MACK E-Tech Service Manual

E-TECH™ ENGINE

SERVICE MANUAL

(Includes Left-Side Redesign)

OCTOBER 2000

(REVISED)

5-106

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ERRATA SHEET — ENGINE

Crankshaft Center Main Bearing

Effective January 2006, Mack Powertrain Engineering has widened the crankshaft center main bearing runout specification. The maximum allowable crankshaft runout specification was changed from 0.005 in. (0.127 mm) to

0.007 in. (0.178 mm). The manuals listed below are affected by this change.

Specification Update

Reference: Engine Manuals

5-101 E7

5-106 E-Tech™

5-107 E7G

5-110 ASET™ AI/AMI

5-111 ASET™ AC

JANUARY 2006 © MACK TRUCKS, INC. 2006 (NEW ISSUE) MACK ENGINE SERIES

SERVICE BULLETIN

NUMBER: SB-210-034

DATE: 5/14/02

MODEL: E-Tech™

(Also applies to Mack Trucks Australia)

MISCELLANEOUS FASTENER CHANGES — E-TECH™ ENGINES

The following fastener changes were made on E-Tech™ engines:

Injection Nozzle Hold-Down Screws — Beginning 3/00, the injection nozzle holddown screws having the 15 mm external hex head have been changed to a new screw (part No. 421GC2116M) that has a 16 mm internal hex head.

Rocker Shaft Mounting Bracket Bolts — Beginning 4/00, the bolts and washers used to secure the rocker shaft mounting brackets to the cylinder head have been changed to a flange-head bolt (part No. 65AM5010). Tightening torque value for this new fastener remains the same at 40 lb-ft (50 N•m).

Air Com pressor Mounting Screw — Beginning 8/00, the original hex-head screw has been changed to a flange-head screw (part No. 27AM16). This change was made so that the mounting screw clamp load is distributed over a wider area of the flat washer.

Camshaft Thrust Washer — Beginning 10/00, the two screws and washers used to secure the camshaft thrust washer to the block were changed to a flange-head screw (part No. 66AM44). Tightening torque value for this fastener remains the same at 15 lbft (20 N•m).

Cylinder Head Capscrews — Beginning 6/01, the cylinder head capscrews and the separate hardened flat washer were replaced in production with capscrews having captured washers (part number series 400GC317M). This change was implemented to prevent the possibility of omitting or installing more than one washer during assembly. Additionally, the outside diameter of the captured washer was reduced slightly (approximately 0.030″) to accommodate the redesigned cylinder head cover that was phased into production 7/01. Cylinder head capscrew torque remains the same at 205 lb-ft (278 N•m).

Flywheel-to-crankshaft m ounting bolts — Beginning 9/01, bolts having captured washers (part Nos. 419GC31M and 419GC31M2) were released into production to replace the previously used bolts and separate hardened flat washer used to secure the flywheel to the crankshaft. Flywheel-to-crankshaft mounting bolt torque remains the same at 185 lb-ft (250 N•m).

Electronic Unit Pump (EUP) hold-down screws — Beginning 11/01, new hold-down screws (part No. 421GC2123M) were released into production for the electronic unit pumps. These screws are dimensionally the same as the previously used screws, but conform to a more stringent specification that controls minor surface forming defects to a greater degree than for common fasteners.Torque of the EUP hold-down bolts has been changed from 42 lb-ft (57 N·m) to 60 lb-ft (81 N·m).

Turbocharger Mounting Nuts — Beginning 5/02, new turbocharger mounting nuts were released into production. These nuts (part No. 142GC247M) are composed of silver-plated stainless steel to provide greater resistance to heat than the previous nuts. Additionally, these nuts have the Spiralock™ self-locking thread feature to prevent loosening in service.

SB-210-034 — Page 1of 1

2002.CNI,SKCURTKCAM©50181AP,NWOTNELLA,SNOITACILBUPECIVRES

E-TECH™ ENGINE

SERVICE MANUAL

(Includes Left-Side Redesign)

MAY 2006 REPRINTED 2.5M SEPTEMBER 2004 REPRINTED 2.5M APRIL 2003 REPRINTED 2.5M JUNE 2002 REPRINTED 2.5M OCTOBER 2001 REPRINTED 2.5M OCTOBER 2000 (REVISED – SUPERSEDED ISSUE JULY 1999)

5-106

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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.

front.fm Page iii Friday, August 4, 2000 11:16 AM

TABLE OF CONTENTS

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TABLE OF CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Advisory Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Service Procedures and Tool Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

EXPLANATION OF NUMERICAL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Changes from the Existing E-Tech™ Service Procedur es Manual . . . . . . . . . . . . . . . . . . . . . . .6

ABOUT THE E-TECH™ ENGINE AND ITS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

ENGINE MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Engine Information Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0

Engine Serial Number Identificati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

DESCRIPTION & OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

E-TECH™ ENGINE DESIGN FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Electronic Unit Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

V-MAC III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Belt Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

J-Tech™ Engine Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Valve Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Low-Pressure Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Fuel Filtration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

High-Pressure Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

High-Pressure Fuel Injection Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Fuel Injector Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Block Heater for Front (Water Pump) Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Cylinder Head Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Vibration Damper Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Centri-Max® Oil Filter Breather Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

GLOSSARY OF TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

ENGINE SYMPTOM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

V-MAC III Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

CAMSHAFT TIMING AND LOBE LIFT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Camshaft Timing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Camshaft Lobe Lift Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

CHASSIS-MOUNTED CHARGE AIR COOLING TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Special Tool Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

CMCAC Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

CMCAC Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Restriction Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

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Core Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

CMCAC Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

CYLINDER HEAD AND CYLINDER BLOCK LEAK TEST PROCEDURE . . . . . . . . . . . . . . . . . . .71

Cylinder Head and Head Gasket Check — In Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Cylinder Head Fuel Passages Leak Check — In Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

Cylinder Block/Cylinder Head Coolant Passages Leak Check — In Chassis . . . . . . . . . . . . . .72

Cylinder Head Oil Passage Leak Check — Out of Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Cylinder Head Coolant Passage Leak Check — Out of Chassis . . . . . . . . . . . . . . . . . . . . . . . .75

Cylinder Block Coolant Passage Leak Check — Out of Chassis . . . . . . . . . . . . . . . . . . . . . . . .76

ENGINE BRAKE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

Operational Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

Hydraulic/Mechanical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Final Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

TABLE OF CONTENTS

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

BELT DRIVE SYSTEM TENSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Manually Tensioned System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Automatically Tensioned System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

FILTER ELEMENT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Crankcase Breather Filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Coolant Conditioner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

Removal from Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

ENGINE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

Filter Element Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

Oil Cooler and Oil Filter Mounting Bracket Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . .101

Mounting Engine in Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

Alternator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

Engine Electronic Control Unit (EECU) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

Fuel Filter Adapter Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

Coolant Conditioner Element Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

Oil Cooler-to-Water Pump Inlet Line Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Thermostat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110

Coolant Manifold Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

Air Inlet Manifold Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

Water Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

Turbocharger Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

Fuel Nozzle Inlet Tube Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

Exhaust Manifold Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

Engine Wiring Harness Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

Engine Electronic Control Unit (EECU) and Cooling Plate Removal . . . . . . . . . . . . . . . . . . . .115

Electronic Unit Pump (EUP) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

Oil Fill Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

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Air Compressor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117

Valve Cover and Spacer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118

Rocker Arm, Valve Yoke and Push Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

Nozzle Holder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Cylinder Head Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Vibration Damper and Crankshaft Hub Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

Oil Pan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 3

Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

Auxiliary Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

Camshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128

Piston and Connecting Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129

Flywheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131

Flywheel Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Main Bearing Cap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Crankshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134

CYLINDER BLOCK RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134

Piston Cooling Spray Nozzle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Cylinder Sleeve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136

Cylinder Sleeve Counterbore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

Cup Plug Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142

Pipe Plug Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

H-Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

Camshaft Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Auxiliary Shaft Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

Cylinder Sleeve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152

Piston Cooling Spray Nozzle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Cylinder Block Dowel Pin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159

CRANKSHAFT AND FLYWHEEL BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161

Crankshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Crankshaft Dowel Pin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Crankshaft Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Crankshaft Wear Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Flywheel Inspection and Resurfacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167

AUXILIARY SHAFT AND CAMSHAFT BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . .168

Auxiliary Shaft Inspecti on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168

Camshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

CONNECTING ROD AND PISTON BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . .173

Connecting Rod Inspection and Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173

Piston Inspection and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

Piston Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Assembling Connecting Rod to Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180

CYLINDER HEAD OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181

Inlet and Exhaust Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181

Cylinder Head Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185

Fire Ring Groove Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Valve Guide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188

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Valve Seat Insert Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

Valve Spring Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196

Injection Nozzle Holder Insert Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197

Valve Yoke Guide Pin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198

Cylinder Head Cup Plug Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199

Cylinder Head Pipe Plug Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200

Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202

VALVE ROCKER ARM SHAFT BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206

Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206

Valve Rocker Arm Shaft Disassembly (without/with Engine Brake) . . . . . . . . . . . . . . . . . . . . . 206

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Valve Rocker Arm Shaft Reassembly (without Engine Brake) . . . . . . . . . . . . . . . . . . . . . . . . . 207

Valve Rocker Arm Shaft Reassembly (with J-Tech™ Engine Brake) . . . . . . . . . . . . . . . . . . .209

LUBRICATION SYSTEM BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211

Oil Cooler Assembly Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211

Oil Pump Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211

COOLING SYSTEM COMPONENTS BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . .215

Oil Cooler Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215

Water Pump Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218

FUEL SYSTEM COMPONENTS BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219

Electronic Unit Pump (EUP) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Installation of Electronic Unit Pump Plunger Spring and Seat . . . . . . . . . . . . . . . . . . . . . . . . .219

Fuel Injector Nozzle Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221

ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222

General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222

Crankshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222

Main Bearing Cap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224

Piston and Connecting Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230

Flywheel Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234

Crankshaft Rear Oil Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238

Flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240

Valve Lifter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242

Camshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242

Camshaft Core Plug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243

Camshaft Idler Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244

Auxiliary Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245

Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246

Front Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247

Crankshaft Front Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248

Crankshaft Hub Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249

Vibration Damper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249

Oil Pan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250

Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252

Exhaust Manifold Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

Nozzle Holder Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257

Push Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259

Valve Yoke Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260

Rocker Arm and Engine Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261

Valve Cover and Spacer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264

Oil Fill Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265

Engine ECU/Cooling Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266

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Air Compressor Install a tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267

Electronic Unit Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

Engine Wiring Harness Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269

Fuel Nozzle Inlet Tube Assembly Installa tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Turbocharger Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

Water Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .271

Oil Cooler and Oil Filter Mounting Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

Coolant Manifold Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

Air Inlet Manifold Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

Thermostat, Housing and Seal Installat ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

Coolant Conditioner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278

Fuel Filter Adapter Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

Engine ECU Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .280

Oil Cooler-to-Water Pump Inlet Line Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

Alternator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

Removing Engine from Engine Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .281

Plate-Type Oil Cooler and Oil Filter Mounting Bracket Assembly Installation . . . . . . . . . . . . .282

ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .284

Engine Installation into Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .284

IN-CHASSIS PART/COMPONENT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .286

Electronic Unit Pump (EUP) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

Camshaft Replacement (Engine in Chassis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

Engine Brake Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

Valve Lifter H-Ring Installation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

ENGINE SETUP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297

Fuel Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297

Valve Yoke, Valve Lash and Engine Brake Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297

Engine Speed and Position Sensors Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . 304

Electronic Unit Pump (EUP) Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

ENGINE FINAL PREPARATION AND OPERATIONAL CHECK . . . . . . . . . . . . . . . . . . . . . . . . .306

Filter Element Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 06

Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306

Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

Engine Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307

REBUILT ENGINE RUN-IN PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308

General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308

Run-In Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308

TABLE OF CONTENTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .309

E-TECH™ ENGINE MECHANICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

Material and Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311

E-Tech™ Component Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .319

SPECIFICATION FOOTNOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .328

E-TECH™ ENGINE LUBRICANT AND SEALANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 329

FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .330

Fastener Selection and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .330

Fastener Sizes and Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .331

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SCHEMATICS & DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

ENGINE SYSTEM SCHEMATICS (FLUIDS FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .334

Cooling System Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .334

Lubrication System Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .335

Fuel System Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .336

SPECIAL TOOLS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .337

E-TECH™ ENGINE SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .338

Special Tools for Engine Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .338

V-MAC III Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .341

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

TABLE OF CONTENTS

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INTRODUCTION

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SAFETY INFORMATION

Advisory Labels

INTRODUCTION

Cautionary manual. Information accented by one of these signal words must be observed to minimize the risk of personal injury to service personnel, or the possibility of improper service methods which may damage the vehicle or cause it to be unsafe. Additional Notes and Service Hin ts are used to emphasize areas of procedural importance and provide suggest ions for ease of repair. The following definitions indicate the use of these advisory labels as they appear through out the manual:

signal words

Activities associated with injury may result from failing to heed the advisory. Serious personal injury may be equated to career-ending inj ury.

Activities associated with from failing to heed the advisory. In this case, personal injury is not equated to career-ending injury, but results in possible change in quality of life.

(Danger-Warning-Caution) may appear in various locations throughout this

Danger

Warning

indicate that death or serious personal

indicate that personal injury may result

Activities associated with Caution indicate that product damage may resul t fr om failing to heed the advisory. Caution is not used for personal injury.

A procedure, practice, or condition that is essential to emphasize.

A helpful suggestion that will make it quicker and/or easi e r to perform a procedure, while possibly reducing service cost.

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Service Procedures and Tool Usage

Anyone using a service procedure or tool not recommended in this manual must fi rst satisfy himself thoroughly that neither h is saf ety nor veh icle saf ety will be je opardized by the ser vice method he selects. Individuals deviating in any manner from the ins tr u ctions provided assume all risks of consequential personal injury or damage to equipment involved.

Also note that particular service proce dures 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.

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

INTRODUCTION

3. Before towing the vehicle, place the transmission in neutral and li ft the rear wheels off the ground, or disconnect the dr iveline to avoid damage to the transmission during towing.

Engine-driven components such as Power Take-Off (PTO) units, fans and fan belts, driveshafts and other related rotating assemblies, can be very dangerous. Do not work on or service engine-driven components unless the engine is shut down. Always keep body parts and loose clothing out of range of these powerful components to prevent serious personal injury. Be aware of PTO engagement or nonengagement status. Always disengage the PTO when not in use.

REMEMBER,

SAFETY . . . IS NO ACCIDENT!

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INTRODUCTION

Mack Trucks, In c. cannot anticipate every possible occurrence that may involve a potential hazard. Accidents can be avoided by recogniz ing potentially hazardous situations and taking necessary precautions. Performing se rvice procedures correctly is cr itical to technician saf ety and safe, reliable vehicle operation.

The following list of general shop safe ty practi ces 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.

r Perform all service work on a flat, level

surface. Block wheels to prevent vehicle from rolling.

r DO NOT wear loose-fitting or torn clothing.

Remove any jewelry before servicing vehicle.

r AL W AYS wear safety glasses and protective

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

r Use hoists or jacks to lift or move heavy

objects.

r NEVER run engine indoors unless exhaust

fumes are adequately vented to the outside.

r Be aware of hot surfaces. Allow engine to

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

r Keep work area clean and orderly. Clean up

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

r Only use tools that are in good condition,

and always use accurately calibrated to rque wrenches to tighten all f asteners to 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 instruct ions.

r Do not store natural gas powered vehicles

indoors for an extended period of time (overnight) without first removing the fuel.

r Never smoke around a natural gas powered

vehicle.

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INTRODUCTION

EXPLANA TION OF 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 MACK Service Labor Time Standards.

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

GROUP 000 — GENERAL DATA

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 three-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 beginning of each procedure, as necessary, to guide you to specific component information.

Additionally, a two-character alpha code [NV] RINGS, PISTON) may be referenced with each procedure. This alpha code, in combination with the three-digit Group number, identifies the specific assembly, sub-assembly or part, and directly relates to the fir st five positions of the operation code listed in MACK Service Labor Time Standards.

(i.e.,

Examples:

Numerical Code

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INTRODUCTION

ABOUT THIS MANUAL

Changes from the Existing E-T ech™ Service Procedures Manual

Mack Trucks, In c. has made many major

improvements to this E-Tech™ Service Procedures Manual, with changes to both content and organization. This is a complete manual, describing engine features and the operation of major systems as well as providing comprehensive overhaul procedures, specifications and adjustments.

All specifications and torque values are given i n English and metric measurements. Critic al torque values are also included in the text, eliminating the need to refer to SPECIFICATIONS section each time a specified torque value is required. The Special Tools list has been revised to include all special tools requi red f or a c omplet e overhau l. Warnings, cautions, notes and service hints help the technician service the engine safely and efficiently.

The engine disassembly procedures show how to remove components in an order t hat requires the least amount of handling. Where appropriate , it includes general information needed to properly service that component.

The engine reassembly procedure includes stepby-step instructions for reassembli ng the engine. This helps to ensure proper installation and longer service life.

Under Engine Setup and Adjustments, the latest setup information is provided for adjust ing all E-Tech™ engine models. Engines perform best and conserve fuel most efficientl y when ad justed properly.

Two addi tional procedures are included as guides for removing and reinstalling the engine. Both sections are generic in nature since E-Tech™ engine installation procedures vary from one vehicle style to another. As such, the 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 E-Tech™ engine. The TROUBLESHOOTING section contains symptom-related questions as well as tests to help the technician consider all possible problem sources.

This service manual also includes applicable information from active service bulletins and service letters since publication of the E-Tech™ Service Procedures Manual dated July 1999.

Various component bench procedures guide the technician in disassembly, cleaning, inspection and assembly of each component. Each bench procedure helps in determining if the part is serviceable or should be replaced.

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INTRODUCTION

ABOUT THE E-TECH™ ENGINE AND ITS SERVICE

This publication is intended to provide technician s

with a working knowledge of the E-Tech™ engine, including both early-production and current-production ver sions.

The E-Tech™ engine has undergone a left-side redesign. Changes include a new plate-type oil cooler and a new oil filter mounting arr angement. This new oil filter arrangement includes a new centrifugal oil filter assembly, where the centrifugal filter assembly is now mounted upside down, and the external oil drain is eliminated. This new centrifugal oil filter is call ed Centri-Max

PLUS. The engine electronic control unit (EECU) has

been relocated to the left side of the engine and is mounted on a new one-piece inlet manifold. Relocating the EECU has eliminated the need fo r the EECU cooling plate, and has also brought about a design change to the unit pump front outboard heat shield. Additionally, with the change to the one-piece inlet manifold, the fuel filter mounting adapter is new and is located slightly forward of the previous location.

Descriptions of these design changes and the other features are provided in the DESCRIP TION & OPERATION section. Additionally, the service effects of these changes on removal, installation, disassembly, assembly, setup and adjustment procedures, etc., are included in the respective sections of this publication.

Development of the E-Tech™ engine has been driven by three basic requirements. It was designed to:

r Meet projected exhaust and noise emissions

regulations.

r Meet customer demands for improved fuel

economy, driveability and engin e braki ng.

r Compete in a world market. Although the drive to reduce emissions and noise

levels is primarily the result of gove rnment mandates, the E-Tech™ engine is designed to provide customers with an improved engine over the existing E7 engine it replaces. Specific improvements include:

r Improved fuel economy. r Increased throttle response (time to

90 percent torque is faster with the E-Tec h ™).

r More retarding horsepower through a newly

designed J-Tech™ Engine Brake from Jacobs.

Mack Trucks, Inc . is looking beyond the borders of North America to increas e its mar ket and br ing the quality, toughness and technology associated with the MACK name to a worldwide audience. The current environment of global regulati ons concerning exhaust emissions, noise and other factors has leveled the playing field on an international basis. This means that the improvements made to meet the North American environmental regulations can now be applied worldwide.

The E-Tech™ engine is used in MACK trucks and European Renault VI trucks.

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IDENTIFICATION

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IDENTIFICATION

ENGINE MODEL IDENTIFICATION

Engine Information Plate

The E-Tech™ engine information plate is located on the top of the front cylinder head cover (back cover for LE and MR chassis). This plate includes information concerning:

r Engine model, serial number and 11GBA

part number.

r Advertised horsepower at rated speed rpm. r Emissions regulations to which the engine

conforms and other pertinent information required by emissions regulations.

r Inlet and exhaust valve lash settings and

engine brake slave piston lash setting.

The following explanations are provided to aid in interpreting some of the key information found on the engine information plate.

Block 1 — U.S. EPA Regulations

r An “X” in block one means the eng ine meets

United States EPA regulations for the year stamped in block four.

Block 3 — ADR Regulations

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

been certified to meet Australian emissions regulations.

r Two dashes in block three mean the engine

does not meet Australian emissions regulations.

Block 4 — Model Year

r The four-digit number stamped in block four

represents the year in which the engi ne was certified.

Block 5 — Federal Family

r A 12-digit number stamped in block five

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

r All domestic engines will have a 12-digit

Federal Family number in block five.

Block 6 — California Family

r If the engine meets California emissions

regulations, the same 12-digit number stamped in the Federal Family block is stamped in block six.

r Two dashes in bl ock one indicate the engine

does not meet United States EPA regulations for the year stamped in block four. This is only permissible with certain export engines. All domestic engines will have an “X” in block one.

Block 2 — California Regulations

r An “X” in block two indicates the engine

meets California emissions regulations for the year stamped in block four. This engine is referred to as a “50-state” engine and can be sold in any state throughout the U.S.

r Two dashes stamped in block two mean 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-sta te” engine, meaning it is not certified for sale in California.

r If the engine does not meet California

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

Block 7 — Initial Injection Timing

r E-Tech™ engines do not have an initial

injection timing, as this is controlled electronically.

r E-Tech™ engines will have “NA” stamped in

block seven.

Block 8 — Engine Brake

r This block is only used when the engine is

equipped with an engine brake. The stamping in this block indicates the engine brake slave-piston lash setting.

Figure 1 illustrates the location of the information plate and Figure 2 illustrates its content.

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IDENTIFICATION

Figure 1 — Engine Information Plate Location

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IDENTIFICATION

Figure 2 — Engine Information Plate

Engine Serial Number Identification

In addition to the engine information plate on the front cylinder head cover, the engine is also identified by the engine serial number stamped into the cylinder block. This serial number is located on the block right side just below the turbo oil drain tube flange as shown in Figure 3.

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Figure 3 — Engine Serial Number

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DESCRIPTION & OPERATION

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DESCRIPTION & OPERATION

E-TECH™ ENGINE DESIGN FEATURES

The E-Tech™ engine evolved from the E7 PLN (commonly referred to as the E7). The four primary design features that differentiate the E-Tech™ engine from the E7 engine are as follows:

r Electronic Unit Pump (EUP) fuel injection

system

r V-MAC r Poly-v belt drive system r J-Tech™ engine brake system from Jacobs

These major changes resulted in subsequent improvements and redesign of related components within the engine.

Electronic Unit Pumps

Electronic Unit Pump (EUP) technology, which has been utilized in the heavy-duty industry for many years, has been adapted for the E-Tech™ engine to achieve:

III electronic control system

The EUP is very similar to a unit injector. The primary difference is that the EUP delivers fuel through a fuel injection line to a convent ionalstyle nozzle-holder assembly, whereas a unit injector has a nozzle mounted directly on it.

The EUP is capable of providing very high fuelinjection pressures. The pump is controlled b y a high-speed solenoid valve (see Figure 4) responding to electronic signals from the V-MAC III engine control module. This electronic control provides a greater timing range. The combination of higher pressures and greater timing control improves the combustion process and optimizes engine performance. This enables the E-Tech™ engine to conform to more stringent emissions regulations while providing performance and fuel economy improvements.

r Optimum performance r Lower emissions r Simplified service r More effective pump/engine diagnostics

(individual cylinders can be isolated)

An EUP is a single-plunger fuel-injection pump, one per cylinder, driven by a third lobe on the engine camshaft. The pump roller follower (tappet) is in contact with the engine cam lobe.

Figure 4 — EUP Components

Electronic unit pumps for engines produced through approximately late 3r d quarter 2000 were fitted with three O-rings on the pump housings. Pumps on engines produced later than 3rd quarter 2000 are fitted with two O-rings in the top and bottom grooves. The O-ring in the center groove has been eliminated.

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