1578 2140

36 3.00 2146 2910

36 4.00 2027 2748

Tightening Torques

Lb-Ft N•m

Page 2-13

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

AUXILIARY DRIVESHAFT (CAPTURED THRUST WASHER)

Shaft bushing — presized ID (front and rear) 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. 58.699–58.725 mm

— press fit in bore (front and rear) 0.002–0.0045 in. 0.0518–0.1143 mm

Shaft end play 0.003–0.012 in. 0.076–0.305 mm

Shaft journal to bushing (front and rear) 0.0020–0.0072 in. 0.0508–0.1829 mm

Shaft journal diameter OD (front and rear) 2.061–2.062 in. 52.349–52.375 mm

Oil pump driving gear ID (press fit) 1.6255–1.6250 in. 41.2877–41.2750 mm

Auxiliary shaft oil pump drive journal 1.6278–1.6272 in. 41.3461–41.3309 mm

Air compressor drive sprocket (press fit) 1.1250–1.242 in. 28.575–31.547 mm

Auxiliary shaft air compressor sprocket journal 1.1272–1.1268 in. 28.6309–28.6207 mm

CAMSHAFT

Bushing — presized ID (No. 1 through No. 7) 2.693–2.692 in. 68.402–68.377 mm

— free OD (No. 1 through No. 7) 2.8785–2.8765 in. 73.1139–73.0631 mm

— bore in block (No. 1 through No. 7) 2.874–2.873 in. 73.000–72.974 mm

— press fit in bore (No. 1 through No. 7) 0.0025–0.0055 in. 0.0635–0.1397 mm

End play 0.003–0.012 in. 0.076–0.305 mm

Journal diameter (No. 1 through No. 7) 2.6895–2.6885 in. 68.3133–68.2879 mm

Journal-to-bushing clearance (No. 1 through No. 7) 0.002–0.004 in. 0.051–0.102 mm

Camshaft gear bore ID 1.8758–1.8750 in. 47.6453–47.6250 mm

Camshaft gear journal (press fit) 1.8784–1.8779 in. 47.7114–47.6987 mm

Camshaft gear driving injection pump drive (press fit) 1.8135–1.8125 in. 46.0629–46.0375 mm

Camshaft gear driving journal 1.8159–1.8153 in. 46.1239–46.1086 mm

CONNECTING ROD

Length between centers 10.4375 in. 26.5113 cm

Cap angle 35 degrees

Bore for bushing 2.4355–2.4345 in. 61.8617–61.8363 mm

Burnish bushing to 2.2305–2.2275 in. 56.6547–56.5785 mm

Finish bore to 2.2504–2.2500 in. 57.1602–57.1500 mm

Crankpin bore diameter — as bored 3.4305–3.4297 in. 87.1347–87.1144 mm

— reassembled 3.4309–3.4294 in. 87.1449–87.1068 mm

Bearing ID in place 2.9993–3.0013 in. 76.1822–76.2330 mm

Journal clearance 0.0012–0.0054 in. 0.0305–0.1372 mm

Standard Size or Fit

English Metric

Page 2-14

SECT2.FR5 Page 15 Tuesday, March 21, 2006 12:43 PM

Fits and Limits (Cont.)

200 SPECIFICATIONS

Component

CONNECTING ROD (CONT.)

Side clearance 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

CRANKSHAFT

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

Main journal OD 4.4974–4.4964 in. 114.2340–114.2086 mm

Journal out-of-round or taper (maximum diameter) 0.00035 in. 0.00889 mm

Max. Runout at No. 4 journal (shaft supported on No. 1 and No. 7) 0.007 in. 0.178 mm

CYLINDER BLOCK

Deck flatness 0.002 in. 0.0508 mm

Dowel pin holes (flywheel housing to block mounting) 0.6237–0.6247 in. 15.8420–15.8674 mm

Cylinder bore in block — upper 5.501–5.500 in. 139.725–139.970 mm

— lower 5.1266–5.1250 in. 130.2156–130.1750 mm

Cylinder bore out-of-round or taper on diameter

For service block only — maximum on reboring block:

0.001 inch (0.0254 mm).

Sleeve, flange channel depth above block deck (do not measure from top of bead)

Sleeve OD at upper pilot diameter 5.5040–5.5030 in. 139.8016–139.7762 mm

Sleeve bead for fire ring — protrusion above sleeve channel 0.0067–0.010 in. 0.1702–0.2540 mm

Sleeve in bore — upper press fit 0.004–0.002 in. 0.1016–0.0508 mm

— lower loose fit 0.0029–0.0003 in. 0.0737–0.0076 mm

Sleeve ID installed STD — minimum 4.8755 in. 123.8377 mm

— maximum 4.877 in. 123.8758 mm

Main bearing bore in block 4.818–4.817 in. 122.3772–122.3518 mm

Main bearing-to-crankshaft journal clearance 0.0022–0.0056 in. 0.0559–0.1422 mm

Main bearing ID in place 4.502–4.4996 in. 104.3508–114.2898 mm

Valve lifter bore 0.6865–0.6875 in. 17.4371–17.4625 mm

Valve lifter shank diameter 0.6855–0.6860 in. 17.4117–17.4244 mm

Valve lifter OD 1.380–1.385 in. 35.052–35.179 mm

Valve lifter to bore clearance 0.0005–0.0020 in. 0.0127–0.0508 mm

NOTE: Extension of the cylinder sleeve above the cylinder block deck can vary under the same head, as long as all are

within the 0.022–0.027 inch specification.

CYLINDER HEAD

Alignment across exhaust ports 0.005 in. 0.127 mm

Deck flatness over 18 in. (45.72 cm) 0.0015 in. 0.0381 mm

Overall height 6.391–6.397 in. 162.331–162.484 mm

0.004 in. max. 0.1016 mm

0.022–0.027 in 0.5588–0.6858 mm

Standard Size or Fit

English Metric

Page 2-15

5-101.bk Page 16 Friday, March 17, 2006 11:05 AM

Fits and Limits (Cont.)

200 SPECIFICATIONS

Component

CYLINDER HEAD (CONT.)

Injection nozzle holder insert to bore fit — upper and intermediate 0.001–0.003 in. tight 0.0254–0.0762 mm

— lower 0.0015–.004 in. tight 0.0381–0.1016 mm

Injection nozzle holder insert bore — upper and intermediate bore 0.9360–0.9375 in. 23.7744–23.8125 mm

— bottom bore 0.904–0.906 in. 22.962–23.012 mm

Injection nozzle holder insert OD — 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 0.005–0.013 in. 0.127–0.330 mm

— ID 5.137–5.139 in. 130.479–130.531 mm

Valve guide OD 0.6886–0.6881 in. 17.4904–17.4777 mm

Valve guide ream ID (after installation)

inlet and exhaust (used with 3/8 valve stem)

Top end of valve guide to valve spring seat 0.959 ± 0.040 in. 24.359 ± 1.016 mm

Valve guide bore in head 0.686–0.687 in. 17.424–17.450 mm

Valve guide to bore (press fit) 0.0011–0.0026 in. 0.0279–0.0660 mm

Valve guide extension (fire deck to top of guide) 5.24 ± 0.03 in. 113.096 ± 0.762 mm

Yoke guide pin OD 0.4389–0.4392 in. 11.1481–11.1557 mm

Yoke guide pin installed height 1.848–1.918 in. 46.939–48.717 mm

Valve seat width — exhaust

— inlet

Valve seat insert face angle

Before November 1996 — inlet and exhaust 30° – 0 November 1996 and later — inlet 20° 30' ± 15'

— exhaust 30° – 0'/+30'

Valve seat width runout 0.001 in. F.I.M. 0.0254 mm

Valve seat insert counterbore diameter — exhaust 1.6875–1.6885 in. 42.8625–42.8879 mm

— inlet 1.8285–1.8295 in. 46.4439–46.4693 mm

Valve seat OD — exhaust 1.692–1.693 in. 42.977–43.002 mm

— inlet 1.831–1.832 in. 46.507–46.533 mm

Valve seat insert press fit in head — exhaust 0.0035–0.0055 in. 0.0889–0.1397 mm

— inlet 0.0015–0.0035 in. 0.0381–0.0889 mm

Valve seat counterbore depth — exhaust 0.372–0.376 in. 9.449–9.550 mm

— inlet 0.360–0.364 in. 9.144–9.246 mm

0.3745–0.3755 in. 9.5123–9.5377 mm

0.051–0.081 or 1/16 ± 1/64 in.

Standard Size or Fit

English Metric

1.295–2.057 mm or

1.588 ± 0.397 mm

1.295–2.057 mm or

1.588 ± 0.397 mm

'/+30'

Page 2-16

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

Fits and Limits (Cont.)

200 SPECIFICATIONS

Component

FLYWHEEL AND HOUSING

Dowel pins

Hole in flywheel housing — LH for round pin 0.6259–0.6263 in. 15.8979–15.9080 mm

— RH for diamond pin 0.6831–0.6835 in. 17.3507–17.3609 mm

— RH for blade pin

Pin OD — LH round pin 0.6251–0.6253 in. 15.8775–15.8826 mm

— RH diamond pin

— RH blade pin

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. T.I.R.* 0.2032 mm*

Flywheel housing transmission pilot bore runout 0.010 in. T.I.R.* 0.254 mm*

Flywheel housing rear seal bore runout 0.009 in. T.I.R.* 0.2286 mm*

Starter motor mounting bore 3.625–3.629 in. 92.075–92.117 mm

* Must be held relative to main bearing bores. Check runout with an alignment bar installed through the cylinder block main

bearing bores.

OIL PUMP

Gear-to-cover end clearance 0.0035–0.0060 in. 0.0889–0.1524 mm

Gear-to-cavity side clearance 0.0030–0.0045 in. 0.0762–0.1143 mm

Gear backlash in pump 0.0235–0.0295 in. 0.5969–0.7493 mm

Oil pump drive gear-to-oil pump driven gear backlash 0.0072–0.0138 in. 0.1829–0.3505 mm

Relief valve spring, free length 6.38 in. 162.052 mm

Spring pressure when compressed to 5.56 inches (14.12 cm) 63 lbs. 28.6 kg

Relief valve opening pressure 90–115 psi 621–793 kPa

OIL PRESSURE RELIEF VALVE

Oil filter bypass relief valve spring, free length 4.648 in. 118.06 mm

Spring pressure when compressed to 3.625 inches (9.27 cm) 12.27 ± .61 lbs. 5.57 ± .28 kg

PISTON

Top, extension above cylinder block deck at TDC (–)0.002 – (+)0.020 in. 0.0508–0.508 mm

Wrist pin — pin bore hole ID (vertical direction only) 2.2491–2.2497 in. 57.1271–57.1424 mm

— length 3.820–3.825 in. 97.028–97.155 mm

— pin to bushing clearance 0.0002–0.0009 in. 0.0051–0.0229 mm

— OD 2.24875–2.24895 in. 57.11825–57.12333 mm

— fit 0.00035–0.00075 in. 0.00889–0.01905 mm

Piston-to-liner clearance 90 degrees from pin axis (Zollner piston No. 240GC590A)

0.004–0.006 in. 0.1016–0.1524 mm

Standard Size or Fit

English Metric

Page 2-17

5-101.bk Page 18 Friday, March 17, 2006 11:05 AM

Fits and Limits (Cont.)

200 SPECIFICATIONS

Component

PISTON (CONT.)

Ring groove service limit over 0.120 inch pins (3.048 mm)

Top groove 4.912 in. 124.765 mm

PISTON RINGS

Piston ring end gap — when checked in 4.875 gauge diameter

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 0.1143 mm

NOTE: Refer to MACK branch or distributor for specifications for piston ring part numbers not listed above. NOTE: For every 0.001 in. (0.0254 mm) increase in gauge diameter, ring gap will increase by 0.003 in. (0.076 mm).

ROCKER ARM

Ratio 1.5:1

Hole ID 1.1306–1.1326 in. 28.7172–28.7680 mm

Hole-to-shaft clearance 0.004–0.0015 in. 0.1016–0.0381 mm

Shaft OD 1.1286–1.1291 in. 28.6664–28.6791 mm

Push rod overall length — intake and non-brake exhaust (flat to cup top)

Push rod overall length — exhaust w/Dynatard (flat to flat) 16.353–16.388 in. 415.366–416.255 mm

TIMING GEAR COVER

Dowel Pins

Holes in cylinder block (both) 0.4987–0.4997 in. 12.6670–12.6924 mm

Hole in timing gear cover — RH for round pin 0.5005–0.5012 in. 12.7127–12.7305 mm

— LH for diamond pin 0.5577–0.5584 in. 14.1656–14.1834 mm

Pin OD — RH for round pin 0.5001–0.5003 in. 12.7025–12.7076 mm

— LH for diamond pin, cylinder block end 0.5001–0.5003 in. 12.7025–12.7076 mm

— LH for diamond pin, timing cover end 0.5570–0.5575 in. 14.1478–14.1605 mm

Crankshaft seal mounting bore 3.9995–4.0025 in. 101.5873–101.6635 mm

Seal square to hub 0.010 in. 0.254 mm

Seal mounting bore-to-crank runout 0.015 in. T.I.R.* 0.381 mm*

Hydraulic steering pump mounting bore 3.2525–3.2545 in. 82.6135–82.6643 mm

* Must be held relative to main bearing bores. Check runout with an alignment bar installed through the cylinder block main

bearing bores.

TIMING GEAR

Backlash — injection pump drive gear to injection pump

driven gear

— all other gears 0.0013–0.0108 in. 0.0330–0.2743 mm

15.751–15.813 in. 400.075–401.650 mm

0.0025–0.0095 in. 0.0635–0.2413 mm

Standard Size or Fit

English Metric

Page 2-18

5-101.bk Page 19 Friday, March 17, 2006 11:05 AM

Fits and Limits (Cont.)

200 SPECIFICATIONS

Component

TURBOCHARGER

Model S3B (S4D)

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)

Model S300, S400

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

VALVE

Deck to valve face — inlet + 0.0425 ± 0.007 in. +1.0795 ± 0.1778 mm

— exhaust (pre-1994) – 0.0414 ± 0.007 in. –1.0516 ± 0.1778 mm

— exhaust (Pyromet, 1994 and later) – 0.021 ± 0.007 in. –1.5334 ± 0.1778 mm

Stem to guide — inlet 0.0015–0.0035 in. 0.0381–0.0889 mm

— exhaust 0.0025–0.0045 in. 0.0635–0.1143 mm

Stem to rocker arm lash (cold static) — inlet 0.016 in. 0.4064 mm

— exhaust (prior to May 1996) 0.024 in. 0.6096 mm

— exhaust (May 1996 and later)* 0.028 in. 0.7112 mm

*Cam part No. 454GC5205

Face runout, inlet and exhaust 0.0015 in. 0.0381 mm

Seat angle before November 1996 — inlet and exhaust 30° + 0

November 1996 and later — inlet 20° 30' ± 15'

— exhaust 30° + 0'/–30'

Stem OD — inlet (3/8 in.) 0.373–0.372 in. 9.474–9.449 mm

— exhaust (7/16 in.) 0.3720–0.3710 in 9.4488–9.4234 mm

VALVE SPRINGS

Free length 2.640 in. 67.056 mm

Spring pressure — when compressed to 1.435 in. (36.45 mm) 142.5–157.5 lbs. 64.6–71.4 kg

VALVE SPRINGS (with Jacob combination compression and exhaust brake)

Free length 2.830 in. 71.882 mm

Spring pressure — when compressed to 1.5 in. (38.1 mm) 190–210 lbs. 86.184–95.256 kg

Standard Size or Fit

English Metric

'/–30'

Page 2-19

5-101.bk Page 20 Friday, March 17, 2006 11:05 AM

200 SPECIFICATIONS

METRIC MISMATCH

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. Metric Thread Fastener Combinations Contributing to Thread Stripping

The following inch/metric screw and nut (or tapped hole) combinations can be finger started (at least two full turns), but will strip if fully assembled.

Inch Screws Metric Nuts

4-40 M3 x 0.5

5/16-18 M8 x 1.25

*5/16-24 M8 x 1.25

3/8-16 *M10 x 1.25

*3/8-24 *M10 x 1.25

M10 x 1.5

*M10 x 1.0

7/16-14 *M12 x 1.25

*7/16-20 M12 x 1.75

*M10 x 1.25

*1/2-20 M14 x 2

*5/8-18 *M16 x 1.5

*7/8-14 M24 x 3

*1-12 M27 x 3

*Fine thread

Inch Nuts Metric Screws

5-40 M3 x 0.5

1/4-20 M6 x 1.0

*1/4-28 M6 x 1.0

*5/16-24 *M8 x 1.0

7/16-14 M10 x 1.5

7/16-14 *M10 x 1.25

7/16-14 *M10 x 1.0

1/2-13 M12 x 1.75

*1/2-20 M12 x 1.75

1/2-13 *M12 x 1.5

*1/2-20 *M12 x 1.5

1/2-13 *M12 x 1.25

9/16-12 M14 x 2

*9/16-18 *M14 x 1.5

*5/18-18 *M16 x 1.5

1-8 *M24 x 2

*Fine thread

Page 2-20

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 Metric Nuts

*4-48 M3 x 0.5

5-40 M3.5 x 0.6

6-40 M3.5 x 0.6

*8-36 M4 x 0.7

*10-32 M5 x 0.8

12-24 M6 x 1.0

*1/4-28 M7 x 1.0

3/8-16 M10 x 1.5

7/16-14 M12 x 1.75

1/2-13 M14 x 2

3/4-10 M20 x 2.5

*3/4-16 *M20 x 1.5

7/8-9 M24 x 3

*Fine thread

Inch Nuts Metric Screws

*5-44 M3 x 0.5

*6-40 M3.5 x 0.6

8-32 M4 x 0.7

*8-36 M4 x 0.7

*10-32 M5 x 0.8

12-24 M5 x 0.8

*12-28 M5 x 0.8

*1/2-20 *M12 x 1.25

3/4-10 M18 x 2.5

*3/4-16 *M18 x 1.5

1-8 M24 x 3

*1-12 M24 x 2

*Fine thread

Incompatible Metric vs. Metric Fastener Systems

Thread mismatch can also result when combining fasteners from incompatible metric fastener systems. The resulting faulty thread engagement typically causes thread stripping and/or assembly weakness which may lead to service failure.

CONVERSION FACTORS

1 inch = 25.4 millimeters

1 mile = 1.61 kilometers

1 pint (U.S. liquid) = .473 liter

1 quart (U.S. liquid) = .946 liter

1 cubic inch = .01639 liter

1 pound-foot = 1.3558 Newton-meters

1 horsepower = .746 kilowatt

1 pound/square inch = 6.895 kilopascals

1 pound/square inch = 27.6 inches of water/2.04 inches of

mercury

degrees Fahrenheit = (1.8 x degrees Celsius) + 32

1 gallon (U.S. liquid) = .83267 imperial gallon

1 millimeter = .03937 inch

1 kilometer = .6214 mile

1 liter = 2.1134 pints (U.S. liquid)

1 liter = 1.0567 quarts (U.S. liquid)

1 liter = 61.024 cubic inches

1 Newton-meter = .7376 pound-foot

1 kilowatt = 1.34 horsepower

1 kilopascal = .145 pound/square inch

degrees Celsius = .556 x (degrees Fahrenheit – 32)

1 imperial gallon = 1.2009 gallons (U.S. liquid)

000068a

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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 (2.54 mm)

945-6041 Connecting Rod Fixture (Sweeney)

HT77136 Valve Seat Insert Counterbore

J 21588 Injector Gasket Retriever

J 22738-02 Universal Spring Tester, Model MST 50

J 23442 Piston Ring Compressor

J 2619-01 Slide Hammer

J 26589 Nozzle Insert Carbon Reamer

J 26637-A Thermostat Seal Installer

J 26948 Depth Gauge

J 28452 Injection Pump Drive Coupling Holder R.B.

J 28452-A Injection Pump Drive Coupling Holder

J 29109 Engine Stand

J 29294-B Valve Spring Keeper Remover

J 29296 Valve Yoke Guide Pin Installer

J 29297 Nozzle Sleeve Installer

J 29510 Keystone Piston Ring Groove Gauge

J 29539-15 Top Dead Center Indicator Metric Adapter

J 29539-A Top Dead Center (TDC) Indicator

J 29600-C Fire Ring Groove Cutter

J 29880 Nozzle Sleeve Extractor

J 34046-A Compression Gauge Adapter Set

J 34046-5 Compression Tester Metric Adapter (Used with J 34046-A)

J 34684 Cylinder Head Core Plug Installer (13/16 inch)

J 34687 Cylinder Head Core Plug Installer (1-1/16 inch)

J 35529 Wear Ring and Seal Installer

J 37077 Position Sensor

J 37078 P7100 Series Injection Pump Holding/Alignment Fixture

J 37085 Pump Drive Gear Aligner

J 37092 Dynatard Valve Lash Adjusting Wrench

J 37093 Injection Nozzle Puller

J 37481 Valve Guide Reamer (3/8-inch diameter)

J 37482 Valve Guide Remover (3/8 inch)

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Special Tool List (Cont.)

Tool No. Description

J 37710-A Timing Gear Cover Diamond Dowel Aligner

J 37711 Flywheel Housing Diamond Dowel Aligner

J 37712 Flywheel Housing/Timing Cover Locating Pin Driver

J 37713 Camshaft Bushing Installation Removal Kit (Use with J 21428-01 Kit)

J 37715-A Crankshaft Front Seal Installer

J 37716-B Crankshaft Rear Seal Installer

J 37717 Connecting Rod Bushing Remover/Installer

J 37718 Piston Pin Burnishing Broach

J 37719 Fire Ring Groove Cutter

J 37720-C Tappet Holders

J 37721-A Piston Cooling Nozzle Spray Position Set (for 1989/1990 production)

J 37809 Valve Guide Installer (3/8 inch)

J 38048 Engine Stand Adapter Plate

J 38373 Injection Pump Drive Hub Retaining Nut Socket

J 38586 Valve Seat Installation Set

J 38587-A Engine Barring Socket

J 38880 Wear Ring Installer

J 39045 Two-Piece Piston Cooling Nozzle Aimer (for 1991 and later production)

J 41071 Air Compressor Coupling Holding Wrench

J 41461 Camshaft Removal/Installation Tool

J 41473 Charge Air Cooler Tester

J 42185 Belt Tension Gauge

J 42453 Valve Seal Installer

J 5347-B Dial Bore Gauge

J 5902-01 Cylinder Hone and Glaze Breaker

J 6692-B Cylinder Compression Gauge

J 7872 Magnetic Base Indicator Tool

J 8092 Universal Driver Handle (threaded 3/4-10)

PT2210 Counterbore Tool

PT2210-14 Hex Key Wrench

PT2210-3A Counterbore Cutter Plate

PT5025 Universal Dial Depth Gauge

PT5025-11 3-inch Stylus Extension

PT5035 Flywheel Housing Dial Indicator Set

PT5035-1 Flywheel Housing Indicator Extension

PT6390 Valve Seat Extractor Tool

PT6390-4 Collet

PT6391 Valve Seat Extractor Kit

200 SPECIFICATIONS

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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. Description

J 37490 Diesel Electronic Connector Replacement Kit

J 37809 Valve Guide Installer (3/8 inch)

J 38351-B Serial Link Adapter Assembly

J 38480 Portable Printer (use with J 38500-1)

J 38500-1 Pro-Link Diagnostic Scan Tool

J 38500-60A Pro-Link Cable (to vehicle), 6-Pin Deutsch

J 38500-61 PC Interface Cable

J 38500-603A Pro-Link V-MAC I Diagnostic Cartridge

J 38500-620A Pro-Link V-MAC II Diagnostic Cartridge

J 38581 Connector, Test Adapter Kit

J 38582 Terminal Crimping and Removal Tool Kit

J 38675-C Pro-Link 9000 V-MAC Diagnostic Kit

J 38675-D V-MAC I/ITC

J 38740 V-MAC Hub Barring Tool

J 38748 V-MAC Test Lead, Seven-Pin Connector

J 39200 Fluke Model 87 Digital Multi-Meter

J 41443 Pro-Link 9000 V-MAC II Diagnostic Kit

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200 ENGINE REMOVAL

ENGINE REMOVAL

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200 ENGINE REMOVAL

GENERAL

Details of the engine removal procedure vary from one vehicle to another. This section provides general guidelines for removing the engine from the vehicle.

Before beginning engine removal, make sure all equipment is available for use and has been inspected for safety.

Vehicle Preparation

It is good practice to steam-clean the engine to remove road grime, grease and oil before starting work. Steam cleaning the engine and engine area allows more detailed inspection and improved workmanship.

Care must be used to keep moisture from entering the air intake system. If moisture does enter the system, make sure it is removed (dried out) before the engine is reinstalled.

3. 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. If vehicle is equipped with air conditioning:

a. Using A/C refrigerant recovery and

recycling equipment, recover the A/C system refrigerant.

b. Disconnect the A/C compressor

discharge hose at connection near the radiator support.

c. Disconnect the A/C line at the

receiver/dryer.

d. Locate and disengage the electrical

connector from binary pressure switch on the receiver/dryer.

e. Locate and disengage the electrical

connector from the low-pressure cutout switch in the A/C refrigerant line.

6. Disconnect the upper radiator hose from the engine coolant outlet fitting.

7. Disconnect the lower radiator hose from the coolant inlet of the oil cooler assembly.

1. Position vehicle on a flat and level surface in an area with ample work space in and around the vehicle. Ensure that a suitable lifting device is available.

2. Apply the parking brake and block the vehicle wheels to prevent vehicle from moving. Observe all safety precautions.

3. Disconnect the battery negative (ground) cable.

4. Drain the air tanks.

Engine Removal

1. Remove the hood and position it away from the work area to prevent accidents or hood damage. Refer to Hood Removal procedures in the appropriate vehicle manual.

2. Place a suitable container beneath the engine and drain engine oil and coolant. Open the coolant drain valves in the block, if applicable.

8. Remove the clamps that retain the coolant overflow tank. Remove tank.

9. Disconnect the chassis-mounted charge air cooler inlet hose at the cooler.

10. Disconnect the chassis-mounted charge air cooler outlet hose at the cooler.

11. Locate the engine coolant temperature sensor and disengage the electrical connector, if applicable. Remove sensor harness from the radiator support.

12. Remove fastener from the bracket that secures the radiator fan air clutch solenoid valve to the radiator support. Set the solenoid valve aside.

13. Remove the retaining bolts from the radiator support rods at the radiator support.

14. Obtain a lifting device (chain fall or engine hoist) and support the radiator.

15. Remove the retaining bolts from the radiator support mounts.

16. Remove the radiator from the vehicle using a lifting device and an assistant, if required.

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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. Remove the air cleaner assembly, if required.

21. Remove the exhaust bracket from the clutch, or the torque converter, flywheel housing and exhaust clamp at the turbocharger.

22. Remove power steering hoses and the reservoir, if applicable.

23. Disconnect any electrical cables or wires still connected to the starter. Remove three mounting capscrews from the mounting flange and remove the starter.

24. Support the transmission with an appropriate transmission jack.

26. Remove the hood rest crossmember(s), if applicable.

27. Obtain the appropriate lifting equipment (bar or chain) and attach to the proper lift points on the engine.

28. Position and attach the engine hoist to the lift bar or chain and place tension on the bar or chain by operating hoist.

29. Remove the clutch linkage and bracket retaining bolts (manual transmission).

30. Remove torque converter access panel and remove capscrews that secure the torque converter to the flywheel (automatic transmission).

31. Remove the retaining bolts that secure the engine mounts to the engine.

32. Obtain assistance for removal of the engine. Remove engine while watching for obstructions that interfere with its removal such as engine or chassis components, brackets, clamps or other parts still attached to the engine.

33. Refer to the ENGINE DISASSEMBLY section of this manual for procedures for mounting the engine on an engine stand.

25. Remove the retaining bolts that secure the transmission bell housing to the flywheel housing.

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NOTES

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200 ENGINE DISASSEMBLY

ENGINE DISASSEMBLY

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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.

Failure to follow the sequence of operations listed below may result in damage to components or personal injury.

[219 EV] CENTRI-MAX™ AND SPIN-ON FILTER ELEMENTS

Refer to Figure 4-1.

1. Place a suitable container below the filter element area to catch any spilled fluids.

Do not apply the filter wrench to any area other than that labeled WRENCH HERE on the Centri-Max™ filter housing, or damage to the Centri-Max™ housing will result.

2. Using a suitable filter wrench, remove the fuel and oil filter elements. Do not reuse filter elements. Discard used elements in a responsible, environmentally safe manner.

3. Loosen drain hose assembly (4) from Centri-Max™ filter housing assembly by loosening hose clamp (3) at the Centri-Max™ housing.

Figure 4-1 — Centri-Max™ Housing Removal Studs

1. Studs

2. Seal ring

3. Clamp

4. Drain hose assembly

5. Washers

6. Nuts

7. Adapter

8. O-ring

9. Centri-Max

10. Centri-Max

200326a

™ housing ™ element

4. Remove two nuts (6) and two washers (5) securing hose adapter (7) to studs (1) at the cylinder block. Discard O-ring (8).

5. Remove drain hose assembly (4).

6. Remove Centri-Max™ housing (9) and element (10). Discard seal ring (2).

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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.

The fuel and oil filter elements, as well as the Centri-Max™ assembly, must be removed before mounting the adapter plate to the engine.

200 ENGINE DISASSEMBLY

Engine stand, Kent-Moore tool number J 29109, and adapter plate J 38048, are recommended to safely support the engine during disassembly and assembly procedures.

When servicing an E7 engine with an isolating oil pan arrangement, avoid using an engine stand that supports the engine on the oil pan rail while the oil pan is still installed. Damage to the oil pan, pan gasket or the isolators may result. If this type of stand must be used and the oil pan is to remain installed, support the engine on the pads provided at each corner of the cylinder block as shown in Figure 6-56.

Special Tools Required

앫 Engine Stand J 29109

앫 Adapter Plate J 38048

Refer to Figure 4-2.

1. Using three mounting capscrews (2), secure adapter plate J 38048 (1) to the left side of the engine.

2. Secure adapter plate (1) to engine stand J 29109 (3) with six mounting capscrews (4).

3. Remove lifting device from the engine.

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200 ENGINE DISASSEMBLY

1. Adapter plate J 38048

2. Capscrews

Figure 4-2 — Mount Engine in Stand

3. Engine stand J 29109

4. Capscrew

200348a

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200 ENGINE DISASSEMBLY

[271 CB] ALTERNATOR

Refer to Figure 4-3.

1. Loosen adjusting capscrew (2) and mounting nuts (6).

2. Remove drive belts (1) and tag belts for reassembly.

3. Disconnect and tag electrical wires by removing mounting hardware.

4. Remove mounting nuts (6) and washers. Pull out capscrews (3) and remove alternator (7).

5. Remove alternator plate (5) by removing mounting hardware (4).

[215 HB] FAN ASSEMBLY

Refer to Figure 4-4.

1. Loosen eight fan assembly mounting nuts (2) and capscrews (1).

2. While supporting fan assembly (3), remove nuts (2) from capscrews (1) and remove fan assembly.

Figure 4-4 — Fan Assembly Removal

200350a

Figure 4-3 — Alternator Removal

1. Drive belt

2. Adjusting capscrew

3. Capscrew

4. Mounting hardware

5. Alternator plate

6. Mounting nuts

7. Alternator

200349a

1. Capscrew

2. Nut

3. Fan assembly

Refer to Figure 4-5.

3. If the fan assembly is equipped with a viscous drive, be sure to store the assembly either horizontally, with the fan face down (hub flange up), or vertically, as shown in Figure 4-5. This will prevent fluid leaking from the assembly.

Do not store the assembly horizontally with the fan face up (hub flange down). Fluid in the viscous drive reservoir can leak out.

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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. Fuel filter adapter assembly

2. Secondary filter fitting (out)

3. Secondary filter fitting (in)

4. Capscrews

5. Primary filter fitting (out)

6. Primary filter fitting (in)

7. Air inlet manifold

8. Mounting flange

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200 ENGINE DISASSEMBLY

[215 LD] COOLANT CONDITIONER ELEMENT

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).

Refer to Figure 4-8.

3. Place a suitable container below the coolant filter area to catch any spilled coolant.

4. Using a suitable filter wrench (J 29927 or equivalent), remove the coolant conditioner filter element (13). Discard element.

5. Remove coolant conditioner head assembly (2) from thermostat housing (5) and coolant manifold (9) by removing mounting capscrews (1).

6. Remove and discard O-ring (4).

7. Carefully remove and examine the check valve assembly (3). Examine check valve assembly by depressing the check ball. If it resists movement and does not return to its seat freely, the check valve assembly must be replaced.

200249

Figure 4-7 — Coolant Conditioner Supply Tube Removal

1. Plastic tie wrap

2. Coolant conditioner supply tube

3. Fittings

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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).

1. Capscrew

2. Coolant conditioner head assembly

3. Check valve assembly

4. O-ring

5. Thermostat housing

6. Thermostat seal

7. Thermostat

Page 4-8

Figure 4-8 — Coolant Conditioner Removal

8. Gasket

9. Coolant manifold

10. Clamps

11. Oil cooler supply tube

12. Coupling

13. Capscrew

14. Coolant conditioner filter element

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200 ENGINE DISASSEMBLY

[214 HD] AIR INLET MANIFOLD

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.

2. Remove air inlet manifold. It may be necessary to gently pry or tap the manifold lightly with a soft mallet to break the seal.

3. If the air inlet manifold is to be replaced, remove sensor (7) located on the inlet manifold (6), if installed.

[215 NK] COOLANT MANIFOLD

Refer to Figure 4-9.

1. Support the coolant manifold sections and remove 12 capscrews (5) retaining the manifold sections (1 and 4) to the cylinder heads.

2. Remove manifold assembly. It may be necessary to pry or tap lightly with a soft mallet on the housing sections to break the seal.

3. If necessary, separate the two coolant manifold sections (1 and 4) by loosening two clamps (3) and removing the coupling (2).

1. Coolant manifold, front section

2. Coupling

3. Clamp

4. Coolant manifold, rear section

5. Capscrew

Figure 4-9 — Air Inlet Manifold Removal

6. Air inlet manifold, rear section

7. Sensor

8. Air inlet manifold, front section

9. Capscrew, 12-point

200251a

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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).

2. Disconnect feed line (2) from the centrifugal filter housing fitting. Tag and cap line and fitting.

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.

3. Disconnect Centri-Max™ filter breather hose (1) by sliding hose from fitting. (For MR chassis Jake Brake applications, remove the Centri-Max™ breather filter. Clean with suitable solvent to make sure breather is clear.)

4. Remove four capscrews (3) securing oil filter feed assembly (4) to engine block.

Effective with the introduction of the S300 and S400 model turbochargers (May 1996), a new style oil inlet line is used. The line is a stainless steel braided line which replaces the conventional hose type line and steel oil inlet tube. The new oil line is connected directly to the threaded oil inlet port at the turbocharger.

Figure 4-10 — Oil Cooler Removal

1. Centri-Max™ filter breather hose (MR chassis with Jake

Brake uses breather assembly)

2. Feed line

3. Capscrew

Page 4-10

4. Oil filter feed assembly

5. Oil filter/cooler assembly

6. Turbocharger lubrication feed hose

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200 ENGINE DISASSEMBLY

[215 SW] WATER PUMP

Refer to Figure 4-11.

1. Disconnect coolant return hose to air

compressor (1) at fitting.

2. Remove three mounting capscrews (3) and

remove water pump (2).

[214 SD] TURBOCHARGER

Refer to Figure 4-12.

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. Remove turbocharger lubrication feed hose (2).

Beginning with May 1996 production, Schwitzer turbocharger models S300 and S400 replace models S3B and S4B. Service old with old and new with new. Also note that with the S300 and S400 models, a stainless-steel braided oil feed line is used.

4. Loosen four turbocharger mounting nuts (6) and remove turbocharger (1).

Figure 4-11 — Water Pump Removal

1. Air compressor coolant return line

2. Water pump

200358a

3. Capscrew

Figure 4-12 — Turbocharger Removal

1. Turbocharger

2. Lubrication feed hose

3. Capscrew

4. Lubrication drain tube

5. Clamp

6. Mounting nut

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200 ENGINE DISASSEMBLY

[222 KD] FUEL NOZZLE INLET TUBE ASSEMBLY

Refer to Figure 4-13.

1. Loosen six tube sleeve nuts (6) at the injection pump. Be careful to avoid twisting lines while loosening nuts.

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.

Figure 4-13 — Fuel Inlet Tube Assembly Removal

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. Oil filler feed tube

8. Oil filler feed tube bracket

9. Capscrew

10. Exhaust manifold

11. Capscrew

200353a

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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.

Refer to Figure 4-16.

1. Remove valve covers (3) by removing six retaining capscrews (4 and 5) from each cover.

2. Discard seals.

Refer to Figure 4-15.

3. If a Jake Brake is installed, perform the following:

a. Remove control wire (3) from left side

of each riser housing (4).

200354a

Figure 4-14 — Inlet Tube Clamp Disassembly

1. Capscrews

2. Clamp plate

3. Insulator

4. Fuel inlet tubes

5. Bracket

6. Nuts

[214 EG] EXHAUST MANIFOLD

Refer back to Figure 4-13.

1. Remove capscrew (9) securing oil filler tube bracket (8) to exhaust manifold (10).

2. If necessary, remove the retaining clamp for the injection pump wiring and connector from the holder.

3. Remove capscrews securing oil filler feed tube (7) to cylinder block. Remove tube.

4. Support the exhaust manifold and remove 12 mounting capscrews (11) securing the manifold (10) to cylinder heads.

5. Remove exhaust manifold.

6. Discard gaskets.

Figure 4-15 — Control Wire Removal

1. Valve cover

2. Capscrew

3. Control wire

4. Riser housing

Refer to Figure 4-16.

b. Disconnect wires (1) at the actuator

solenoid connector (14).

c. Remove risers (2). Discard seals.

200355a

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200 ENGINE DISASSEMBLY

[213 LP, NV & LH] ROCKER ARM, VALVE YOKE AND PUSH ROD

Refer to Figure 4-16.

If equipped with a Jake Brake, perform the following:

1. Remove three capscrews (6) from each actuator assembly (15).

2. Remove actuator assemblies from cylinder heads (one actuator assembly per head).

If a Jake Brake was not installed, there will be six capscrews per rocker arm assembly. If a Jake Brake was installed, there will be only three capscrews per rocker arm assembly remaining.

3. Remove remaining capscrews (13) and washers (12) from rocker arm shaft brackets (7). Remove rocker arm assembly (11) from each head.

4. Remove valve yokes (8) from each pair of valves by lifting straight up on each yoke. Tag yokes for reassembly.

5. Remove valve push rods (10) and tag rods for reassembly.

200263a

Figure 4-16 — Valve Cover and Rocker Arm Removal

1. Wire connector

2. Riser

3. Valve cover

4. Short capscrew

5. Long capscrew

6. Actuator capscrew

7. Rocker arm shaft bracket

8. Valve yoke

9. Head bolt with threaded hole

10. Push rod

11. Rocker arm assembly

12. Washer

13. Capscrew

14. Connector

15. Actuator assembly

16. Actuator solenoid

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200 ENGINE DISASSEMBLY

[222 KG] NOZZLE HOLDER

Special Tool Required

앫 Injection Nozzle Puller J 37093

After removing the nozzles, it is a good practice to label or tag them for reinstallation into the same cylinders. After removal, place nozzles on a clean surface.

Refer to Figure 4-17.

1. Remove nozzle holder retainer (2).

2. Assemble injection nozzle puller J 37093 as follows:

a. Attach nut (12), bearing (11), spacer

(10) and rubber washer (9) to tool handle (1).

b. Screw handle (1) in threaded hole of

nozzle holder (5) until rubber washer (9) is slightly compressed.

3. With tool in position, turn nut (12) clockwise to draw nozzle holder from cylinder head nozzle mounting hole (8).

4. Continue turning nut until nozzle holder is free of insert. Remove nozzle holder and puller tool as an assembly.

5. Remove nozzle holder gasket (7). The gasket is manufactured from a special iron material 0.060 inch (1.524 mm) thick.

Figure 4-17 — Nozzle Holder Removal

1. Handle

2. Nozzle holder retainer

3. O-ring

4. O-ring

5. Nozzle holder

6. Nozzle

7. Gasket

8. Nozzle mounting hole

9. Rubber washer

10. Spacer

11. Bearing

12. Nut

201280a

6. Remove remaining nozzle holders in the same manner.

Current production nozzle holders do not have the lower O-ring groove.

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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. Remove fuel return line (1) at the front of the forward cylinder head.

3. Remove cylinder head bolts (2 and 5). Refer to cylinder head bolt torque sequence chart in Cylinder Head Installation for location of bolts, if necessary.

4. Using a suitable lifting device, remove heads from the engine block.

5. Remove gaskets and six fire rings. Discard gaskets and fire rings.

1. Fuel return line

2. Bolt

3. Fuel return tube

Page 4-16

Figure 4-18 — Cylinder Heads

4. Cylinder head

5. Bolt with hole in head

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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.

2. Remove vibration damper (3) and fan belt drive pulley (1) together.

3. Using a 1-7/16 inch wrench, remove crankshaft hub capscrew (2).

4. Using a suitable puller such as J 24420-C, remove the crankshaft hub.

[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.

Figure 4-19 — Vibration Damper Removal

1. Pulley

2. Capscrew

3. Vibration damper

4. Capscrew

Figure 4-20 — Air Compressor Connections

1. Coolant supply line

2. Air compressor head

200359a

3. Capscrew

200258a

4. Coolant return line

5. Air governor mounting flange

The air compressor is heavy. Lifting the air compressor may require the help of an assistant or suitable lifting device. Attempting to lift the compressor without such assistance may result in severe personal injury.

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200 ENGINE DISASSEMBLY

Refer to Figure 4-21.

1. Remove three mounting capscrews (5) securing air compressor (1) to auxiliary driveshaft housing (3).

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. Air compressor

2. Oil supply tube

3. Auxiliary driveshaft

Figure 4-21 — Air Compressor Removal

4. Oil drain openings

5. Capscrew

200360a

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[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. This will allow ease of installation. Refer to the SETUP AND ADJUSTMENTS section for Fuel Injection Pump Fixed Timing Procedure.

200 ENGINE DISASSEMBLY

3. Remove rear support link assembly by removing mounting hardware (7 and 8), V-MAC engines only.

4. Mechanically governed engines — Working from the front of the engine, remove four capscrews securing the injection pump drive gear and remove gear. For V-MAC engines, omit this step and go on to step 5.

5. Remove mounting capscrews securing pump to adapter.

6. Remove injection pump by moving it away from mounting flange.

Figure 4-22 — Fuel Line Removal

1. Return from secondary filter

2. Cylinder head overflow line

3. Return to tank line

4. Return to secondary filter

5. Return from primary filter

6. Lubrication supply line

7. Capscrew

8. Capscrew

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200 ENGINE DISASSEMBLY

[221 CD] ECONOVANCE

V-MAC Equipped Engines

Refer to Figure 4-23.

1. Working from front of engine, remove four capscrews securing the injection pump drive gear. Remove gear.

Figure 4-23 — Fuel Injection Pump Drive Gear Removal

Refer to Figure 4-24.

2. Remove mounting capscrews (1) securing injection pump adapter (2) to Econovance housing. Remove adapter.

3. Remove the drive coupling (3) by slipping it off of the splines (6).

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. Splines

[211 NB] OIL PAN

Refer to Figure 4-25.

1. Remove the nuts from the two studs securing the oil pan to the timing gear cover.

2. Remove the two nuts from the two studs securing the oil pan to the flywheel housing.

3. Remove the remaining shouldered bolts securing the oil pan to the pan rails and remove the oil pan.

200364a

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. When the Celeron drive coupling requires replacement, replace the drive coupling with the updated two-piece style. Older style shown.

4. Remove the Econovance (5) by removing four mounting capscrews (4). Rotate shaft to clear the camshaft gear.

Page 4-20

Oil pans with isolating gaskets are secured with nuts and shouldered studs at the timing gear cover and flywheel housing. Refer to Figure 4-25.

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200 ENGINE DISASSEMBLY

1. Studs and nuts at timing gear cover

2. Studs and nuts at flywheel housing

Figure 4-25 — Oil Pan Bolt Locations

3. Shouldered bolts along pan rails

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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).

Remove the oil pump as a unit by removing three retaining capscrews (1).

200264a

1. Capscrews

2. Capscrews

3. Capscrews, 12-point

4. Sump

5. Capscrews

Page 4-22

Figure 4-26 — Lubrication Oil Pump

6. Washer

7. Screen

8. Relief valve cap

9. Capscrews

10. Plate

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200 ENGINE DISASSEMBLY

[211 RP] TIMING GEAR COVER

Do not attempt to remove timing gear cover without removing oil pan. Doing so may result in damage to the isolating oil pan gasket.

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.

3. If not equipped with an auxiliary pump,

remove cover (12) and gasket (8) by removing mounting nuts (10) and washers (11).

4. Remove the injection pump timing cover

(14) by removing the mounting capscrews (1 and 13). Discard O-ring (2).

5. Remove remaining mounting capscrews

(13) from timing gear cover (3).

200257

Do not damage the timing indicator (5), if equipped, when removing timing gear cover.

6. Remove timing gear cover. It will be

necessary to pry the cover from the engine block. Be careful not to damage cover or block while using sharp tools around machined surfaces.

Figure 4-27 — Timing Gear Cover Removal

1. Capscrew

2. O-ring

3. Timing gear cover

4. Front engine mount pedestal

5. Timing indicator

6. Capscrew

7. Capscrew

8. Gasket

9. Capscrew

10. Nut

11. Washer

12. Cover

13. Capscrew

14. Injection pump timing cover

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200 ENGINE DISASSEMBLY

[212 CV] AUXILIARY DRIVESHAFT

Refer to Figure 4-28.

1. Remove auxiliary driveshaft gear retaining nut (1).

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.

Figure 4-28 — Auxiliary Driveshaft Gear Removal

1. Nut

2. Auxiliary driveshaft gear

3. Capscrew

200361a

4. Captured thrust washer

5. Shaft splines

Refer to Figure 4-29.

Figure 4-29 — Auxiliary Driveshaft Removal

1. Rear bushing

2. Front journal

3. Auxiliary driveshaft

4. Rear journal

5. Oil pump drive gear

200362a

[213 CH] CAMSHAFT

Make sure all loose components are secured to, or removed from, the engine before rotating engine on the stand. Failure to do so may result in damage to components or severe personal injury.

1. Rotate engine so that the deck surface is downward and the oil pan rail is upward (engine inverted).

Be very careful to avoid damaging the auxiliary driveshaft bushings or journals while removing the shaft.

Remove the auxiliary driveshaft (3) by pulling it rearward out of the air compressor mounting flange opening. With engine oil pump in position, a rotating motion may be necessary to clear the engine oil pump drive gear (5).

Page 4-24

When engine is rotated, the valve lifters will fall downward into the push rod holes but will be captured by their heads. They will be out of the way for camshaft removal.

Refer to Figure 4-30.

2. Remove the two 12-point capscrews (3) that retain camshaft thrust washer (1). Camshaft may have to be rotated slightly to make the capscrews accessible through openings (2) in the camshaft drive gear (4).

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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.

Figure 4-30 — Camshaft Thrust Washer Capscrews

1. Thrust washer

2. Openings

200365a

3. Capscrew, 12-point

4. Camshaft drive gear

5. Remove valve lifters.

Valve lifters have established wear patterns and should be reinstalled in same locations. Label each valve lifter upon removal and place on a clean work surface.

[212 NP & LQ] PISTON AND

CONNECTING ROD ASSEMBLY

The crankshaft and related components are heavy, have sharp edges and many possible pinch points. Always be careful while working in this area to avoid serious personal injury.

Refer to Figure 4-31.

3. Install the camshaft removal/installation tool J 41461 (3) in position on the rear segment of the camshaft (1), securing it with the clip (2) to the shaft.

200573a

Figure 4-31 — Camshaft Removal/Installation Tool

1. Rear segment of camshaft

2. Tool retaining clip

3. Camshaft removal/ installation tool

Before removing pistons, connecting rods and rod caps, ensure they are marked so they can be reinstalled in the same cylinders from which they were removed.

Remove connecting rod and piston assemblies in companion cylinder sets: 1 and 6, 2 and 5, and 3 and 4.

1. Rotate engine stand 90 degrees so that pistons lie horizontally in the block with top of pistons and connecting rods accessible.

2. Rotate crankshaft so that pistons 1 and 6 are lowered in the cylinder at least two inches (51 mm) to allow adequate room to remove carbon from upper edge of sleeves.

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200 ENGINE DISASSEMBLY

Refer to Figure 4-32.

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.

Refer to Figure 4-33.

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

Figure 4-33 — Piston and Connecting Rod

Assembly Removal

5. Using a hammer handle, push piston 1 from the cylinder bore. Remove piston 6 in the same manner.

6. After removing pistons 1 and 6, rotate crankshaft so that next set of pistons (2 and 5) is at bottom dead center.

7. Repeat steps 2 through 6 for removing piston sets 2 and 5, and 3 and 4.

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[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. Carefully tap flywheel by alternating from side to side to work it off the aligning dowel pins.

200 ENGINE DISASSEMBLY

The flywheel is heavy. Lifting the flywheel will require the help of an assistant or the use of a suitable lifting device (J 25026-A or equivalent). Attempting to lift a flywheel without such assistance may result in severe personal injury.

Remove flywheel timing pointer, if present, to avoid damaging the pointer during flywheel removal.

Figure 4-34 — Flywheel Removal

5. Support the flywheel and remove two guide capscrews.

6. Using a suitable lifting device such as J 25026-A, or adequate assistance, remove flywheel.

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200 ENGINE DISASSEMBLY

[211 HD] FLYWHEEL HOUSING

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.

[211 JA] MAIN BEARING CAP

Before removing main bearing caps, ensure they are marked so they can be reinstalled on the same journals. Keep the bearings with the same cap and tag or mark them to identify the cam side of the bearings.

Refer to Figure 4-36.

1. Remove eight buttress capscrews (2 and 3).

2. Remove main bearing capscrews (1) from each of the seven bearing caps (4 and 5). The center main bearing cap (5) houses the thrust washers.

3. Position a lady-foot pry bar under the tabs provided on bearing caps and pry bearing caps upward. To work them loose, it may be necessary to tap the bearing caps alternately from side to side with a soft mallet.

Figure 4-35 — Flywheel Housing Removal

1. Capscrew locations

2. Flywheel housing

3. Capscrew

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200 ENGINE DISASSEMBLY

1. Main bearing cap capscrews

2. Buttress capscrews, 80 mm

3. Buttress capscrews, 110 mm

Figure 4-36 — Buttress Capscrew Installation

4. Main bearing caps

5. Center main bearing cap

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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.

2. Lift crankshaft from engine block and store in a secured stand, or horizontally on V-blocks.

[219 RV] PISTON COOLING SPRAY NOZZLE

To avoid damaging spray nozzles, remove them before removing sleeves.

It is best to use a 10-mm, 6-point socket on a 12-inch extension to remove the nozzle retaining capscrews.

Refer to Figure 4-38.

1. Remove piston cooling spray nozzle (2) by removing retaining capscrew (3).

2. Carefully pull outward on the spray nozzle to remove it from the block.

3. Remove and discard elastomer seal (1).

Figure 4-37 — Crankshaft Removal

4. Repeat steps 1 through 3 to remove remaining spray nozzles.

Figure 4-38 — Spray Nozzle Removal

1. Elastomer seal

2. Spray nozzle

3. Capscrew

200613a

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200 ENGINE DISASSEMBLY

[212 NC] CYLINDER SLEEVE

Special Tool Required

앫 Cylinder Liner/Sleeve Puller PT6435

Refer to Figures 39 and 40.

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).

3. Position puller above the sleeve and guide the puller shaft through the sleeve.

Extreme care must be taken to make sure the puller shoe is properly aligned in the bottom of the sleeve to prevent damage to the block.

4. Position puller shoe so that it catches the lower lip of the sleeve. Ensure that it does not extend beyond outside edges of the sleeve so it will not come into contact with the cylinder block as the sleeve is removed.

6. Remove puller from sleeve.

7. Remove crevice seal (1) from sleeve.

8. Repeat steps 2 through 7 to remove remaining cylinder sleeves.

5. Tighten screw on the puller until sleeve comes free from cylinder block bore. Remove shims (3), if installed.

Figure 4-39 — Cylinder Liner/Sleeve Puller PT6435

Figure 4-40 — Sleeve Removal

1. Crevice seal

2. Cylinder sleeve

200614a

3. Shims

4. Cylinder block

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NOTES

Page 4-32

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200 BENCH PROCEDURES

BENCH PROCEDURES

Page 5-1

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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. If the cylinder block deck was not resurfaced but cylinder sleeve counterbore surface shows excessive pitting or erosion, recut the counterbore as required.

Use shims to re-establish the correct liner flange height. Shims are available in the following thicknesses: 0.002, 0.003, 0.004, 0.008, 0.010,

0.012 and 0.014 inch.

Universal dial depth gauge PT5025, with a 3-inch stylus extension PT5052-11, is recommended for measuring the counterbore.

3. Measure and record the counterbore in four places, 90 degrees apart. Using a depth gauge with a 3-inch extension, mark the shallowest point. Subtract the lowest number from the highest number. This is the minimum amount to be machined for cleanup.

SETTING UP COUNTERBORE TOOL PT2210 WITH CUTTER PLATE PT2210-3A

Refer to Figure 5-1.

1. Loosen the two cutter bit hold-down capscrews (9). Install cutter bit (11) into cutter plate PT2210-3A (13) by turning the cutter bit adjuster (10) counterclockwise. Cutter bit face must be facing a clockwise rotation cut.

To resurface the cylinder sleeve counterbore area of the cylinder block, use counterbore tool PT2210 with counterbore cutter plate PT2210-3A.

This procedure can be performed either in or out of the chassis. If performing the procedure in the chassis, be sure to cover the crankshaft and any holes in the block to prevent contamination from machining chips.

Do not cut seats deeper than 4.034 inches (102.464 mm).

1. Make sure that the top of the deck is clean and free of burrs. Use a finish mill file and crocus cloth, if necessary, to create a smooth, flat surface for positioning the tool.

Do not tighten the cutter bit hold-down cap (12).

The cutter point should not extend beyond the outer edge of the cutter plate. If the cutter bit does stick out, damage to the bit will occur when installing counterbore tool onto cylinder block.

2. Install the cutter plate on the main shaft (15). Use the large end of hex key wrench PT2210-14 (18) to hold the cutter plate and tighten securely. The hole in the side of the cutter plate accepts the large end of the tool.

Do not allow the cutter bit (11) to touch the cylinder sleeve bore wall.

2. Using compressed air, thoroughly remove all debris.

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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. Secure the cutter plate to the cylinder block

with four M16 x 2 x 90 hex-head capscrews (3) and special washers (4) from the counterbore tool kit PT2210.

5. Cross-torque the capscrews to 30 lb-ft

(41 N폷m) using torque wrench J 24406 or equivalent.

Lift T-handle (2) slightly (so cutter plate is not in contact with the counterbore) and rotate the mainshaft (15) counterclockwise to ensure cutter plate turns freely without binding. If necessary, loosen the capscrews and relocate the tool.

It may be necessary to use a flashlight to see the cutter bit adjusting screw.

11. Using hex key wrench PT2210-14 (18), turn the cutter bit adjusting screw clockwise until the cutter bit rests on the counterbore ledge.

12. If the cutter bit will not adjust, adjust the lower depth-set collar (16) 0.005 inch (0.127 mm) more and recheck cutter bit hold-down screws for looseness.

13. Zero the depth-set collars:

a. Back off the lower depth-set collar (16)

and carefully lower the cutter plate (13) into the bore and allow the cutter to rest on the counterbore ledge.

b. Rotate both depth-set collars (5 and 16)

down until the bottom collar contacts the main housing (8).

Do not force the collar beyond this point, as it will lift the cutter plate and prevent an accurate zero reading.

6. Using the counterbore tool T-handle (2), raise the cutter plate approximately 1/2 inch (12.7 mm) from the counterbore ledge.

7. Using hex key wrench PT2210-14 (18), turn the cutter bit adjusting screw (10) clockwise until the cutter bit contacts the counterbore ledge. Do not touch the counterbore wall.

8. Back off the lower depth-set collar (16) and lower the cutter plate until the cutter rests on the ledge.

9. Rotate the lower depth-set collar down until the collar contacts the main housing.

10. Rotate the collar an additional five increments: 0.005 inch (0.127 mm). Each graduation of the collar is one-thousandth (0.001) of an inch (0.025 mm). This will lift the cutter bit 0.005 inch (0.127 mm) off the counterbore ledge, allowing an accurate setting of the cutter bit.

14. Set the depth of the cut. Determine the final depth of the cut and back off the top depthset collar accordingly. Each increment on the depth-set collar increases the depth of the cut by one-thousandth (0.001) of an inch (0.025 mm). Tighten the thumbscrew (17) on the upper collar (5) securely.

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200 BENCH PROCEDURES

Figure 5-1 — Counterbore Ledge Tool Installation

200328a

1. Cutter plate holder

2. T-handle

3. Capscrews, M16 x 2 x 90

4. Special washers

5. Upper depth-set collar

6. Lower thumbscrew

7. Oil fill tube

8. Main housing

9. Hold-down capscrews

Page 5-4

10. Cutter bit adjuster

11. Cutter bit

12. Hold-down cap

13. Cutter plate

14. Cylinder block

15. Main shaft

16. Lower depth-set collar

17. Upper thumbscrew

18. Hex key wrench

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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. Stop the handle in a different position to avoid creating a ridge in the counterbore.

4. Continue backing off the lower depth-set collar, no more than two graduations per cut. Check the depth measurement between each adjustment. Plan to remove 0.001 inch (0.025 mm) on the final cut to meet the final predetermined counterbore depth. This ensures achieving a very fine machined finish.

[212 CV] AUXILIARY DRIVESHAFT

Description

All current production engines (effective February 27, 1992, serial No. 2E1233) are equipped with a “fast ratio” auxiliary driveshaft assembly and oil pump assembly. This arrangement raises oil pump speed to increase operating oil pressure 25%. Refer to Auxiliary Driveshaft Installation instructions in the ENGINE ASSEMBLY section for ratio information.

Do not mix “fast ratio” and “standard ratio” components. Serious damage may occur.

Inspection

1. Thoroughly clean auxiliary driveshaft.

5. Remove the tool from the cylinder bore.

a. Loosen the two cutter bit hold-down

capscrews (9) and rotate the cutter bit adjusting screw (10) counterclockwise until the cutter bit is retracted into the cutter plate (13).

b. Remove the four machine hold-down

bolts (3) and special washers (4).

c. Remove the tool from the cylinder bore.

6. Follow steps 1 through 5 for the remaining cylinders.

2. Inspect auxiliary driveshaft journals and gear teeth for evidence of cracks, pitting, scoring or severe wear. If any of these conditions exist, replace the auxiliary driveshaft.

[212 LP] CONNECTING RODS

Description

Refer to Figure 5-2.

Early E7 engine connecting rods were machined to give rod cap bottoms a contoured appearance. Since mid-1992, connecting rod caps have had a flat, machined bottom. The rods are the same in strength and configuration, with the only difference being the rod cap bottom surface machining.

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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. This connecting rod assembly has two alignment sleeves (3), one sleeve in each capscrew hole of the rod cap (1) to locate and align the cap and rod thrust faces. These sleeves provide the best alignment when sleeve gaps are positioned at a location approximately 90 degrees to the tongue or groove (2). The sleeve gaps must not be in line with the tongue or groove.

Figure 5-3 — E7 Connecting Rod with Alignment

1. Rod cap

2. Bearing insert

Sleeves

3. Alignment sleeve

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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.

Old-style connecting rods (without alignment sleeves) and new-style connecting rods (with alignment sleeves) may be intermixed in an engine. However, the capscrews and alignment sleeves are not interchangeable between the two rod assemblies. The alignment sleeves will physically fit into either of the connecting rod assemblies, but the sleeve must be used in the new-style 367GC4267M or M2 connecting rods ONLY. The capscrews cannot be mixed. The difference in the thread size between the two rod assemblies is significant enough that the 14-mm threaded capscrews will not even engage the 16-mm tapped hole in the old-style (367GC4255M or M2) rod assemblies. The 16-mm threaded capscrew cannot be assembled into the 14-mm tapped hole of the new-style (367GC4267M or M2) connecting rod assemblies.

It is essential to closely control the weight of reciprocating parts. MACK E7 connecting rods fall into two weight classes. Prior to mid-1996 production, the weight classes are identified by an “M” number (M1 or M2) stamped onto the connecting rod bearing cap. Effective with mid1996 production, the M2 connecting rod is no longer stamped with this weight designation. The M1 weight class rod will continue to be stamped on the rod cap. When installing a single rod, or less than a full set, examine removed rod for part number and M number. Installing parts with the same weight class is preferred.

200 BENCH PROCEDURES

Special Tools Required

앫 Piston Pin Bushing Remover/Installer

J 37717

앫 Piston Pin Burnishing Broach J 37718

앫 Connecting Rod Fixture 945-6041

Inspection

앫 Inspect connecting rods for nicks, cracks,

signs of overheating, bends or twisting that can cause rod failure.

앫 Inspect bolt holes for elongation or pulled

threads.

앫 Check mating surfaces between rod and cap

for correct fit.

앫 Inspect the crankshaft journal bearing

surface and wrist pin bushing.

If any of the above parts are suspected of being faulty, replace the connecting rod.

If it is determined that the condition of any part or component is questionable or is at the limit of tolerance, throw it out; it may fail or become out of tolerance after a short time in operation. It is costefficient to replace components when rebuilding.

Always use genuine MACK replacement parts.

Wrist Pin Repair

WRIST PIN BUSHING REMOVAL

If the wrist pin bushing is found to be out of tolerance, it should be replaced.

Refer to Figure 5-4.

Connecting rods can be weighed to ensure using proper weight class. Connecting rod weights for each engine, within each weight class, should not vary by more than 0.46 ounce (13.04 grams). The maximum weight difference between the heaviest possible M2 rod and the lightest possible M1 rod is 0.83 ounce (23.53 grams).

To replace bushing:

1. Position rod in a press with piston pin bushing remover/installer J 37717 inserted into wrist pin bushing.

2. Press bushing out of rod.

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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

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.

1. Position rod, bushing and piston pin bushing remover/installer J 37717 in press, and press bushing into rod.

2. Align hole in bushing with rifle-drilled hole in rod.

Make certain that bushing is fully expanded in the connecting rod bore or it will loosen in service.

Figure 5-5 — Burnishing Wrist Pin Bushing

4. Using a suitable lubricant, press broach through bushing to expand bushing.

Refer to Figure 5-6.

5. After machining bushing, check connecting rod for twisting or bending. Use Sweeney connecting rod fixture 945-6041. Accessory mandrel and plunger extension assemblies for various engines are required for use with this fixture, and are also available from the Sweeney Company.

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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. Capscrews hold the caps in position. The bearing caps are not interchangeable and each has a number stamped on it which signifies its correct location and alignment in the crankcase. The caps are numbered 1 through 7, with No. 1 main bearing cap in front of engine. The bearing inserts are precision designed. Bearings are inserted between the crankshaft and crankcase, and between the crankshaft and bearing caps. Thrust flanges to support thrust washers are located at the center main bearing (No. 4).

200329a

Figure 5-6 — Connecting Rod Fixture

Maximum twist of connecting rod within 12 inches (30.5 cm) is 0.010 inch (0.254 mm). The maximum bend of connecting rod within 12 inches (30.5 cm) is 0.004 inch (0.102 mm). Distances are center to center.

[212 HP] CRANKSHAFT

Description

The crankshaft is fully counterbalanced and journals are induction-hardened. There are seven main bearings. Thrust washers located at the center main bearing (position No. 4) absorb fore and aft end thrust. Crankshaft extension at forward end carries the main drive gear, vibration damper and accessory drive pulleys. The main drive gear has a shrink fit and the vibration damper hub has a press fit. The main drive gear is keyed to the crankshaft and proper assembly is

Extreme care must be taken to guarantee cleanliness of crankcase, crankshaft, and bearings during servicing and after service has been completed. Whenever possible, crankshaft should be removed when bearings are being installed in order to clean crankcase thoroughly.

All bearing surfaces must be free of grit and burrs. Small particles of dust and dirt left between crankshaft and bearings will cause rapid wear and scoring of crankshaft journal and inserts. Any foreign material left between bearings and crankshaft bearing caps will cause distortion of bearing and a reduction in operating clearance at that point. The resulting frictional heat will cause bearing material to melt away from steel backing of bearing at that point. Such melted material will create further hot spots until complete bearing failure occurs. Anything that interferes with operating clearance of any bearing, or proper heat dissipation, affects bearing life. Cleanliness cannot be overstressed.

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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.

Some crankshafts may have journals which are

0.002 inch (0.0508 mm) undersize. They are marked by a streak of white paint adjacent to the journal. Always check journals to ensure using proper size bearing inserts.

[212 HA] Crankshaft Dowel Pin Replacement

1. Inspect crankshaft journals for straightness, out-of-round, taper, and surface finish.

2. Visually check crankshaft for any apparent cracks, worn journals and damage to threads, dowel or main drive gear.

3. Magnaflux the crankshaft. This process requires special equipment and application methods.

4. Using standard machinist inspection practice, check crankshaft for straightness.

5. Measure crankshaft journals with a micrometer. Measure each journal in two locations, 90 degrees apart, and record measurements.

6. Check measurements against specifications in the FITS AND LIMITS section of this manual.

Crankshaft regrinding by anyone other than Mack Trucks, Inc. is NOT recommended due to the tight control required on maintaining geometrical tolerances, and the hardened characteristics of the crankshaft journals and journal fillets.

The “diamond” locating dowel pins used for installing flywheel to crankshaft have been replaced by blade-style locating dowel pins. The diamond pins were dual diameter-type pins. There was a smaller diameter at the round end than at the diamond end. There are no changes in the size of the hole in the flywheel. However, the crankshaft will have larger holes to accept blade-style pins.

The blade-type dowel pin was introduced in May 1992, starting with serial No. 2K. You must use the dowel size that is appropriate for the crankshaft. (Service old with old, and new with new.)

Effective May 1993, all E7 engine crankshafts are equipped with flywheel-to-crankshaft dowel 183GC238 installed in the rear flange. Prior to this date, only V-MAC engine crankshafts had the 183GC238 dowel. Crankshafts in mechanically governed engines did not have a dowel pin hole in the rear flange. However, all E7 engine crankshafts have always had a crankshaft manufacturing locator hole in the rear flange. This hole is approximately 1/2 inch (12.7 mm) in diameter and 3/8 inch (9.52 mm) deep, and is used only in the manufacturing process.

If the crankshaft is not serviceable, both new and reground crankshafts are available through the MACK Parts Distribution Centers.

If crankshaft main journals or rod journals are not a standard size, be sure to use properly sized bearing inserts. Bearing inserts are marked with a “P” which follows the part number, and is stamped on the back side of the bearing insert. For example, if a journal is 0.010 inch (0.254 mm) undersize, a 0.010-inch undersize bearing is required and will be stamped “P10”.

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The flywheel locating dowel hole — located directly opposite the manufacturing locator hole — is approximately 9/16 inch (14.29 mm) in diameter by 7/8 inch (22.23 mm) deep in crankshafts made since May 1992 using dowel 183GC238. V-MAC crankshafts made prior to May 1992 have a flywheel locating dowel hole 1/2 inch (12.7 mm) in diameter by 7/8 inch (22.23 mm) deep for dowel 183GC221.

MACK E7, E7 Overhaul Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual