Mack ASET AC Service Manual

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ASET™ AC

DIESEL ENGINE

SERVICE MANUAL

OCTOBER 2006

(REVISED)

for Engines with Exhaust Gas Recirculation (EGR)

5-111

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Page 1 ASET™ AC DIESEL ENGINE SERVICE MANUAL OCTOBER 2006 (REVISED) for Engines with Exhaust Gas Recirculation (EGR) 5-111...
Page 2 Please include a copy of each page in question and mark your comments and suggestions. Name: ________________________________ Phone: (_____) _____-_______ Company: _______________________________________________________ Address: ________________________________________________________ City: _________________________________ State: _______ Zip: _______ Position Title: ____________________________________________________ Thank You For Your Assistance Mack Trucks, Inc. (ATTENTION: RTS STAFF, 6S3) DO NOT STAPLE — USE TRANSPARENT TAPE...
Page 3 IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO. 1602 ALLENTOWN, PA POSTAGE WILL BE PAID BY ADDRESSEE SERVICE PUBLICATIONS (RTS), 6S3 MACK TRUCKS INC WORLD HEADQUARTERS PO BOX M ALLENTOWN PA 18105-9972 FOLD ALONG THIS LINE...
Page 4 5-111.bk Page i Monday, July 10, 2006 2:26 PM ASET™ AC ENGINE SERVICE MANUAL View of ASET™ AC Engine OCTOBER 2006 © MACK TRUCKS, INC. 2006 (REVISED — SUPERSEDES ISSUE DATED JANUARY 2005) ENGINE 5-111...
Page 5 No part of this publication may be reproduced, stored in a retrieval system, or be transmitted in any form by any means including (but limited electronic, mechanical, photocopying, recording, otherwise without prior written permission of Mack Trucks, Inc. Page ii...
Page 6 5-111.bk Page iii Monday, July 10, 2006 2:26 PM TABLE OF CONTENTS TABLE OF CONTENTS Page iii...
Page 7: Table Of Contents
ABOUT THE MACK ASET™ AC DIESEL ENGINE ........
Page 8 ENGINE BRAKE TESTS (MACK POWERLEASH™) ........111...
Page 9 5-111.bk Page vi Monday, July 10, 2006 2:26 PM TABLE OF CONTENTS EGR Mixer Tube Removal ........... . 155 Thermostat Housing Removal .
Page 10 Valve Rocker Arm Shaft Reassembly (with J-Tech™ Engine Brake) ....266 Valve Rocker Arm Shaft Reassembly (with MACK PowerLeash™ Engine Brake) ..268 LUBRICATION SYSTEM BENCH PROCEDURES .
Page 11 5-111.bk Page viii Monday, July 10, 2006 2:26 PM TABLE OF CONTENTS Camshaft Installation ............307 Camshaft Core Plug Installation .
Page 12 5-111.bk Page ix Monday, July 10, 2006 2:26 PM TABLE OF CONTENTS CAMSHAFT REPLACEMENT (IN-CHASSIS) ........376 Preliminary Steps .
Page 13 5-111.bk Page x Monday, July 10, 2006 2:26 PM TABLE OF CONTENTS ENGINE FINAL PREPARATION AND OPERATIONAL CHECK ......462 Filter Element Installation .
Page 14: Introduction
5-111.bk Page 1 Monday, July 10, 2006 2:26 PM INTRODUCTION INTRODUCTION Page 1...
Page 15: Safety Information
5-111.bk Page 2 Monday, July 10, 2006 2:26 PM INTRODUCTION 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 cause it to be unsafe.
Page 16: Service Procedures And Tool Usage
5-111.bk Page 3 Monday, July 10, 2006 2:26 PM INTRODUCTION 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.
Page 17 5-111.bk Page 4 Monday, July 10, 2006 2:26 PM INTRODUCTION Mack Trucks, Inc. cannot anticipate every Use hoists or jacks to lift or move heavy possible occurrence that may involve a potential objects. hazard. Accidents can be avoided by recognizing...
Page 18: Explanation Of Numerical Code
GROUP 400 — STEERING, AXLES, WHEELS AND TIRES, DRIVELINE NUMERICAL CODE GROUP 500 — BRAKES, AUXILIARY The organization of MACK service manuals has SYSTEMS been upgraded to standardize manual content according to a reference system based on GROUP 600 — CAB, TRUCK BODY component identification.
Page 19: Conversion Chart
5-111.bk Page 6 Monday, July 10, 2006 2:26 PM INTRODUCTION CONVERSION CHART Conversion Units Multiply By: Length Calculations Inches (in) Millimeters (mm) 25.40 Inches (in) Centimeters (cm) 2.540 Feet (ft) Centimeters (cm) 30.48 Feet (ft) Meters (m) 0.3048 Yards (yd) Centimeters (cm) 91.44 Yards (yd)
Page 20 5-111.bk Page 7 Monday, July 10, 2006 2:26 PM INTRODUCTION Conversion Units Multiply By: Weight Calculations Ounces (oz) Grams (g) 28.5714 Pounds (lb) Kilograms (kg) 0.4536 Pounds (lb) Short Tons (US tons) 0.0005 Pounds (lb) Metric Tons (t) 0.00045 Short Tons (US tons) Pounds (lb) 2000 Short Tons (US tons)
Page 21 5-111.bk Page 8 Monday, July 10, 2006 2:26 PM INTRODUCTION Conversion Units Multiply By: Pressure Calculations Atmospheres (atm) Bars (bar) 1.01325 Atmospheres (atm) Kilopascals (kPa) 101.325 Bars (bar) Atmospheres (atm) 0.98692 Bars (bar) Kilopascals (kPa) Bar (bar) Pounds per Square Inch (psi) 14.5037 Inches of Mercury (in Hg) Kilopascals (kPa)
Page 22: About The Mack Aset™ Ac Diesel Engine
ASET™ AC diesel engine with cooled exhaust gas Mack Trucks, Inc. is looking beyond the borders recirculation. MACK offers a similar engine to the of North America to increase its market and bring...
Page 23 5-111.bk Page 10 Monday, July 10, 2006 2:26 PM NOTES Page 10...
Page 24: Visual Identification
5-111.bk Page 11 Monday, July 10, 2006 2:26 PM VISUAL IDENTIFICATION VISUAL IDENTIFICATION Page 11...
Page 25: Engine Model Identification
5-111.bk Page 12 Monday, July 10, 2006 2:26 PM VISUAL IDENTIFICATION ENGINE MODEL Item 5 — Federal Family IDENTIFICATION The 12-digit number stamped in block 5 denotes the Federal Family to which the engine belongs, for emissions certification (ASET™ AC ENGINE) purposes.
Page 26 5-111.bk Page 13 Monday, July 10, 2006 2:26 PM VISUAL IDENTIFICATION Item 9 — PowerLeash™ Engine Brake Figure 1 illustrates the location of the information plate and Figure 2 illustrates its content. Figure 3 An X in block 9 indicates the engine was illustrates a completed sample information plate built with a PowerLeash™...
Page 27: Engine Serial Number Identification
5-111.bk Page 14 Monday, July 10, 2006 2:26 PM VISUAL IDENTIFICATION Figure 3 — Sample of Completed 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.
Page 28: Description And Operation
5-111.bk Page 15 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION DESCRIPTION AND OPERATION Page 15...
Page 29: Engine Design Features
(ASET™ AC ENGINES) reduced NOx emissions. Included are both ® ® Econodyne and Maxicruise In the fall of 2002, Mack Trucks introduced two new engines that comply with changes in ASET™ AC ENGINE APPLICATIONS governmental laws regulating engine emissions. Engine Chassis Both engines evolved from the E7 E-Tech™...
Page 30: Aset™ Ac Engine Technologies
5-111.bk Page 17 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION ASET™ AC Engine Technologies The ASET™ AC engine uses current controlled rate shaping (CCRS) phased into production during 2001. Current controlled rate shaping provides a modulated two-phase injection of fuel into the cylinder.
Page 31 5-111.bk Page 18 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Figure 7 — Redesigned Valve Seat Inserts 1. Exhaust Valve Seat (with 30-Degree Contact Face) 2. Inlet Valve Seat (with 20-Degree Contact Face) With the ASET™ AC (CEGR) engine technology, The additional hardware required for the CEGR exhaust gas is recirculated by first being cooled engine exhaust gas recirculation includes...
Page 32: Aset™ Ac (Cegr) Engine Features And Components
5-111.bk Page 19 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION ASET™ AC (CEGR) Engine COOLED EXHAUST GAS RECIRCULATION Features and Components The ASET™ AC engine with cooled exhaust gas recirculation (CEGR) incorporates an EGR valve and cooler along with the necessary piping and The primary external features that identify the AC mixer tube (Figure 8).
Page 33 5-111.bk Page 20 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Figure 8 — Cooled Exhaust Gas Recirculation System (Engine Top View) 1. Water Pump-to-EGR Cooler Tube (Coolant Inlet) 6. EGR Valve 2. EGR Cooler-to-Bypass Tube (EGR Cooler Coolant Outlet) 7.
Page 34 5-111.bk Page 21 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION EGR Valve — The poppet-type valve, operated For current production (starting in March 2004), by hydraulic pressure from the engine oil system, the design of the EGR control valve shaft seal meters exhaust gas from the exhaust manifold has been changed to prevent contaminants from into the EGR circuit (Figure 9).
Page 35 5-111.bk Page 22 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION EGR Cooler — The cooler (Figure 11) is a EGR MASS Flow System Tubes and stainless steel assembly mounted on the lower Clamps — A one-piece, 2-inch (51 mm) diameter right side of the cylinder block.
Page 36 5-111.bk Page 23 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Figure 12 — MASS Flow System (with One-Piece Cool Tube Assembly) 1. EGR Cool Tube 7. MASS Flow Sensors 2. Upper Clamp 8. Lower Clamp 3. Coupling Hose and Clamps 9.
Page 37 5-111.bk Page 24 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Exhaust gases exiting the EGR valve are hot, near 1200°F (649°C). As such, the two tubes and four clamps are made of stainless steel to provide maximum service life. The hot tube section has an integral bellows that allows for expansion and contraction as engine temperatures change.
Page 38 5-111.bk Page 25 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION EGR MASS Flow System — As mentioned earlier, the EGR MASS Flow System (MFS) consists of a one-piece cool tube, two MASS flow sensors and the MFS electronic module. The MASS flow sensors are permanently mounted in the EGR tube bosses, and harnesses connect the sensors to the MFS electronic module.
Page 39 5-111.bk Page 26 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Boost Relief Valve (BRV) — Under certain EGR Valve Heat Shield — To protect the EGR operating conditions, high boost pressures and valve, its harness connection, oil supply and temperatures can be produced.
Page 40 5-111.bk Page 27 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION VARIABLE TURBINE GEOMETRY (VTG) In operation, modulated air pressure applied to TURBOCHARGER the actuator closes the vanes. As the vanes close, the exhaust gases flow faster through a The ASET™...
Page 41 5-111.bk Page 28 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION The VTG Position Control Valve, which is located Engines produced after May 4, 2004 have an oil on the intake manifold at the No. 4 cylinder coalescing air filter (Figure 19) incorporated into position, provides the modulated air pressure the air line supplying the control valve to prevent required for opening and closing the turbine...
Page 42 5-111.bk Page 29 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION COOLING SYSTEM CHANGES Redesigned Water Pump Housing Assembly — The water pump housing is a When replacing or reinstalling a removed completely new assembly (Figure 20) covering assembly, it is critical that the setup procedures the upper part of the cylinder block just above the are followed to prevent the housing from being front timing cover.
Page 43 5-111.bk Page 30 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Dual Thermostat Housing — To get the Dual Thermostat Housing Revisions for 2004 additional cooling capacity and flow requirements for the EGR system, two thermostats are used. The thermostat housing has an internal cast wall The thermostats are mounted in a new aluminum which divides the thermostat housing into two housing bolted to the top of the coolant (water)
Page 44 5-111.bk Page 31 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Heater Hose Connection Revisions — hose connection point. This change relocates the Beginning second quarter of 2004, a cooling heater coolant return hoses from the thermostat system revision was phased into production that housing bypass area to a new location on the affects the ASET™...
Page 45 5-111.bk Page 32 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Coolant and Inlet Manifolds — The coolant and Oil Cooler Filter Screen — A filter screen in the inlet manifolds are both new designs changed to Y-shaped hose at the oil cooler inlet has been accommodate the dual thermostat housing and added to collect debris and particulates the EGR mixer tube (Figure 24).
Page 46 5-111.bk Page 33 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION FRONT FAN AND ACCESSORY DRIVE Specific accessory drive belt routing per chassis ARRANGEMENT is included in the “SCHEMATIC & ROUTING DIAGRAMS” section of this manual. In the dual poly-V drive belt arrangement, the fan drive is driven directly from the crankshaft pulley by a 10-rib poly-V belt.
Page 47 5-111.bk Page 34 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Figure 27 — Dual Exhaust Springs (to Mid-Year 2003) Figure 28 — Dual Exhaust Springs (Mid-Year 2003 and Later) 1. Spring Rotator (Tip-End) 3. Exhaust Spring (Outer) 2. Hardened Spring 4.
Page 48 5-111.bk Page 35 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Figure 29 — Bottom Rotators 1. Rotator for Dual Springs 2. Rotator for Single Valve (Exhaust Location) Spring (Inlet Location) Valve Stem Seals Figure 30 — Valve Stem Seal (Later Design) The seal introduced with ASET™...
Page 49 5-111.bk Page 36 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION How Spring-Loaded Push Rods Operate During the valve closing cycle, as the lifter roller travels down the ramp and into the cam lobe During the “valve opening” cycle, as the lifter sub-base circle area, the push rod spring roller rides up the ramp of the cam lobe, the push expands making the push rod longer, thus...
Page 50 5-111.bk Page 37 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION INCREASED CAPACITY OIL PAN AND An improved centrifugal oil filter assembly was IMPROVED FILTRATION introduced in ASET™ AC engines in August 2003. This new centrifugal filter is called The capacity of the oil pan is 36 quarts ®...
Page 51 5-111.bk Page 38 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION EECU — The EECU is a completely new unit for long service life. Circuits are routed through (Figure 33). Because of its increased capacity the three connectors, EJ1 (36 pin), EJ2 (89 pin) and power, a cooling plate is required to maintain and EJ3 (16 pin), for control of: operating temperatures below the maximum...
Page 52 5-111.bk Page 39 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Figure 35 — ASET™ AC Engine Sensors (Right Side) 1. VTG Wheel-Speed Sensor (in Bearing Housing) 4. To Chassis-Mounted Compressor Discharge Temperature 2. VTG Position Sensor Sensor 3. Connector-to-Fan Speed Sensor 5.
Page 53 5-111.bk Page 40 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Ambient Air Temperature Sensor — P/N Inlet Manifold Temperature Sensor — P/N 64MT2118 64MT450A, mounted at a mid-point on the inlet manifold. Oil Pressure Sensor — Mounted at the side of the oil filter adapter housing.
Page 54: Mack Fuel Filtration System
(Figure 37) replaces the traditional primary and have the integral pre-pump screen and primary secondary fuel filter system. filter. Figure 37 — MACK Fuel Filtration System (SPIFF) 1. Fuel Pump 3. Pre-Pump Filter (Used in production prior to December 22, 2. Spin-On Type Filter (3–5 Microns) 2003;...
Page 55: Electronic Unit Pumps (Eup)
EUP delivers fuel three-piece delta O-ring seal is available through through a fuel injection line to a the MACK Parts System. The delta seal, a conventional-style nozzle-holder assembly; triangular O-ring with two nylon support rings...
Page 56: Engine Brake
MACK POWERLEASH™ ENGINE BRAKE FEATURES AND OPERATION The MACK PowerLeash™ engine brake has the hydraulically controlled valve train components integrated into the exhaust rocker arms. During engine brake operation, one of the exhaust...
Page 57 When the engine brake is “enabled” (switch in either LOW or HIGH position), the V-MAC electronic control system commands engine Figure 41 — MACK Engine Brake Cut-Away View brake power (engine brake “active”) only when the following conditions are true: 1.
Page 58 5-111.bk Page 45 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION If the engine brake is active, it will automatically The MACK PowerLeash™ engine brake may be be deactivated by depressing either the activated or deactivated by other vehicle systems accelerator or the clutch, or if the engine speed such as ABS and Headway control systems.
Page 59 The 0.125-inch brake-bump camshaft is stroke. mandatory for the PowerLeash™ engine brake. Figure 44 — MACK Engine Brake Exhaust Rocker Arm with Hydraulic Actuator Figure 43 — MACK Engine Brake Exhaust Lobe Profile 1. Valve Lash Adjusting 4. Engine Brake Lash Screw Adjusting Screw —...
Page 60 5-111.bk Page 47 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION The exhaust rocker arm has two adjusting screws. The adjusting screw located at the push rod end of the rocker arm adjusts engine brake plunger lash. The adjusting screw located at the valve end of the rocker arm adjusts exhaust valve lash.
Page 61 5-111.bk Page 48 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Solenoid Energized — When the engine brake exhaust valve open, oil pressure in the plunger solenoid energizes, oil flows into the rocker shaft cavity increases, forcing the check valve ball to “control”...
Page 62 5-111.bk Page 49 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Figure 47 — Rocker Shaft 1. Engine Brake Solenoid Port 3. Constant Supply Oil Gallery 2. Control Oil Gallery Oil is supplied to the rocker shaft through an oil This screen is a relatively fine (100 x 100 mesh) supply passage in the front rocker shaft mounting stainless steel screen with a nominal rating of...
Page 63 DESCRIPTION AND OPERATION Figure 50 — Spring-Loaded Push Rod Assembly 1. Push Rod Spring Cylinder Head Cover — The MACK PowerLeash™ engine brake is completely integrated with the valve train; therefore, Figure 49 — Exhaust Yoke, Actuating Pin and Valve...
Page 64 5-111.bk Page 51 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION J-TECH™ ENGINE BRAKE FEATURES AND High-pressure oil causes the slave piston to OPERATION move down, opening the outboard exhaust valve via a valve-actuating pin that passes Refer to Figure 52. through the center of the yoke adjusting screw.
Page 65 5-111.bk Page 52 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION The J-Tech™ engine brake may be activated or deactivated by other vehicle systems such as ABS and Headway control systems. Refer to the Deactivating the cruise control function does not literature concerning these systems for additional disable the engine brake.
Page 66: Camshaft
5-111.bk Page 53 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION With the J-Tech™ engine brake, the standard ASET™ engine valve yokes are used at both inlet and exhaust locations. However, a hollow yoke adjusting screw with a floating pin in the screw is used in the exhaust yokes (Figure 53).
Page 67 5-111.bk Page 54 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Pin-Type Yoke Figure 57 — Roller Lifters Figure 58 — Current Valve Yoke 1. Current Ceramic Roller 2. Non-Current Steel Roller Lifter Lifter 1. Headed Pin 3. Valve Yoke 2.
Page 68 5-111.bk Page 55 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION A second method of identifying the “button-head” The valve yokes used on the ASET™/E-Tech™ yoke is to look at the side view. On the yoke engines have a deeper engagement at the yoke design used for the ASET™...
Page 69 5-111.bk Page 56 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Figure 62 — Yoke/Valve Combinations 1. Correct E7 Yoke/Valve Combination 4. ASET™/E-Tech™ Yoke with E7 Valve 2. Correct ASET™/E-Tech™ Yoke/Valve Combination Note: Arrows identify problem areas. 3. E7 Yoke with ASET™/E-Tech™ Valve Page 56...
Page 70 Inlet and non-brake exhaust valve lash Approximately two years prior to ASET™ engine adjustments are performed in the normal manner introduction, MACK standardized the use of with the rocker arm adjusting screw. For the pinless valve yokes at all inlet valve locations, engine brake exhaust valves, it is still necessary together with standard push rods.
Page 71 5-111.bk Page 58 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION ROCKER ARM AND SHAFT ASSEMBLY Further rocker arm improvements include adjusting screws that have a groove around the Rocker Arm Improvements Effective January center of the screw, an oil passage cross-drilled 2002 through the shank of the screw and an oil passage drilled along the vertical center line of...
Page 72 5-111.bk Page 59 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Rocker Arm Improvements Effective January Rocker Arm Shaft 2003 Heavier wall thickness for added strength Effective January 2003, the following new and Increased radius in all retainer ring grooves, improved components were introduced into also for strength improvement production.
Page 73: Low-Pressure Fuel System
5-111.bk Page 60 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION The revised rocker arm components described above cannot be intermixed with previous version components. With the heavier rocker arms, it is mandatory to use the pinless valve yoke having the chamfered tip at the top of the inboard end.
Page 74 5-111.bk Page 61 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Figure 69 — Low-Pressure Fuel System for ASET™ AC Engine with SPIFF Filtration System Page 61...
Page 75 5-111.bk Page 62 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Figure 70 — Low-Pressure Fuel System for ASET™ AC Engine with Optional Fuel Filter Arrangement Page 62...
Page 76: High-Pressure Fuel System
5-111.bk Page 63 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION High-Pressure Fuel System Fuel is supplied to each of the unit pumps by the fuel supply gallery in the cylinder block. The high pressure required for fuel injection is generated The high-pressure fuel system (Figure 71) is by a pump plunger (10 mm diameter, 18 mm designed to provide fuel to the combustion...
Page 77: High-Pressure Fuel Injection Lines
5-111.bk Page 64 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION High-Pressure Fuel Injection Lines The high-pressure fuel lines for each cylinder (Figure 72) are short (17 inches) and have the strength to withstand the high fuel pressure generated by the electronic unit pumps. A standard configuration with the same part number is used for all cylinders and all engine models.
Page 78: Cylinder Block
5-111.bk Page 65 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Cylinder Block Due to the large camshaft diameter, the cam bore position is shifted up and outboard to operate the unit pumps and provide cam-to-crank clearance The cylinder block is a single-piece design made (Figure 74).
Page 79 5-111.bk Page 66 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION The main oil gallery runs along the left side of the block. A second oil gallery — the valve lifter/EUP oil supply gallery — runs along the right side of the block.
Page 80: Crankshaft
5-111.bk Page 67 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Crankshaft Block Heater The crankshaft is fully counterbalanced and has The engine accepts a straight element unit in the induction-hardened journals. It is supported with rear location. Effective with ASET™ engine main bearings at seven locations.
Page 81: Cylinder Head
5-111.bk Page 68 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Cylinder Head exhaust valves per cylinder. Circular grooves in the deck surface correspond with the fire ring bead on the cylinder sleeves. This design sets The cast-iron cylinder head (Figure 77) is the fire ring directly over the liner.
Page 82: Cylinder Head Gasket
5-111.bk Page 69 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Figure 78 — Cylinder Head and Cover (ASET™ Engines) Cylinder Head Gasket ASET™ engines use the same fire ring as the E7 engine, but the cylinder head gaskets are different.
Page 83: Gear Train
5-111.bk Page 70 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Gear Train rotate in the same direction, unlike the E7 engine. In addition, the power steering pump and air compressor rotate in a direction opposite that of The gear train (Figure 80) is designed to the E7.
Page 84: Air Compressor
5-111.bk Page 71 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Power Steering Pump All ASET™ engines have the capability of driving There are 45 gear teeth on the crankshaft gear, a power steering pump from either the front or 90 teeth on the camshaft gear and 48 on the idler rear of the auxiliary shaft.
Page 85: Front Cover
5-111.bk Page 72 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Front Cover The canister lid and element are removable to allow element cleaning. The front cover (Figure 83) has been designed with a boss for the automatic belt tensioner, room for the idler gear, a mounting for the crankcase breather, and a boss for the engine position sensor.
Page 86: Lubrication System
5-111.bk Page 73 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Lubrication System VALVE LIFTER/EUP OIL GALLERY Refer to Figure 86. ASET™ engines have oil galleries at both the left and right sides of the cylinder block. The galleries A second oil gallery, located above the camshaft, along with the corresponding passages supply supplies oil to the valve lifter bores and EUP...
Page 87 In replacing any of these critical parts, and not toward the pump cover, as with the E7 always refer to part number information in engine. the MACK Parts System to ensure the correct component is being used. Page 74...
Page 88 5-111.bk Page 75 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION OIL COOLER AND FILTER MOUNTING BRACKET The engines are equipped with a plate-type oil cooler and a centrifugal oil filter assembly, called ® Centri-Max ULTRA or ULTRA PLUS, that is inverted and mounted on top of the bracket.
Page 89 5-111.bk Page 76 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Ports for the V-MAC III oil pressure and oil OIL FILTERS temperature sensors are located on this mounting The lubrication system includes a centrifugal oil assembly. Remote oil supply ports are provided filter as well as primary and secondary full-flow for the turbocharger, EGR valve, J-Tech™...
Page 90 5-111.bk Page 77 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION ® The Centri-Max ULTRA was used from the start The ULTRA PLUS filter was introduced in a of ASET™ engine production through mid-2003 one-piece spindle configuration and later in a ®...
Page 91 5-111.bk Page 78 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION OIL COOLER A 2-1/4-inch diameter steel coolant tube connects the oil cooler water outlet to the water pump inlet The oil cooler is a plate-type assembly that has a (Figure 94).
Page 92 5-111.bk Page 79 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Figure 94 — Oil Cooler-to-Water Pump Inlet Line 1. Thermostat Bypass Tube 3. Oil Cooler-to-Water Pump Coolant Tube 2. Oil Cooler-to-Radiator Tube Connection OIL COOLER DE-AERATION LINE A de-aeration line is used to vent air which may otherwise become trapped in the plate-type oil cooler when filling the cooling system with coolant.
Page 93: Glossary Of Terms
Carbon Monoxide (CO) ASET™ AI (IEGR) engines, it is mounted near An odorless, colorless gas resulting from the rear of the manifold. With the MACK incomplete combustion of hydrocarbons; found in V-MAC III system, the EECU controls fuel timing diesel truck exhaust; poisonous to humans and and delivery, exhaust gas recirculation, fan animals.
Page 94 5-111.bk Page 81 Monday, July 10, 2006 2:26 PM DESCRIPTION AND OPERATION Internal Exhaust Gas Recirculation (IEGR) Poly-V Belt A system whereby the exhaust gas is drawn from A multi-ribbed belt design which is incorporated the exhaust manifold back into the combustion into the accessory drive belt and pulley chamber during the intake stroke to control the arrangement at the front of the engine.
Page 95 With the MACK V-MAC III system, the VECU controls engine speed, cruise control, accessory relay controls, idle shutdown and trip recorder functions.
Page 96: Component Locator
5-111.bk Page 83 Monday, July 10, 2006 2:26 PM COMPONENT LOCATOR COMPONENT LOCATOR Page 83...
Page 97: Component Location Views
5-111.bk Page 84 Monday, July 10, 2006 2:26 PM COMPONENT LOCATOR COMPONENT LOCATION VIEWS The locations of primary component assemblies of the ASET™ AC engine are identified in the illustrations contained in this section. These views, however, do not include sensor locations. Sensor locations are identified under “Engine Electronic Control Unit (EECU) and System Sensors”...
Page 98 5-111.bk Page 85 Monday, July 10, 2006 2:26 PM COMPONENT LOCATOR Figure 96 — ASET™ AC Engine, Right Side 1. EGR Gas Tube (Hot Side) 7. Turbo Wheel Speed Sensor (behind Actuator) 2. Variable Turbine Geometry (VTG) Turbocharger 8. EGR Coolant Return Hose 3.
Page 99 5-111.bk Page 86 Monday, July 10, 2006 2:26 PM NOTES Page 86...
Page 100: Troubleshooting
5-111.bk Page 87 Monday, July 10, 2006 2:26 PM TROUBLESHOOTING TROUBLESHOOTING Page 87...
Page 101: Engine Symptom Diagnosis For Mack Aset™ Engines
5-111.bk Page 88 Monday, July 10, 2006 2:26 PM TROUBLESHOOTING ENGINE SYMPTOM DIAGNOSIS FOR MACK ASET™ ENGINES V-MAC III Diagnostics When operating in cold weather, fuel waxing can cause many of the problems described below. Also, water in the fuel can damage unit pumps and nozzles.
Page 102 5. Poor quality fuel, or water in fuel. 5. Drain fuel from tank. Replace fuel filters and fill fuel tank with MACK-specified diesel fuel. 6. Incorrect engine oil viscosity. 6. Drain oil. Replace oil filters and fill crankcase with recommended grade oil.
Page 103 2. Poor quality fuel, or water or dirt in fuel. 2. Drain fuel from tanks. Replace fuel filters and fill tank with MACK-specified diesel fuel. 3. Air in fuel system. 3. Check fuel system for air leaks. Repair as necessary. (Air generally gets into the fuel system on suction side of the fuel pump.)
Page 104 5-111.bk Page 91 Monday, July 10, 2006 2:26 PM TROUBLESHOOTING ENGINE STALLS AT LOW SPEEDS Possible Cause Correction 1. Code(s) present. 1. Correct cause of code(s). 2. Cylinder cutting out. 2. Isolate cylinder and determine cause of cutting out. Refer to item 8 in ENGINE MISFIRES —...
Page 105 7. Poor quality fuel. 7. Drain fuel tank(s), clean system and replace fuel filters. Fill tank with MACK-specified diesel fuel. Bleed system. 8. Low fuel pressure. 8. Check for sufficient fuel in the fuel tank. Check fuel filters (including the pre-pump filter screen, if so equipped), replace if necessary.
Page 106 5. Improper grade of fuel. 5. Drain fuel from tank(s). Replace fuel filters and fill tank(s) with MACK-specified diesel fuel. 6. Defective fuel injection nozzle or unit pump. 6. Isolate defective nozzle and replace. Refer to item 8 under ENGINE MISFIRES —...
Page 107 5. Drain excess lubricating oil. If the oil is contaminated with either fuel or coolant, completely drain the oil pan. Change the oil filters. Locate the source of the leak and correct. Fill with MACK-specified engine oil. Check the oil level with the dipstick. DO NOT overfill.
Page 108 5-111.bk Page 95 Monday, July 10, 2006 2:26 PM TROUBLESHOOTING EXCESSIVE OIL CONSUMPTION Possible Cause Correction 1. External oil leaks. 1. Check engine for visible signs of oil leakage. Look for loose or stripped oil drain plugs, broken gaskets (cylinder head cover, etc.), and front and rear oil seal leakage.
Page 109 5-111.bk Page 96 Monday, July 10, 2006 2:26 PM TROUBLESHOOTING HIGH EXHAUST TEMPERATURE Possible Cause Correction 1. Operating chassis in wrong gear ratio for load, 1. Instruct operator on correct gear selection for load and grade grade and/or altitude. conditions. 2.
Page 110 MACK specifications. 5. Engine oil diluted with diesel fuel. 5. Check fuel system for leaks. Make necessary repairs. Drain diluted oil, change oil filters, and refill with oil meeting MACK specifications. 6. Defective oil pump. 6. Remove oil pressure relief valve and check condition of seat.
Page 111 5-111.bk Page 98 Monday, July 10, 2006 2:26 PM TROUBLESHOOTING LOW COMPRESSION Possible Cause Correction 1. Improper valve lash adjustment. 1. Adjust valve lash to specified clearance. 2. Blown head gasket. 2. Replace head gasket. 3. Broken or weak valve springs. 3.
Page 112: Camshaft Timing And Lobe Lift Checks
5-111.bk Page 99 Monday, July 10, 2006 2:26 PM TROUBLESHOOTING CAMSHAFT TIMING AND LOBE 3. Loosen (back off) the inlet valve rocker adjusting screw jam nut. Ensure that the LIFT CHECKS valve yoke is correctly adjusted. Adjust the [213 CH] inlet valve to zero lash.
Page 113: Chassis-Mounted Charge Air Cooling Tests
5-111.bk Page 100 Monday, July 10, 2006 2:26 PM TROUBLESHOOTING CHASSIS-MOUNTED CHARGE Hot turbocharged air, varying in pressure from 0.0–25 psi (0.0–172 kPa), passes through core AIR COOLING TESTS tubes where heat is transferred to the ambient air [233 FA] by heat-exchanging fins.
Page 114: Cmcac Pressure Test
5-111.bk Page 101 Monday, July 10, 2006 2:26 PM TROUBLESHOOTING CMCAC Pressure Test 5. When plugs are secured, attach an air line (fitted to a pressure regulator and gauge) to the air line adapter in the core outlet Refer to Figure 97. opening.
Page 115: Restriction Pressure Test
5-111.bk Page 102 Monday, July 10, 2006 2:26 PM TROUBLESHOOTING Restriction Pressure Test 6. If the cooler passes the restriction and pressure tests, remove the test equipment, reinstall inlet and outlet tubes, hoses and clamps. Reinstall the gauge-port plugs on systems so equipped.
Page 116: Core Inspection
5-111.bk Page 103 Monday, July 10, 2006 2:26 PM TROUBLESHOOTING Core Inspection GUIDELINES With the exception of straightening minor bends in the cold fins, the CMCAC core is not repairable and should be replaced when more extensive damage is encountered. To ensure that the CMCAC system will function properly after repair or replacement, a pressure/leak test is recommended.
Page 117: Cylinder Head And Cylinder Block Leak Test Procedure
5-111.bk Page 104 Monday, July 10, 2006 2:26 PM TROUBLESHOOTING CYLINDER HEAD AND Cylinder Head and Head Gasket CYLINDER BLOCK LEAK TEST Check — In Chassis PROCEDURE 1. Look for coolant stains around the 3/4-inch NPT pipe plugs on top of the cylinder heads. Verify suspected leaks in the cylinder heads or Check plug torque.
Page 118: Cylinder Head Fuel Passages Leak Check - In Chassis
5-111.bk Page 105 Monday, July 10, 2006 2:26 PM TROUBLESHOOTING 4. Remove the upper and lower hoses from the thermostat housing. Remove the thermostat housing and thermostat(s). It is normal for some air bubbles to form in the 5. Secure a suitable plate and gasket over the cooling system as a result of the engine warming thermostat housing opening in the coolant up to operating temperature.
Page 119 5-111.bk Page 106 Monday, July 10, 2006 2:26 PM TROUBLESHOOTING Refer to the repair procedures in this manual to correct leaks. Figure 99 — Cylinder Block/Cylinder Head Leak Check (In Chassis) 1. Water Pump Inlet Cover Plate 7. Install additional hose clamp. 2.
Page 120: Cylinder Head Oil Passage Leak Check - Out Of Chassis
trouble.fm Page 107 Tuesday, July 11, 2006 10:38 AM TROUBLESHOOTING Cylinder Head Oil Passage Leak 4. Bolt the modified bracket with air fitting to the cylinder head over the oil supply Check — Out of Chassis passage. 5. Immerse the cylinder head in water. Heat Refer to Figure 100.
Page 121: Cylinder Head Coolant Passage Leak Check - Out Of Chassis
5-111.bk Page 108 Monday, July 10, 2006 2:26 PM TROUBLESHOOTING Cylinder Head Coolant Passage 3. Use suitable plate and gasket to seal the water manifold openings. Install an air fitting Leak Check — Out of Chassis onto the plate. 4. Immerse the cylinder head in water. Heat Refer to Figure 101.
Page 122: Cylinder Block Coolant Passage Leak Check - Out Of Chassis
5-111.bk Page 109 Monday, July 10, 2006 2:26 PM TROUBLESHOOTING Cylinder Block Coolant Passage 2. Remove the water pump assembly and seal the opening with a suitable plate and rubber Leak Check — Out of Chassis gasket. The plate must be fabricated with adapters so that water heated to 150°F Refer to Figure 102.
Page 123 5-111.bk Page 110 Monday, July 10, 2006 2:26 PM TROUBLESHOOTING Figure 102 — Cylinder Block Coolant Passage Leak Check (Out of Chassis) 1. Cylinder Block 4. Rubber Gasket 2. 1/4-inch Rubber Gaskets 5. Plate with Air/Water Inlet Fittings 3. 3/4-inch Steel Plates Page 110...
Page 124: Engine Brake Tests (Mack Powerleash™)
POWERLEASH™) The ASET™ engines may be equipped with Engine brake will not engage until coolant either a MACK PowerLeash™ engine brake or a temperature has reached 125°F (52°C). J-Tech™ engine brake. The test procedures in this section apply only to the MACK 1.
Page 125: Electrical Troubleshooting
A low resistance reading indicates a short to ground in the The MACK PowerLeash™ engine brake is solenoid wire or solenoid coil. activated by the V-MAC system. When the ignition switch is turned ON, the engine brake...
Page 126: Mack Powerleash™ Checks (Hydraulic/Mechanical)
Repeat for all valve cover/spacer terminals. 3. Check solenoid operation. The solenoid used with the MACK PowerLeash™ has a 0.200 inch diameter hole in the top that provides a means of troubleshooting solenoid operation. To check solenoid operation, insert a pin (having a diameter less than 0.200 inch) into the hole, then...
Page 127 Personal injury may problem as described under “OIL PRESSURE result. DROPPING BELOW MINIMUM REQUIRED FOR ENGINE BRAKE OPERATION” in the MACK PowerLeash™ Troubleshooting Guide included in this section. Brake lash settings must be made with the engine stopped and cold and with the exhaust valves closed.
Page 128: Mack Powerleash™ Troubleshooting Guide
Readjust if needed or replace if voltage will Engine brake improperly wired — Check not pass through switch. wiring in accordance with MACK wiring diagrams. Control pistons binding in bore — Remove control piston. If body is scored, Do not touch electrical connection when replace the control piston.
Page 129 Have an oil analysis of lube oil to determine lower snap ring. If plunger does not move if fuel is present. Correct per MACK freely, replace the rocker arm assembly. procedures. Control piston binding in rocker arm Low engine oil level —...
Page 130: Removal And Inspection Of Mack Powerleash™ Engine Brake Components
5-111.bk Page 117 Monday, July 10, 2006 2:26 PM TROUBLESHOOTING Removal and Inspection of MACK ONE OR MORE CYLINDERS FAIL TO STOP BRAKING OR ENGINE STALLS PowerLeash™ Engine Brake Control piston spring/valve inner spring Components broken — Replace piston spring.
Page 131 5-111.bk Page 118 Monday, July 10, 2006 2:26 PM TROUBLESHOOTING 3. Verify check valve function by carefully 4. If the check valve, control piston and control inserting a small screwdriver, drift pin or piston spring are OK, remove the rocker arm similar type of tool into the control piston and check the hydraulic actuator plunger as bore and pushing on the check valve ball.
Page 132: Engine Brake Tests (J-Tech™)
There should The ASET™ engines may be equipped with be no signs of “mushrooming” or other either a MACK PowerLeash™ engine brake or a damage where the plunger contacts the J-Tech™ engine brake. The test procedures in head of the actuating pin.
Page 133: Electrical Troubleshooting
ENGINE BRAKE ® V-MAC control feature that automatically Retarding boost pressures for MACK ASET™ engines provides a level of protection by activating the equipped with J-Tech™ engine brakes were not available engine brake only after the recommended at time of publication.
Page 134: J-Tech™ Checks (Hydraulic/Mechanical)
5-111.bk Page 121 Monday, July 10, 2006 2:26 PM TROUBLESHOOTING ONLY ONE HOUSING OPERATING POOR PERFORMANCE Connect a volt/ohmmeter (multimeter) to the 1. Determine which housing is not operating by electrical connector on the valve cover/spacer. closing all the switches and checking the Verify that a steady voltage signal is present power at the wires leading to the solenoid when the engine brake is active.
Page 135 5-111.bk Page 122 Monday, July 10, 2006 2:26 PM TROUBLESHOOTING INSPECTION OF J-TECH™ ENGINE BRAKE COMPONENTS If oil pressure at the brake housings is sufficient Brake slave piston clearance settings must be for brake operation, then inspect the engine made with the engine stopped and cold and with brake components for excess wear, damage or the exhaust valves closed.
Page 136 5-111.bk Page 123 Monday, July 10, 2006 2:26 PM TROUBLESHOOTING 5. If the control valves and springs are OK and the master and slave pistons were observed not to be operating, remove the housings for Reset screw assemblies are not field serviceable. inspection.
Page 137: J-Tech™ Troubleshooting Guide
121. Make sure wiring is in gaskets and covers. accordance with MACK wiring instructions. 6. Test drive the vehicle following the Test Low engine oil pressure — Determine oil...
Page 138 If unable to remove burrs, Engine brake improperly wired — Check replace piston or housing. Inspect lube oil for wiring in accordance with MACK wiring signs of contaminants. If any are present, diagrams. replace oil and filter and correct cause of contamination.
Page 139 Lubricating oil being diluted by fuel oil — Upper solenoid valve seal missing or Have an oil analysis of lube oil to determine damaged — Remove solenoid and replace if fuel is present. Correct per MACK upper seal ring. procedures. Low engine oil level — Consult engine manual for specifications.
Page 140: Maintenance
5-111.bk Page 127 Monday, July 10, 2006 2:26 PM MAINTENANCE MAINTENANCE Page 127...
Page 141: Lubrication System Maintenance For Aset™ Engines
5-111.bk Page 128 Monday, July 10, 2006 2:26 PM MAINTENANCE LUBRICATION SYSTEM MAINTENANCE FOR ASET™ ENGINES Crankcase Breather Element Cleaning [219 ER] All ASET™ engines are equipped with a fiberglass-reinforced nylon crankcase breather element canister. The procedure for cleaning the element is as follows: 1.
Page 142: Oil Level Check
5-111.bk Page 129 Monday, July 10, 2006 2:26 PM MAINTENANCE Oil Level Check For accurate oil level readings, the dipstick must be inserted into the dipstick tube with the “L” and “F” markings facing upward. On conventional When checking oil levels, the vehicle must be cabs, this will be with the finger-loop facing parked on level ground and the units at normal outboard, or away from the engine.
Page 143: Oil And Filter Change Procedure
Add oil if necessary. Use of anything other than genuine MACK filters may cause damage and void the engine warranty. Change filters according to the ®...
Page 144 5-111.bk Page 131 Monday, July 10, 2006 2:26 PM MAINTENANCE ® CENTRI-MAX ULTRA OR ULTRA PLUS OIL FILTER [219 EV] The following procedure applies for both the ULTRA and ULTRA PLUS filters. However, the ULTRA PLUS rotor bushing hole sizes and the mating shaft journals are smaller than those of the ULTRA filter.
Page 145 5-111.bk Page 132 Monday, July 10, 2006 2:26 PM MAINTENANCE ® Centri-Max ULTRA PLUS Spindle Replacement (If Required) ® The Centri-Max ULTRA PLUS with the two-piece spindle and new smaller diameter shaft became the standard for all ASET™ engines in the fourth quarter of 2003.
Page 146 5-111.bk Page 133 Monday, July 10, 2006 2:26 PM MAINTENANCE 6. Install a new O-ring on the filter housing base (Figure 115). The O-ring should be installed dry, non-lubricated. ® Figure 113 — Apply Loctite 271 to Spindle Threads 5. Assemble the new spindle to the oil filter mounting adapter.
Page 147: Fuel Filter Element Replacement For Aset™ Ac Engines
5-111.bk Page 134 Monday, July 10, 2006 2:26 PM MAINTENANCE FUEL FILTER ELEMENT REPLACEMENT FOR ASET™ AC ENGINES Primary/Secondary Fuel Filter Change [231 BA] SPECIAL TOOL REQUIRED Fuel and Oil Filter Wrench J 24783 For engines produced before December 22, 2003, clean or replace the pre-pump filter screen and change the secondary fuel filter at each specified oil and filter change interval.
Page 148 5-111.bk Page 135 Monday, July 10, 2006 2:26 PM MAINTENANCE PRE-PUMP FILTER CARTRIDGE CLEANING 2. With a suitable container in place under the OR REPLACEMENT filter element, open the drain fitting to remove residual fuel from the element. This To remove, clean or replace the pre-pump filter step is necessary to avoid fuel spillage as cartridge (if so equipped): the filter is tilted to move it out from between...
Page 149 5-111.bk Page 136 Monday, July 10, 2006 2:26 PM MAINTENANCE Figure 117 — MACK Fuel Filtration System (AC Engine) 1. Fuel Supply Pump with Filter Mounting Provision 3. Pre-Pump Filter (Used in production prior to 2. Fuel Filter Element December 22, 2003; replaced by a plug and O-ring in later production.)
Page 150: Coolant Conditioner Element Replacement For Aset™ Engines
5-111.bk Page 137 Monday, July 10, 2006 2:26 PM MAINTENANCE COOLANT CONDITIONER OIL COALESCING AIR FILTER ELEMENT REPLACEMENT FOR REPLACEMENT ASET™ ENGINES Engines produced after May 4, 2004 have an oil coalescing air filter incorporated into the air line Coolant Conditioner Replacement supplying the control valve to prevent oil condensation and possible “coking”...
Page 151: Drive Belt Replacement And Tensioning For Aset™ Ac Engines
maintenance.fm Page 138 Tuesday, July 11, 2006 10:49 AM MAINTENANCE DRIVE BELT REPLACEMENT 1. Rotate the knob on the air line shut-off valve to the horizontal (off) position. When the AND TENSIONING FOR ASET™ valve is closed, residual pressure in the filter AC ENGINES and lines is bled to the atmosphere.
Page 152: Automatically Tensioned System
5-111.bk Page 139 Monday, July 10, 2006 2:26 PM MAINTENANCE Automatically Tensioned System Refer to ASET™ AC ENGINE DRIVE BELT INSTALLATION SPECIFICATIONS section for belt sizing and part Swing the tensioner to the fully sprung position numbers. and, without force, place the belt over the pulleys. Do not allow the tensioner to snap against its stops.
Page 153 5-111.bk Page 140 Monday, July 10, 2006 2:26 PM NOTES Page 140...
Page 154: Repair Instructions, Part 1
5-111.bk Page 141 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 REPAIR INSTRUCTIONS, PART 1 Page 141...
Page 155: Engine Removal
5-111.bk Page 142 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 ENGINE REMOVAL 3. Using an appropriated filter wrench, remove the oil filters, fuel filter(s) and coolant conditioner. General Instructions 4. If the vehicle is equipped with air conditioning: Details of the engine removal procedure vary Recover the refrigerant using A/C...
Page 156 5-111.bk Page 143 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 13. Remove the fan assembly as follows: Loosen the eight fan assembly mounting nuts and capscrews. Refer to Figure 120. While supporting the fan assembly, remove the nuts from the capscrews and remove the assembly.
Page 157 5-111.bk Page 144 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 18. Loosen clamps that secure the air intake 22. Remove the exhaust bracket from the tube to the turbocharger and air filter. clutch, torque converter or flywheel housing. Remove the intake tube.
Page 158: Engine Disassembly
5-111.bk Page 145 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 ENGINE DISASSEMBLY 25. Support the transmission with an appropriate transmission jack. 26. Remove the retaining bolts that secure the General Instructions transmission bell housing to the flywheel housing.
Page 159: Dipstick Tube Removal
5-111.bk Page 146 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Dipstick Tube Removal ASET™ AC engines are all built with the dipstick tube mounted on the left side of the engine which extends into the oil pan. This tube must be removed after all the oil has been drained, but before the oil filter mounting bracket assembly can be removed.
Page 160: Oil Coalescing Air Filter Removal
5-111.bk Page 147 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Oil Coalescing Air Filter Removal If so equipped, the oil coalescing air filter assembly and bracket must also be removed before mounting the engine in a stand. Refer to Figure 126 and remove the assembly as follows: 1.
Page 161: Mounting Engine In Stand
5-111.bk Page 148 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Mounting Engine in Stand Engine stand, Kent-Moore tool number J 29109, and adapter plate J 38048, are recommended to The engine weighs approximately 2,300 lbs. safely support the engine during disassembly and (1043 kg) wet.
Page 162 5-111.bk Page 149 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 128 — Mounting Engine in Stand 1. Adapter Plate J 38048 3. Engine Stand J 29109 2. Capscrews 4. Capscrew Page 149...
Page 163: Alternator Removal
5-111.bk Page 150 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Alternator Removal Engine Electronic Control Unit (EECU) and Cooling Plate Removal [271 CB] [230 EA] Refer to Figure 129. 1. Loosen the adjusting capscrew and mounting capscrews. The following procedure applies for an EECU 2.
Page 164 5-111.bk Page 151 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 4. Remove the eight bolts, two each at the top, 6. Disconnect the two harness leads from the bottom and sides, that secure the EECU to EGR MASS Flow module mounted to the the cooling plate.
Page 165: Egr Gas Tube Removal
5-111.bk Page 152 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 EGR Gas Tube Removal 7. Disconnect the fuel lines at the inlet and outlet ports at the top of the cooling plate [214 HN, HP & HR] (Figure 133) and position the lines out-of-way.
Page 166 5-111.bk Page 153 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 2. Loosen and remove the clamps securing the cool tube to the brackets at the EGR valve and the front section of the exhaust manifold (Figure 135). Figure 135 —...
Page 167: Egr Cooler Removal
5-111.bk Page 154 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 2. Loosen and remove the clamp connecting the hot tube-to-EGR valve outlet flange. The hot tube also is fitted with wire-mesh seals in Early-production engines will use coupling the flanges at both ends.
Page 168: Egr Mixer Tube Removal
5-111.bk Page 155 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 EGR Mixer Tube Removal 3. Remove the capscrews attaching the mixer tube to the inlet manifold (Figure 141) and [214 HL] remove the tube. 1. Disconnect the electrical leads to the CMCAC outlet pressure and temperature sensors.
Page 169: Thermostat Housing Removal
5-111.bk Page 156 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Thermostat Housing Removal 2. Remove the cab heater coolant return hose from the thermostat housing (if applicable). [215 NG] Also remove the optional fuel heater coolant return hose from the thermostat housing (if 1.
Page 170: Oil Supply Lines Removal
5-111.bk Page 157 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Oil Supply Lines Removal To remove the oil lines, first cut the stainless steel straps (if so equipped) that secure the lines [214 HS, HT & RN] together and to any support brackets.
Page 171 5-111.bk Page 158 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 EXTERNAL OIL SUPPLY ARRANGEMENT mounting bracket and a junction block at the left ASET™ AC ENGINES BUILT AFTER side of the cylinder heads. Oil is supplied to the DECEMBER 2003 J-Tech™...
Page 172: Egr Valve Removal
5-111.bk Page 159 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 EGR Valve Removal 2. Remove the three nuts retaining the EGR valve upper mounting bracket to the spacer [214 QE] studs and remove the bracket and washers. 3.
Page 173: Water Pump Housing Removal
5-111.bk Page 160 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Water Pump Housing Removal Figure 148 — Water Pump Assembly 1. Engine Lifting Bracket 5. Low-Position Mounting Capscrews 2. Threaded Inserts and Upper Mounting Capscrews 6. Water Pump Assembly 3.
Page 174 5-111.bk Page 161 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 150 — Pump Cartridge Assembly 1. Cartridge Assembly 2. Pump Housing 3. Disconnect the coolant supply hose to the EGR cooler from the fitting on the water pump.
Page 175: Vtg Position Control Valve Removal
5-111.bk Page 162 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 VTG Position Control Valve 7. Remove the water pump stiffening bracket by first removing the two M8 flanged nuts Removal from the studs at the forward position of the coolant manifold.
Page 176: Coolant Manifold Removal
5-111.bk Page 163 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Coolant Manifold Removal 2. Remove the air inlet manifold. It may be necessary to gently pry or tap the manifold [215 NK] lightly with a soft mallet to break the seal. 3.
Page 177: Fuel Nozzle Inlet Tube Assembly Removal
5-111.bk Page 164 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Fuel Nozzle Inlet Tube Assembly Removal [222 KD] 1. Remove the three retaining nuts and remove the two outer EUP heat shields (Figure 155). 2. Remove the four retaining nuts securing the inner heat shield to the cylinder block and remove the shield.
Page 178: Exhaust Manifold Removal
5-111.bk Page 165 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Exhaust Manifold Removal 3. Loosen the tube line nut at the unit pump for the No. 1 cylinder (Figure 156). Be careful to [214 EG] avoid twisting the line while loosening the nut.
Page 179: Electronic Unit Pump (Eup) Removal
5-111.bk Page 166 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Electronic Unit Pump (EUP) 5. Remove the outboard EUP screw completely and remove the EUP from the Removal cylinder block. Refer to Figure 158. Place the EUP in a clean area and cover it to [221 GP] prevent entry of dirt and other contaminants.
Page 180: Air Compressor Removal
5-111.bk Page 167 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Air Compressor Removal [261 CK] The air compressor is heavy. Lifting the air compressor may require the help of an Refer to Figure 160. assistant or suitable lifting device. Attempting to lift the compressor without such Disconnect the coolant supply and return lines at assistance may result in severe personal...
Page 181 5-111.bk Page 168 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 161 — Air Compressor Removal 1. Air Compressor 4. Oil Drain Openings 2. Oil Supply Tube 5. Capscrew 3. Auxiliary Shaft Page 168...
Page 182: Cylinder Head Cover And Spacer Removal
Engines equipped with the MACK PowerLeash™ engine brake do not have the spacer installed. If the solenoid wire is damaged from failure to WITHOUT ENGINE BRAKE disconnect the wire as described above, the solenoid assembly will need to be replaced.
Page 183: Rocker Arm, Valve Yoke And Push Rod Removal
5-111.bk Page 170 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Rocker Arm, Valve Yoke and Push Rod Removal Should the cylinder head cover be removed [213 LP, NV & LH] without first disconnecting the solenoid wire from the connector on the inside of the cover, the wire can easily be damaged.
Page 184 5-111.bk Page 171 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 165 — Rocker Arm Shaft Assembly with J-Tech™ Engine Brake 1. Cylinder Head Cover 8. Exhaust Valve Yokes 2. Spacer 9. Actuator Pin Assembly 3. Capscrew 10.
Page 185: Revised Rocker Arm Shift Mounting Bolts
ASET™ cylinder head. engines. 2. If the engine is equipped with a MACK PowerLeash™ engine brake, disconnect the ground and power wires. If any rocker shaft mounting bolts are found to be broken, all 12 mounting bolts MUST be replaced.
Page 186: Nozzle Holder Removal
5-111.bk Page 173 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Do not replace an entire rocker shaft assembly (which includes the rocker arms, mounting brackets, etc.) if only replacement of the shaft is required. Reuse components which are not damaged.
Page 187 5-111.bk Page 174 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 168 — Cylinder Heads 1. Bolt 3. Cylinder Head 2. Cylinder Block 4. Bolt (with Bracket Mounting Capscrew Hole in Head) Page 174...
Page 188: Vibration Damper And Crankshaft Hub Removal
5-111.bk Page 175 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Vibration Damper and Crankshaft Hub Removal [212 RB, RH] 1. Remove the capscrews attaching the vibration damper to the crankshaft hub (Figure 169). Six or 12 capscrews may be used to mount the damper to the hub depending on date of production.
Page 189 5-111.bk Page 176 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 171 — Isolating Oil Pan Hex-Head Shoulder Bolt (A) and Shoulder Stud (B) Locations Page 176...
Page 190: Oil Pump Removal
5-111.bk Page 177 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Oil Pump Removal [219 MU] Refer to Figure 172. If the oil pump must be disassembled for any reason, it will be easier to loosen the housing cover retaining capscrews, the screen, the oil inlet tube capscrews, the cover plate capscrews, and the relief valve cap while the pump is still...
Page 191: Front Cover Removal
5-111.bk Page 178 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Front Cover Removal Auxiliary Shaft Removal [211 RP] [212 CV] The engine can remain inverted on the stand or Refer to Figure 174. rotated with the cylinder deck up for removal of the front cover and auxiliary shaft if preferred.
Page 192: Camshaft Removal
5-111.bk Page 179 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 3. Remove the two retaining capscrews from the auxiliary shaft captured thrust washer. Remove the thrust washer. When the engine is rotated, the roller valve lifters will fall downward into the push rod holes and rest against the H-rings.
Page 193: Piston And Connecting Rod Assembly Removal
5-111.bk Page 180 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Piston and Connecting Rod 4. Install the camshaft removal/installation tool J 41682 (Figure 178) in position on the rear Assembly Removal segment of the camshaft, securing it to the shaft with the clip.
Page 194 5-111.bk Page 181 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 180 — Carbon Removal from Cylinder Sleeves Figure 181 — Piston and Connecting Rod Assembly Removal 4. Rotate the crankshaft so that pistons 1 and 6 5.
Page 195: Flywheel Removal
5-111.bk Page 182 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Flywheel Removal [212 UC] 1. With the engine stand rotated so that the engine is inverted (crankshaft horizontal), loosen all six flywheel retaining capscrews. On vehicles equipped with an automatic transmission, it may be necessary to remove additional components to gain access to the flywheel retaining capscrews.
Page 196: Flywheel Housing Removal
5-111.bk Page 183 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Flywheel Housing Removal Main Bearing Cap Removal [211 HD] [211 JA] 1. Support the flywheel housing and remove the eight mounting capscrews (Figure 183). 2. Remove the flywheel housing. It may be Before removing the main bearing caps, ensure necessary to tap lightly on the housing with that they are marked for reinstallation on the...
Page 197 5-111.bk Page 184 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 184 — Buttress Capscrew Installation 1. Main Bearing Cap Capscrews 4. Main Bearing Caps 2. Buttress Capscrews, 80 mm 5. Center Main Bearing Cap 3. Buttress Capscrews, 110 mm Page 184...
Page 198: Crankshaft Removal
5-111.bk Page 185 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Crankshaft Removal CYLINDER BLOCK RECONDITIONING [212 HP] [211 DB] Refer to Figure 185. Special Tools Required 1. Using a suitable lifting device, secure a sling or crankshaft support tool around the Camshaft Bushing Installation/Removal Kit crankshaft and lifting device hook.
Page 199: Cylinder Sleeve Removal
5-111.bk Page 186 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 4. Position the puller shoe so that it catches the lower lip of the sleeve. Ensure that it does not extend beyond the outside edges of the sleeve so that it will not come into contact with the cylinder block as the sleeve is removed.
Page 200: Cleaning And Inspection
5-111.bk Page 187 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Cleaning and Inspection The engine should have been thoroughly steam cleaned prior to component removal. If heavy accumulations of dirt and grease are still present, steam clean the block as thoroughly as possible before attempting to clean with solvents.
Page 201 5-111.bk Page 188 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 SOLVENT TANK CLEANING Use a cleaning tank large enough to accommodate the largest component to be cleaned. Fill the tank with a suitable solvent and always use caution while cleaning parts. Parts may be dried with compressed air.
Page 202 5-111.bk Page 189 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 SALVAGING A DAMAGED VALVE LIFTER LIFTER BORE CLEANING AND LIFTER BORE CHECKS Occasionally, a failure will result in severe wear While the camshaft is removed and lifter bores and breakage of the roller and roller axle.
Page 203: Cylinder Sleeve Counterbore
5-111.bk Page 190 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Cylinder Sleeve Counterbore [211 DB] Do not cut seats deeper than 4.040 inches (102.616 mm). If the maximum recut dimension is reached and visible pitting remains, the pitting is INSPECTION AND REPAIR acceptable as long as there is not a complete If the cylinder block deck is resurfaced, the...
Page 204 5-111.bk Page 191 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 2. Install the cutter plate on the main shaft. Use 9. Rotate the lower depth-set collar down until the large end of hex key wrench PT2210-14 the collar contacts the main housing. to hold the cutter plate and tighten securely.
Page 205 5-111.bk Page 192 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 190 — Counterbore Ledge Tool Installation 1. Cutter Plate Holder 10. Cutter Bit Adjuster 2. T-Handle 11. Cutter Bit 3. Capscrews, M16 x 2 x 90 12.
Page 206 5.225″ (132.715 mm) and the 5.161″ (131.089 mm) inside diameters on the Shims can be ordered through the MACK Parts same sleeve seat. System using part Nos. 505GC26P2, P3 ,P4, P10, P12, P14, P20, P31 and P42.
Page 207: Cup Plug Replacement
5-111.bk Page 194 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Cup Plug Replacement 2. Using a proper driver, align the plug in the hole and drive it inward until the outer lip of the plug is 0.090 ± 0.040 inch (2.286 ± REMOVAL 1.016 mm) below the machined counterbore.
Page 208: H-Ring Replacement
5-111.bk Page 195 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 INSTALLATION ® Apply an appropriate Teflon thread sealant to the threads and install the plug. Tighten the plug to specification. Refer to the torque chart in the SPECIFICATIONS section.
Page 209 5-111.bk Page 196 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 In some cases, the H-ring remover tool may not position the collet far enough into the H-ring to provide proper engagement for removal. If this situation occurs, remove 0.375 inch (9.5 mm) of the threads by grinding or cutting them down;...
Page 210: Camshaft Bushing Replacement
5-111.bk Page 197 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 196 — H-Ring Installation Tool Figure 198 — H-Ring When installing an H-ring, it is possible for ® ® Loctite to run down the lifter bore. The Loctite will not cure until the lifter is installed, because the tight clearance between the lifter and the bore ®...
Page 211 5-111.bk Page 198 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 REMOVAL If the camshaft bushings are being replaced in the chassis, a special tool is required to remove Camshaft bushings are identified in sequence, the No. 7 camshaft bushing. The tool is included 1 to 7, starting from the front of the engine.
Page 212 5-111.bk Page 199 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 CAMSHAFT BUSHING ALIGNMENT No. 7 bushing — When installed correctly, there is an approximate 1/8-inch (3.18 mm) Each camshaft bushing is located at set wide section of bore visible at the front face distances from the camshaft thrust washer of the bushing.
Page 213 5-111.bk Page 200 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 BUSHING INSTALLATION 1. Clean the surfaces of the bushing and the bore. Dry both surfaces with compressed Correct installation of each camshaft bushing is air. very important. If a bushing is not properly aligned with both its oil supply and oil feed 2.
Page 214: Auxiliary Shaft Bushing Replacement
5-111.bk Page 201 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Auxiliary Shaft Bushing BUSHING INSTALLATION Replacement [212 CB] Correct installation of the auxiliary shaft bushings is very important. If the front bushing is The front and rear auxiliary shaft bushings are misaligned, lubrication oil flow to the front identical.
Page 215 5-111.bk Page 202 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 205 — Front Camshaft and Auxiliary Shaft Assembly Notch Locations Page 202...
Page 216 5-111.bk Page 203 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 206 — Rear Auxiliary Bushing Alignment Figure 207 — Auxiliary Shaft Bushing Alignment 1. Clean the surfaces of the bushing and the 1. Alignment Mark 4. Camshaft Bushing bore.
Page 217 5-111.bk Page 204 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 The front auxiliary shaft bushing must be flush or recessed within 0.030 inch (0.763 mm) of the machined front surface of the cylinder block. Incorrect recess will cause misalignment of the oil supply hole, resulting in insufficient lubrication of the journal.
Page 218: Cylinder Sleeve Installation
5-111.bk Page 205 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Cylinder Sleeve Installation INSTALLATION PROCEDURE Refer to Figure 209. [212 NC] GENERAL INFORMATION Satisfactory cylinder sleeve service life and good head gasket seal is dependent on uniform cylinder block counterbores and the correct extension of the sleeve flanges above the top deck of the cylinder block.
Page 219 3. Apply approximately a 0.090–0.130-inch number of shims required to achieve the (2.286–3.302 mm) bead of RTV silicone proper cylinder sleeve flange height. Always ® (MACK Silastic 342SX32, Dow Corning place the thickest shim on the bottom. ® Silastic RTV732, General Electric RTV130...
Page 220 5-111.bk Page 207 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 5. With the palms of the hands placed on the upper end of the cylinder sleeve 180 degrees apart, push downward with Applying an RTV silicone bead is mandatory quick, even pressure.
Page 221: Piston Cooling Spray Nozzle Installation
HONING THE CYLINDER SLEEVE BORE The height of the cylinder sleeves above the cylinder block deck (under the same cylinder All MACK engines currently produced have fine head) can vary as long as all are within precision-finished cylinder sleeves. Because of specification.
Page 222 5-111.bk Page 209 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 PISTON COOLING NOZZLE SPRAY POSITIONING Refer to Figure 214. The piston cooling oil spray target location on the underside of the piston is important. It ensures adequate dissipation of heat from the piston. Correct positioning of the nozzles also ensures that the crankshaft counterweights do not strike the nozzles.
Page 223 5-111.bk Page 210 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Using piston cooling nozzle spray position set J 39045, check the direction of the spray from the nozzles. Refer to Figure 215. 1. Position rod in the end of the spray nozzle. 2.
Page 224: Cylinder Block Dowel Pin Replacement
5-111.bk Page 211 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Cylinder Block Dowel Pin ROUND DOWEL PIN INSTALLATION Replacement 1. Insert the round dowel pin into the locating pin driver J 37712. The pin must be [211 HA] positioned in the driver with the tapered end of the dowel facing outward.
Page 225 5-111.bk Page 212 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 BLADE-TYPE DOWEL PIN INSTALLATION Refer to either Figure 217 or Figure 218. 1. Position the round end of the blade-type dowel pin into the dowel pin hole in the cylinder block.
Page 226: Crankshaft And Flywheel Bench Procedures
MACK Parts Distribution Centers. Current-production flywheels no longer have the timing grooves milled into the face surface. Crankshaft Inspection Crankshaft regrinding by anyone other than Mack Trucks, Inc. is NOT recommended due to the [212 HP] tight control required for maintaining geometrical...
Page 227: Crankshaft Gear Replacement
5-111.bk Page 214 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 All new service replacement crankshafts, short DOWEL PIN REMOVAL blocks or basic engines will have a dowel pin in To remove the crankshaft dowel pin: the crankshaft rear flange. In nearly all cases, the flywheel will already have a hole in it to accept the 1.
Page 228: Crankshaft Wear Ring Installation
5-111.bk Page 215 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 REPLACEMENT Refer to Figure 221. 1. Using a suitable puller, such as J 21834-4A, or equivalent, remove the gear and key. The threads in the end of the crankshaft are M8 x 1.25.
Page 229 5-111.bk Page 216 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 REMOVAL INSTALLATION Refer to Figure 223. A limited number of crankshafts were manufactured with a repair sleeve installed on the On some wear rings it may be difficult to flange.
Page 230: Flywheel Inspection And Resurfacing
5-111.bk Page 217 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 ® WEAR RING WITH DOUBLE-LIP TEFLON SEAL (AUTOMATIC TRANSMISSION) The oversize inside diameter lip seal and wear ring are shipped as an assembly with the seal installed on the wear ring. For this combination, the seal and the wear ring are installed as an assembly.
Page 231 5-111.bk Page 218 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 2. Resurface the flywheel as required. To ensure satisfactory service life, the maximum amount of material that may be When resurfacing a flat-style flywheel, it is very removed from the flywheel surface is important that the machine shop NOT leave a 0.070 inch (1.78 mm).
Page 232: Auxiliary Shaft And Camshaft Bench Procedures
All ASET™ engine models use a straight key, P/N 43AX9, in the camshaft-to-gear keyway. The [212 CV] offset key used in earlier MACK engine models no longer applies. The auxiliary shaft is identified by three machined circumferential cuts in front of the stamped part number.
Page 233 5-111.bk Page 220 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 CAMSHAFT GEAR INSTALLATION The camshaft gear is shrink-fitted to the camshaft. To install the gear, it must be heated in an oven to 425°F (204°C). DO NOT attempt to heat the gear with a welding torch as this method will not provide even heating and could cause weakening of the metal.
Page 234 5-111.bk Page 221 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Some non-current MACK engine models had used an offset key which was positioned to the right or left depending on the engine model. This is not an issue with ASET™ engines. All ASET™...
Page 235 5-111.bk Page 222 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 4. Set the camshaft close to the oven in which the camshaft gear will be heated. It should be set vertically on the floor with the front of Wear protective gloves when handling the the shaft up.
Page 236: Connecting Rod And Piston Bench Procedures
Now, however, only the M1 rod carries the when rebuilding. weight class identification stamped on the rod Use genuine MACK replacement parts. cap. The M2 connecting rod is no longer stamped with the weight class identifier. When installing a single rod, or less than a full set, examine the removed rod(s) for part number and M number.
Page 237 5-111.bk Page 224 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 WRIST PIN BUSHING REPLACEMENT Wrist Pin Bushing Installation If the wrist pin bushing is found to be out of tolerance, it should be replaced. The wrist pin bushing has a lubrication hole Refer to Figure 231.
Page 238 5-111.bk Page 225 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 4. Apply a suitable lubricant to the bushing and broach. Then, press the broach through the bushing to expand the bushing for a tight fit in the wrist pin bore. Refer to Figure 233.
Page 239: Piston Inspection And Cleaning
5-111.bk Page 226 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Piston Inspection and Cleaning [212 NP] Be sure that the cleaning solvent is approved for steel and aluminum. Incompatible solvents may cause damage to the pistons or skirts. SPECIAL TOOLS REQUIRED Piston Ring Expander PT6587 3.
Page 240 5-111.bk Page 227 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 2. Using a four- to five-inch micrometer, measure the distance between the outer edges of the two parallel pins. Check each Do not file or grind chrome-plated piston rings. compression ring groove in two locations: This may cause the chrome to flake, resulting in parallel and perpendicular to the wrist pin...
Page 241 5-111.bk Page 228 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 4. Perform steps 1, 2 and 3 on each piston. RING INSTALLATION 5. Check the oil control ring as follows: Using a thickness gauge, check for excessive wear of the oil control ring Identification markings on the rings should face groove side clearance (Figure 237).
Page 242: Assembling Connecting Rod To Piston
5-111.bk Page 229 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Be sure that the piston and rod assemblies are clearly marked with the cylinder location. They must be returned to same cylinder from which they were removed. Figure 239 —...
Page 243: Cylinder Head Overhaul
5-111.bk Page 230 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 CYLINDER HEAD OVERHAUL Valve Stem Seal Remover J 38820-1 (Early Seal Design) [213 EV] Valve Stem Seal Remover J 45915 (Current Seal Design) Special Tools Required Valve Seat Extractor Kit PT6391 Basic Heavy-Duty Dowelout Kit PT6575 Valve Insert Installer Set J 38586 Collet PT6390-4...
Page 244 5-111.bk Page 231 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Bottom Rotators Tip-End Rotators The current configuration of the ASET™ engine ASET™ engines used a tip-end valve rotator uses a bottom valve rotator installed under the installed at the top of the valve springs until valve springs.
Page 245 5-111.bk Page 232 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 244 — Valve Rotators 1. Exhaust Rotator Spring 2. Inlet Rotator Spring Support Area Support Area Do not clean the tip-end rotators in a hot tank or use any type of cleaning method which could introduce contaminants to the rotator’s internal parts or damage the rotator insert.
Page 246 5-111.bk Page 233 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 246 — Rotator and Spring Removal (Current Figure 247 — Tip-End Rotator and Spring Removal Design) (Non-Current Design) 1. Outer Exhaust Spring 3. Spring Rotator (Bottom) 1.
Page 247: Cylinder Head Cleaning And Inspection
5-111.bk Page 234 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Cylinder Head Cleaning and Valve Stem Seals Inspection The current design valve seal can be identified by the fact that it fits on the top of the valve guide. Cleaning the cylinder head is important.
Page 248: Fire Ring Groove Cutting
5-111.bk Page 235 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Fire Ring Groove Cutting INSPECTION GENERAL INFORMATION Pressure Test — It is recommended that cylinder Fire ring grooves are located in the machined flat heads be pressurized and checked for internal surface (deck) of the cylinder head that mates cracks and leaks.
Page 249 5-111.bk Page 236 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 GROOVE CUTTING PROCEDURE 1. Place the cutter base on the cylinder head (Figure 250). Insert the hold-down capscrews into the appropriate mounting holes (per application) until the hold-down capscrews bottom out in the mounting holes.
Page 250 5-111.bk Page 237 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 5. Adjust the cutter head J 37719 until it bottoms out on the deck surface of the existing fire ring groove. Tighten the cutter head in this position and remove the two thickness gauges.
Page 251: Valve Guide Replacement
5-111.bk Page 238 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 7. After the groove is cut, remove the cutter head and base from the cylinder head. 8. Use a honing stone to remove any burrs around the fire ring groove. 9.
Page 252 5-111.bk Page 239 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 INSPECTION Worn valve guides may result in poor valve-to-seat contact, valve damage or oil consumption. 1. Inspect the valve guides for wear, damage, cracks and looseness. Use a small bore gauge to obtain an accurate valve guide bore measurement (Figure 256).
Page 253 5-111.bk Page 240 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 2. Use a depth gauge to check valve guide extension (Figure 257). Figure 257 — Checking Valve Guide Extension When reconditioning the cylinder head, it is recommended that all valve guides be replaced. VALVE GUIDE REMOVAL Figure 258 —...
Page 254: Valve Seat Insert Replacement
5-111.bk Page 241 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 6. Repeat steps 1 through 5 to install the remaining valve guides. 7. Thoroughly clean all metal debris from the The current-production valve guide is 0.042 inch valve guides and the surrounding area.
Page 255 5-111.bk Page 242 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 — Exhaust Oversize Service (0.015): INSPECTION 1.707–1.708 inches Visually inspect the valve seat inserts for (43.358–43.383 mm) looseness, cracks or other conditions that may — Exhaust Oversize Service (0.031): result in improper operation.
Page 256 5-111.bk Page 243 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 261 — Valve Seat Extractor Kit PT6391 1. Grinding Wheels 6. Grinder Base 2. T-Handle and Shaft Assembly 7. Grinder 3. Collet, PT6390-4 (Not Included in Kit) 8.
Page 257 5-111.bk Page 244 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 1. Clean any carbon buildup from the removal chamfer in the valve insert. 2. Attach the collet, PT6390-4, to the T-handle and shaft assembly. 3. Position the collet in the valve seat insert so the ridge of the collet will grip the chamfer on the inner upper edge of the insert (Figure 262).
Page 258 5-111.bk Page 245 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 VALVE SEAT INSERT COUNTERBORE INSPECTION Refer to Figure 264. 1. With the valve seat insert removed from the cylinder head, clean the surface thoroughly Valve seat counterbore depth (3): with a wire brush.
Page 259 5-111.bk Page 246 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 VALVE SEAT INSERT INSTALLATION 3. Grind the inlet/exhaust valve seat inserts to specification. Inlet valve inserts: 20° 30′ ± 15′ angle Exhaust valve inserts: 30° 15′ ± 15′ Oversize inlet and exhaust valve seat inserts are available in 0.005-, 0.015-, 0.031-, 0.047- and 0.062-inch sizes if the counterbore requires...
Page 260: Valve Spring Inspection
5-111.bk Page 247 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Valve Spring Inspection [213 MB] 1. Visually inspect the inside surfaces of the spring coils. Also, feel the inside surfaces of each spring for any indication of roughness or grooving.
Page 261: Injection Nozzle Holder Insert Replacement
5-111.bk Page 248 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 268 — Checking Valve Spring Pressure Figure 269 — Removing Injection Nozzle Holder Insert 1. Spring Tester J 22738-02 2. Valve Spring 1. Slide Hammer J 2619-01 2.
Page 262 5-111.bk Page 249 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 INSTALLATION PROCEDURE 1. Clean the nozzle insert bore in the cylinder ® head and the contact surfaces with Loctite Primer T. ® 2. Apply Loctite 620 to the cylinder head and insert surfaces.
Page 263: Valve Yoke Guide Pin Replacement
5-111.bk Page 250 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Valve Yoke Guide Pin Replacement 3. Drill a 13/64-inch hole completely through the broken section of the yoke pin. [213 FH] 4. Tap all the way through the broken yoke pin, using a 1/4-inch -20 tap and cutting oil.
Page 264: Cylinder Head Cup Plug Replacement
5-111.bk Page 251 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 INSTALLATION PROCEDURE Place the new valve yoke guide pin in position and use guide pin installer J 29296 to drive the The cup plug should be driven in until the pin into the cylinder head.
Page 265: Cylinder Head Pipe Plug Replacement
5-111.bk Page 252 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Cylinder Head Pipe Plug REPLACEMENT (3/4-INCH PLUGS) Replacement Refer to Figure 276. 1. Heat the pipe plug to 400°F (205°C) with a torch. GENERAL INFORMATION 2. With the pipe plug heated sufficiently, Current-production 3/4-inch pipe plugs are remove the plug from the cylinder head.
Page 266: Inlet And Exhaust Valve Inspection
5-111.bk Page 253 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Inlet and Exhaust Valve Inspection Visually inspect valves for cracks, pits or other conditions that may cause improper operation. Check valve seat angle. Also check stem length, diameter and condition.
Page 267: Inlet And Exhaust Valve Installation
5-111.bk Page 254 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Inlet and Exhaust Valve Installation 2. With these new valve stem seals, pre-lubrication during installation is extremely important. Pre-lubricate the seals For identification purposes, the exhaust valve has as follows: two stem grooves in addition to the valve spring keeper groove;...
Page 268 5-111.bk Page 255 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 4. Current Design Valve Stem Seal 5. Check the valve stem tip for nicks or burrs that may damage the valve stem seal upon Following valve stem-to-guide and valve installation.
Page 269 5-111.bk Page 256 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 281 — Spring and Tip-End Rotator Installation (to Figure 282 — Spring and Bottom Rotator Installation Mid-Year 2003) (Mid-Year 2003 and Later) 1. Spring Rotator (Tip-End) 3.
Page 270 5-111.bk Page 257 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 7. Install the tip-end rotators or valve retaining 8. Reattach the valve spring compressor to the washers onto the inlet and exhaust valves. cylinder head. Use spring compressor Ensure that the correct rotator, inlet or J 43887 for valves with tip-end rotators or exhaust, is installed at the correct location.
Page 271 5-111.bk Page 258 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 10. After the valves are installed, check each inlet valve for head height above the cylinder deck. The protrusion dimension for inlet valves should be 0.0425 +0.009/−0.007 inch (1.0795 +0.229/−0.178 mm).
Page 272 5-111.bk Page 259 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 286 — Inlet/Exhaust Valve Head Height/Depth Measurement 1. Inlet Protrusion Above Deck: 0.047 inch 3. Exhaust Valve +0.009/−0.007 inch (1.194 +0.229/−0.178 mm) 4. Exhaust Valve Depth Below Deck: 0.021 inch 2.
Page 273: Valve Rocker Arm Shaft Bench Procedures
5-111.bk Page 260 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 VALVE ROCKER ARM SHAFT Further rocker arm improvements include adjusting screws that have a groove around the BENCH PROCEDURES center of the screw, an oil passage cross-drilled [213 LP] through the shank of the screw and an oil passage drilled along the vertical center line of...
Page 274 5-111.bk Page 261 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Rocker Arm Improvements Effective January Shaft end closure by pipe plugs, to provide a 2003 more secure closure than the previously used cup plugs Effective January 2003, the following new and The shaft has two additional oil supply holes improved components were introduced into to each rocker for directed lubrication to the...
Page 275: Valve Rocker Arm Shaft Disassembly (With/Without Engine Brake)
Disassembly (with/without Engine Brake) Refer to Figure 295, Figure 296 and Figure 298. The shaft assembly is disassembled as follows: 1. If equipped with MACK PowerLeash™ Figure 290 — Rocker Arms engine brake, remove the solenoid from the shaft. 1. Wider Casting at Nut 3.
Page 276: Inspection
5-111.bk Page 263 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Inspection Perform a general inspection of all On engines where the rocker shaft mounting components of the rocker arm shaft and bolts have come loose or have broken on one bracket assembly for evidence of damage or cylinder head only, the rocker shaft on the other wear.
Page 277: Valve Rocker Arm Shaft Reassembly (Without Engine Brake)
5-111.bk Page 264 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 4. Lubricate the spring washers and install the washers on the shaft, one on each side of the mounting bracket. 5. Lubricate the exhaust rocker arm and install it on the shaft.
Page 278 5-111.bk Page 265 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 295 — Valve Rocker Arm Shaft Assembly (without Engine Brake) 1. Flat Washer and C-Clip 6. Mounting Bracket 2. Spring Washer 7. Inlet Rocker Arm 3. Locating Screw and Lock Washer 8.
Page 279: Valve Rocker Arm Shaft Reassembly (With J-Tech™ Engine Brake)
5-111.bk Page 266 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Valve Rocker Arm Shaft 6. Lubricate the exhaust rocker arm and install it on the shaft. Reassembly (with J-Tech™ Engine 7. Install a flat washer and C-clip on the shaft Brake) to retain the exhaust rocker arm.
Page 280 5-111.bk Page 267 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 296 — Valve Rocker Arm Shaft Assembly (with J-Tech™ Engine Brake) 1. Flat Washer and C-Clip 8. Standard Adjusting Screw and Jam Nut 2. Spring Washer 9.
Page 281: Valve Rocker Arm Shaft Reassembly (With Mack Powerleash™ Engine Brake)
Locating Bolt Bracket (Press Fit) 4. Lock Washer As mentioned above, the front mounting bracket on MACK PowerLeash™ rocker shafts is a press-fit, and alignment of the oil passage between the bracket and shaft is critical. A pre-assembled rocker shaft/front mounting bracket (part No.
Page 282 5-111.bk Page 269 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 298 — Mack PowerLeash™ Rocker Shaft Assembly 1. Retaining Ring 5. Inlet Rocker Arm 2. Flat Washer 6. Rocker Shaft Mounting Bracket (Slip Fit) 3. Exhaust Rocker Arm (with Engine Brake Hydraulic 7.
Page 283 A new solenoid supplied through 15. Complete the assembly by lubricating a the MACK Parts System includes the spring spring washer with clean engine oil and retainers and O-ring. The retainers are also sliding it over the end of the rocker shaft...
Page 284 5-111.bk Page 271 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 4. Insert the solenoid into the rocker shaft port 5. Snap both clips around the bottom of the and push downward firmly with the palm of rocker shaft. the hand to fully seat the solenoid.
Page 285 5-111.bk Page 272 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 302 — Inspect Solenoid-to-Rocker Shaft Mounting Surfaces A solenoid that has not been completely seated on the rocker shaft can partially turn the engine brake ON while the engine is under power, resulting in an engine miss and extremely poor engine performance.
Page 286: Lubrication System Bench Procedures
In replacing any of these critical parts, always refer to part number information in the MACK Parts System to ensure the correct component/part is being used. Figure 303 — Oil Pump Pressure Relief Valve 1. Oil Pump Housing Cover 3.
Page 287 5-111.bk Page 274 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Standard E-Tech™/ASET™ with Oil Pressure Relief Valve Spacers This oil pump configuration is very similar to the original oil pump configuration except that two spacers have been added to the relief valve cap.
Page 288 5-111.bk Page 275 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 3. Remove the oil pressure relief valve cap and 8. Turn the oil pump upside down and remove collect the pressure relief spacers (if the oil pump shaft nut and washer. equipped).
Page 289 5-111.bk Page 276 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 INSPECTION AND CLEARANCE CHECKS End Clearance Check Refer to Figure 306. Refer to Figure 307. With the pump gear and idler 1. Clean and inspect the oil pump housing for gear in place, position a straightedge across the scoring, cracks or other damage.
Page 290 5-111.bk Page 277 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Side Clearance Check Backlash Check Refer to Figure 308. With the straightedge Refer to Figure 309. positioned across the housing and the face of the gears, check side clearance as follows: Check the backlash between the pump gear and idler gear with a thickness gauge.
Page 291 5-111.bk Page 278 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 REASSEMBLY 8. Install the oil pressure relief valve spring in the relief valve housing. Refer back to Figure 306. 9. Clean the relief valve cap and pressure relief 1.
Page 292: Cooling System Components Bench Procedures
If a pump failure occurs, exchange it for a new or remanufactured unit available through the MACK Parts System. If damaged, do not weld repair the support bracket to either side panel or the bottom of the cooler.
Page 293: Fuel System Component Bench Procedures
5-111.bk Page 280 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 FUEL SYSTEM COMPONENT Installation of Electronic Unit Pump BENCH PROCEDURES Plunger Spring and Seat Improper removal of an electronic unit pump Electronic Unit Pump (EUP) (EUP) from an engine, or certain failures such as Inspection broken EUP hold-down bolts, will result in a rapid pop-up of the pump from the bore.
Page 294 5-111.bk Page 281 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 2. Pull the plunger out of the unit pump bore until the gold portion of the plunger is visible through the retaining clip slot. The shoulder of the plunger (where the silver-colored and gold-colored areas meet), will just align with the bottom of the unit pump housing.
Page 295 9. For engines which have a history of small fuel leakage into the crankcase, a new delta seal (available through the MACK Parts System) should be installed on the lower O-ring position. Due to the design of the delta seal O-ring, the...
Page 296: Fuel Injector Nozzle Cleaning
5-111.bk Page 283 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Fuel Injector Nozzle Cleaning ULTRASONIC CLEANING METHOD Ultrasonic cleaning is the preferred method for [222 KG] cleaning the fuel injector nozzles. Ultrasonic cleaning units use sound waves or mechanical Refer to Figure 319.
Page 297: Vtg System Bench Procedures
MACK Parts System. Figure 320 — VTG Control Valve Using Figure 320 as a reference, replace the 4.
Page 298 9. Lubricate the O-ring on the new solenoid the 1/8 punch must be in good condition so that with MACK O-ring lubricant (part it seats squarely against the end of the pin, and No. 243SX41), or equivalent. care must be used to ensure that the punch tip is kept squarely against the end of the pin as it is 10.
Page 299: Engine Reassembly
5-111.bk Page 286 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 ENGINE REASSEMBLY 3. Place the upper half of the bearing insert in the cylinder block main bearing bore, making sure that the locating tab fits into the General Instructions notch in the bore (Figure 321).
Page 300: Main Bearing Cap Installation
5-111.bk Page 287 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 322 — Main Bearing Insert Part Numbers and Locations 1. Upper Insert — 646B348; Lower Insert — 646B343 5. Upper Insert — 646B345; Lower Insert — 646B343 2.
Page 301 5-111.bk Page 288 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 SPECIAL TOOL REQUIRED 3. Lubricate the threads of the bearing capscrews with clean engine oil and place Magnetic Base Indicator Tool J 7872 the capscrews in the cap holes. 4.
Page 302 5-111.bk Page 289 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 10. Position the lower thrust washer sections on the center bearing cap (aluminum-faced or bronze-faced side with oil reservoir grooves To prevent damage, ensure the thrust washers and tip-face reliefs toward crankshaft) and are installed in the correct position when install the cap (Figure 326).
Page 303 5-111.bk Page 290 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 326 — Main Bearing Cap/Thrust Washer Installation 1. Bearing Cap 3. No. 4 Journal 2. Thrust Washer 11. Install a magnetic base indicator tool, 16. If the end play is out of specification, remove J 7872, or equivalent, on the block and the thrust washers and install properly sized position the plunger against a crankshaft...
Page 304 5-111.bk Page 291 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 18. Recheck the end play to ensure the thrust 4. Tighten the capscrews to the specified washers have been installed correctly and torque, 210 lb-ft (285 N m), using torque that end play is within specification.
Page 305 5-111.bk Page 292 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 7. If the clearance is not within specification, 8. Reposition the cap on the journal. Lubricate correct the clearance as required. Be sure to the capscrews with clean engine oil of the use the proper size bearing(s).
Page 306: Piston And Connecting Rod Installation
5-111.bk Page 293 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 9. After obtaining the proper main bearing clearance at all seven journal locations, check the torque of the main bearing capscrews, 210 lb-ft (285 N m), using torque wrench J 24407, or equivalent.
Page 307 5-111.bk Page 294 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 2. Place the piston marked No. 1 on a clean, flat surface. Rest the piston and rod assembly on the piston crown with the rod The hole in the upper connecting rod bearing upward.
Page 308 5-111.bk Page 295 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 10. Make sure the connecting rod is aligned with the crankshaft journal. 11. While applying downward pressure to the ring compressor tool to keep it in contact with the cylinder sleeve, use a hammer handle to push the piston through the tool (Figure 331).
Page 309 5-111.bk Page 296 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Do not force the piston. This indicates an Running clearance must be checked after incorrectly aligned ring. Remove the piston installing each piston. Damage to the engine may assembly, correct the problem, and then reinstall result if clearance is not within specification.
Page 310 5-111.bk Page 297 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 The angle-torque method applies for 14 mm capscrew part Nos. 396GC211M and 396GC212M with partial and full threaded shanks, respectively. Intermixing the partial and full threaded 14 mm capscrews on the same connecting rod is permissible.
Page 311: Flywheel Housing Installation
Service replacement flywheel housings are the standardized flywheel housing. The appropriate mounting hardware comes with the new-style flywheel housing supplied by the Mack Trucks Parts System. Figure 336 — Ductile Iron Flywheel Housing with Internal Structure Ribs (Current Production) Not Shown —...
Page 312 5-111.bk Page 299 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Dowel Pins — A combination of round- and blade-style locating dowel pins are used to install the front cover and flywheel housing. A blade-style pin is used for the flywheel. When installing the blade-style pins, make sure the blade is properly positioned: Vertically (pointing up and down) —...
Page 313 5-111.bk Page 300 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 5. Align the flywheel housing on the dowels Flywheel housing runout specifications are as and position it flush against the cylinder follows: block surface. Refer to Figure 339. Runout checked with an alignment bar installed through the cylinder block main bearing bores: 0.010 inch (0.254 mm) TIR...
Page 314: Crankshaft Rear Oil Seal Installation
Indicator Crankshaft Rear Oil Seal Installation [212 JH] MACK engines with dry flywheel housings (standard transmission) use single-lip seals, while those with wet flywheel housings (automatic transmission) use double-lip seals. The single-lip replacement seals are available in either Viton or ®...
Page 315 5-111.bk Page 302 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 3. Using the three guide pins, attach the adapter plate to the crankshaft flange. Refer to Figure 343. Figure 343 — Adapter Plate J 37716-B Installation 4. Determine the seal and wear ring installation depth: Refer to Figure 344.
Page 316 5-111.bk Page 303 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 INSTALLATION — WEAR RING WITH 4. The lip of one side of the oil seal is yellow. ® DOUBLE-LIP TEFLON SEAL Install the seal with the yellow lip toward the transmission.
Page 317: Flywheel Installation
5-111.bk Page 304 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Flywheel Installation [212 VC] TIMING SCALE The flywheel has a stamped timing scale of top center (TC) to 45 degrees of engine travel (engine timing) and three stamped locations, 120 degrees apart, for valve settings as shown in Figure 346.
Page 318: Valve Lifter Installation
5-111.bk Page 305 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 INSTALLATION PROCEDURE After resurfacing, any flywheel with drilled balance holes on the clutch side requires rebalancing by a machine shop. On vehicles equipped with an automatic transmission, it may be necessary to install different components to the flywheel retaining capscrews.
Page 319 5-111.bk Page 306 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 2. Submerge the valve lifters into a container of If the original lifters are being reused clean engine oil to allow oil to fill the and the fit is tight, trial fit a new lifter(s) passages to the roller axles.
Page 320: Camshaft Installation
5-111.bk Page 307 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Camshaft Installation 4. Apply clean engine oil to the installation guide. [213 CH] Before installing a camshaft in any engine, The camshaft is heavy, weighing approximately ensure that cam is clean, undamaged and 90 pounds with the gear.
Page 321: Camshaft Core Plug Installation
5-111.bk Page 308 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Camshaft Core Plug Installation Camshaft Idler Gear Installation [213] [213 DE] After the camshaft is installed, install the core Before installing the idler gear/hub assembly, plug. determine which is the top mounting hole on the hub.
Page 322: Auxiliary Shaft Installation
5-111.bk Page 309 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 2. Align the timing marks. First look at the 5. Coat the hub bolts with clean engine oil and timing marks on both the camshaft and thread the bolts a few turns into the crankshaft gears.
Page 323: Oil Pump Installation
If reusing the old nut, apply Loctite or 277 to the threads and install the nut. If using a new nut from the MACK Parts System, it is not Make sure that the oil pump is in satisfactory ®...
Page 324: Front Cover Installation
5-111.bk Page 311 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 358 — Oil Pump Installation 1. Lubrication Oil Pump 3. Cylinder Block 2. Mounting Capscrews Front Cover Installation [211 RP] After the oil pump has been installed, check the backlash between the auxiliary shaft gear and the With the crankshaft, camshaft and auxiliary shaft oil pump driven gear.
Page 325: Crankshaft Front Seal Installation
5-111.bk Page 312 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Crankshaft Front Seal Installation [211 JB] SPECIAL TOOLS REQUIRED Crankshaft Front Seal Installer J 37715-A Crankshaft Front Seal Adapter J 37715-2 INSTALLATION PROCEDURE Installation depth of the front crankshaft seal, relative to the front crankshaft stem, is controlled by the installation tool adapter.
Page 326: Crankshaft Hub Installation
Replace the hub if the crankshaft seal lip has made a significant wear groove on the outer diameter of the hub. Mack Trucks, Inc. DOES NOT recommend the use of a service sleeve to repair this type of hub damage. Also, if there is any galling, scoring or fretting on the inner diameter, replace the hub.
Page 327: Oil Pan Installation
5-111.bk Page 314 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Oil Pan Installation INSTALLATION PROCEDURE 1. Place the vibration damper and drive pulley [211 NB] in position on the crankshaft hub. 2. Install the mounting capscrews and tighten GENERAL INFORMATION the capscrews to the specified torque, 45 lb-ft (61 N m).
Page 328 (approximately 1/8–1/4 inch gasket with one hand while carefully pulling [0.014–0.028 mm] wide) of RTV silicone the rubber cone through the hole with the ® sealant (MACK Silastic 342SX32, Dow other hand until seated (Figure 364). ® Corning Silastic...
Page 329: Cylinder Head Installation
Refer to the cylinder head inspection procedures under “Cylinder Head Reconditioning” in the REPAIR INSTRUCTIONS section. All MACK head gaskets are precoated and do not require any type of additional sealing compound. Refer to Figure 366. 1. Place the head gaskets in position on the locating pins in the cylinder block deck.
Page 330 5-111.bk Page 317 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 366 — Cylinder Head Gasket and Fire Ring Positioning 1. Cylinder Head 4. Guide Pins 2. Fire Rings 5. Cylinder Block 3. Gasket 4. Check the condition of the capscrews and 5.
Page 331 5-111.bk Page 318 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 367 — Cylinder Head Alignment 1. Cylinder Heads 3. Straightedge 2. Cylinder Block 7. Using torque wrench J 24407, or equivalent, tighten all cylinder head mounting capscrews to specification in three steps as listed below.
Page 332: Exhaust Manifold Installation
This requires that all exhaust studs be sealed at installation to prevent oil leakage. Replacement studs from the MACK Parts System come with thread sealer pre-applied. On some engines, the lower or upper exhaust...
Page 333: Nozzle Holder Assembly Installation
3. Place the exhaust manifold in position on the mounting studs. Oil the nut threads and 1. Install the 12 new studs from the MACK flanges with clean engine oil and install the Parts System in position on the cylinder 12 retaining nuts.
Page 334 5-111.bk Page 321 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 371 — Nozzle Holder Gasket Installation 1. Washer 2. Nozzle 2. Lubricate the surface of the nozzle holder with clean engine oil and install the top O-ring on the holder.
Page 335 5-111.bk Page 322 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 4. Insert the nozzle holder in the nozzle holder 7. Insert the gauge block into the nozzle holder sleeve. Be sure to align the locator pin in the sleeve bore.
Page 336: Push Rod Installation
5-111.bk Page 323 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 8. Lubricate the threads of the retaining plug 1. Apply lubricating oil to the spherical end of and install it as shown in Figure 376. Tighten each push rod. the plug to the specified torque, 45 lb-ft 2.
Page 337: Valve Yoke Installation
5-111.bk Page 324 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Valve Yoke Installation The second method of identifying the valve yoke is by viewing the yoke from the side. The top [213 NV] surface of the adjusting screw end will appear on the same plane as the bottom surface of the “button-head.”...
Page 338 5-111.bk Page 325 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 MACK PowerLeash™ Exhaust Valve Yoke INSTALLATION PROCEDURE The PowerLeash™ exhaust yokes are different from either the J-Tech™ and the non-brake yokes in that they contain a hole for the exhaust Make sure the correct yokes are used.
Page 339 A parts kit, part No. 215SB321, that contains new design reset screws, slave piston springs and actuating pin adjusting screws (part No. 421GC41CM) is available through the MACK Parts System to update the engine brake units. However, always verify that the engine is not already equipped with these new components.
Page 340 The exhaust valve yokes on engines equipped with an engine brake (J-Tech™ or MACK) use an actuator pin assembly in place of the standard yoke adjusting screw. Ensure that the yokes with actuator pin assemblies are in position over the exhaust valves.
Page 341: Rocker Arm And Engine Brake Installation
With the rocker arm depressed in The MACK PowerLeash™ engine brake uses a this fashion, rotate each push rod to be sure completely different exhaust rocker arm design it is properly seated in the lifter cup and at with an integral brake piston.
Page 342 1. Make sure the oil supply screw is in position implemented into production. These bolts are on the rocker arm mounting bracket for each available through the MACK Parts System, and cylinder head and tightened to specification, should be used as the replacement bolt anytime 5 lb-ft (6.8 N m).
Page 343 5-111.bk Page 330 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 7. Starting with the center pair of mounting bolts, tighten all six bolts on each housing just enough to seat the housing on the If the rocker shaft assembly is lifted off the rocker shaft brackets.
Page 344 5-111.bk Page 331 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 387 — Rocker Arm Shaft and J-Tech™ Engine Brake Components 1. Cylinder Head Cover 8. Exhaust Valve Yokes 2. Spacer 9. Actuator Pin Assembly 3. Long Capscrew 10.
Page 345 1. Make sure all 12 push rods are properly implemented into production. These bolts are seated in the respective lifter sockets. When available through the MACK Parts System, and installing push rods, use care to gently lower should be used as the replacement bolt anytime them into position on the lifter cups.
Page 346 5-111.bk Page 333 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 4. Again, depress the rocker arm screw end of each rocker arm into each push rod and rotate each push rod to ensure proper The mounting bracket-to-rocker shaft bolts at the installation.
Page 347: Cylinder Head Cover And Spacer Installation
5-111.bk Page 334 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 7. After the rocker shaft assembly has been To prevent heat-related damage which can occur installed, route the solenoid ground wire to the cylinder head cover/J-Tech™ engine brake under the rocker shaft and up through the spacer gaskets, particularly in the area of the end of the solenoid retainer clip.
Page 348 4. On the MACK PowerLeash™ engine brake, connect the electrical lead from the rocker arm solenoid to the cylinder head cover electrical pass-through connector, inside the cover.
Page 349: Oil Fill Tube/Dipstick Installation
5-111.bk Page 336 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Oil Fill Tube/Dipstick Installation 6. Place the cylinder head covers in position on the cylinder heads or on the J-Tech™ spacers (if so equipped) as shown in ASET™...
Page 350 5-111.bk Page 337 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 395 — Air Compressor Installation 1. Air Compressor 4. Oil Drain Openings 2. Oil Supply Tube 5. Capscrew 3. Auxiliary Shaft Page 337...
Page 351: Electronic Unit Pump (Eup) Installation
O-ring (Figure 396) mounting screw hole in the engine block for is available through the MACK Parts System. rusty or damaged threads. Clean or tap the This seal should be used in the lower O-ring block screw holes to remove any rust or dirt position when necessary to correct leakage.
Page 352: Engine Wiring Harness Installation
5-111.bk Page 339 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 4. Repeat steps 2 and 3 to install the five remaining EUP assemblies. To avoid O-ring damage, the cam lobe must be positioned with the base circle up prior to installation of each EUP.
Page 353 5-111.bk Page 340 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 5. Connect the line at the No. 1 unit pump. Tighten the line nut to the specified torque, using torque wrench J 24407, or equivalent. Line nut at cylinder head: 35 lb-ft (47 N m) Line nut at EUP: 25 lb-ft (34 N m) An open-ended “crow’s foot”...
Page 354 5-111.bk Page 341 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 401 — EGR and EUP Heat Shield Installation 1. Outer EUP Heat Shields 4. Cylinder Heads 2. Inner EUP Heat Shield (Two Piece) 5. Exhaust Manifold 3.
Page 355: Turbocharger Installation
5-111.bk Page 342 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Turbocharger Installation 4. Apply a coating of clean engine oil to the flanges and threads of the four nuts. Install [214 SC] the nuts and using torque wrench J 24406, or equivalent, tighten the nuts in a cross-pattern sequence (Figure 402) in two Refer to Figure 403.
Page 356: Coolant Manifold Installation
5-111.bk Page 343 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Coolant Manifold Installation [215 NK] INSPECTION Check the coolant manifold for restrictions, cracks and flange wear. The manifold cannot be repaired. Replace if any signs of damage are present.
Page 357: Air Inlet Manifold Installation
5-111.bk Page 344 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Air Inlet Manifold Installation [214 HD] Refer to Figure 404. 1. Lubricate the threads of the air inlet manifold capscrews. 2. Place the inlet manifold in position on the cylinder head and install the capscrews.
Page 358: Water Pump Housing Installation
5-111.bk Page 345 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Water Pump Housing Installation [ 215 SD] The ASET™ AC water pump assembly is completely redesigned with very different and essential steps required for proper installation. Refer to Figure 406 as you work through the procedure.
Page 359 O-ring in the groove at the coolant inlet secure the housing from falling. The housing flange. Use MACK Code 442 grease or any should be free to move slightly back for quality O-ring grease to hold the O-rings in installation of the engine lifting bracket in the place for assembly.
Page 360 5-111.bk Page 347 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 11. Position the water pump stiffening bracket 12. Install the coolant inlet tube (from the oil over the two studs at the forward position of cooler) on the inlet port at the back of the the coolant manifold.
Page 361: Egr Valve Installation
5-111.bk Page 348 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 15. Place the pump cartridge assembly in position on the pump housing (pump only fits one way due to the spacing of the seven holes) and install the seven mounting capscrews (Figure 411).
Page 362 5-111.bk Page 349 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Figure 414 — EGR Valve Installation 1. EGR Valve Assembly 2. Exhaust Manifold Figure 415 — EGR Valve, Installed 1. EGR Valve 4. Mounting Studs/Nuts 2. Electrical Connection 5.
Page 363: Oil Supply Lines Installation
5-111.bk Page 350 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Oil Supply Lines Installation For all ASET™ AC engines produced before December 2003, the oil supply source for the [214 HS, HT & RN] EGR valve, J-Tech™ engine brake assemblies and VTG turbocharger is from the supply port on top of the oil filter mounting bracket as illustrated EXTERNAL OIL SUPPLY ARRANGEMENT...
Page 364 5-111.bk Page 351 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 1. If the engine is equipped with a J-Tech™ To install a stainless steel strap: engine brake, install the respective junction 1. Bend the strap around the lines to be tied blocks (with brackets) at the left and right together and slide the open end into the sides of the engine.
Page 365 5-111.bk Page 352 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 EXTERNAL OIL SUPPLY ARRANGEMENT in Figure 418. These are both direct oil lines ASET™ AC ENGINES BUILT AFTER without the use of any junction blocks or DECEMBER 2003 F-fittings.
Page 366: Thermostat Housing Installation
5-111.bk Page 353 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Thermostat Housing Installation [215 NU, NG & LD] Beginning with March 2004 production, a filter screen has been added to the oil inlet port on the 1. Check to see that the stainless steel wear EGR valve.
Page 367 5-111.bk Page 354 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Press the barrel seal into the housing bore by applying smooth, uniform pressure with a press fitting tool. Press When replacement is required, always replace fitting tools are available through the thermostats in pairs.
Page 368 5-111.bk Page 355 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 The seals attached to the thermostats provide total sealing for the housing-to-coolant manifold joint. No other sealant is required. Figure 424 — Thermostat Positioning on Dual Figure 423 — Thermostat Positioning Thermostat Housing 1.
Page 369: Egr Mixer Tube Installation
5-111.bk Page 356 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 6. Install the cab heater coolant return hose and valve into the thermostat housing (if applicable). Also install the optional fuel heater coolant return hose into the thermostat housing (if equipped).
Page 370: Egr Cooler Installation
5-111.bk Page 357 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 EGR Cooler Installation 2. Install the coolant supply and return hoses at the cooler inlet and outlet tubes. Install the [214 HM] clamps and tighten to specification (Figure 430).
Page 371: Egr Gas Tube Installation
5-111.bk Page 358 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 EGR Gas Tube Installation 2. Lightly tap the clamps with a hammer and retighten them to specification. [214 HN, HP, HR] 3. Tighten the EGR valve retaining nuts to specification, 40 lb-ft (55 N m).
Page 372 5-111.bk Page 359 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Install the one-piece cool tube assembly as instructed below: 1. Slide a hose clamp onto the EGR mixer tube and the EGR cooler cool-tube ports (or coupling adapters, if so equipped). 2.
Page 373: Eecu And Cooling Plate Installation
5-111.bk Page 360 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 EECU and Cooling Plate Installation 2. Non-current lower mounting nuts must be tightened to 180 lb-in (20 N m). [230 EA] Current Cooling Plate Design Beginning 5/15/03, the EECU cooling plate The EECU cooling plate mounting arrangement arrangement used on the ASET™...
Page 374 5-111.bk Page 361 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 6. Connect the wiring harness leads to the 7. Make sure the cooling plate and EECU EGR MASS Flow module (Figure 435). mating surfaces are clean. Place the EECU in position on the cooling plate and install the eight retaining bolts.
Page 375: Coolant Conditioner Installation
5-111.bk Page 362 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 8. Connect the wiring harness to the EECU Place the harness retainer in position on the (Figure 437). support bracket and install the retaining screw. Coolant Conditioner Installation Make sure that the seals are firmly seated on the [215 LD] connectors and that the EECU terminal pins are...
Page 376: Alternator Installation
5-111.bk Page 363 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 1. Check to ensure that the check valves have been properly installed. Inlet and outlet check valves must be installed with the direction arrows on the barrels of the check valves matching the arrows on the filter casing.
Page 377: Oil Coalescing Air Filter Installation
5-111.bk Page 364 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 Oil Coalescing Air Filter Installation Oil Cooler and Oil Filter Mounting Bracket Assembly Installation If so equipped, install the oil coalescing air filter [215 DW, 219 EP] as follows: 1.
Page 378 5-111.bk Page 365 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 5. Install the filter assembly pedestal onto the stud with the forward end of the assembly tilted downward approximately 1 inch (to allow clearance with the inlet manifold). Once the assembly is mounted on the stud, pivot the assembly clockwise to align the remaining three mounting holes of the...
Page 379: Dipstick Tube Installation
Engine installation details vary from vehicle to 1. Install the tube guide into the side of the oil vehicle. The following procedure provides pan and tighten the guide nut to general installation guidelines for MACK engines. specifications. ® Before beginning, make sure all equipment has 2.
Page 380 5-111.bk Page 367 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 3. Install the engine mount capscrews to secure the engine to the engine mounts. Tighten the capscrews to specification. 4. Remove the transmission jack from under the transmission. 5.
Page 381 5-111.bk Page 368 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 16. Install the accessory drive belts and adjust the belts to specification. 17. Using a lifting device, place the radiator in position at the front of the engine. 18.
Page 382 5-111.bk Page 369 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 1 23. Install the CMCAC inlet tube and hoses 27. Install upper radiator tube and hoses. The between the turbocharger and the cooler. connection is made at the coolant outlet fitting on the thermostat housing.
Page 383 5-111.bk Page 370 Monday, July 10, 2006 2:26 PM NOTES Page 370...
Page 384: Repair Instructions, Part 2
5-111.bk Page 371 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 REPAIR INSTRUCTIONS, PART 2 Page 371...
Page 385: In-Chassis Part/Component Procedures
5-111.bk Page 372 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 IN-CHASSIS 4. On chassis with inlet manifold-mounted fuel filters, remove both the inlet and outlet fuel PART/COMPONENT hoses from the secondary fuel filter. This PROCEDURES allows additional fuel to drain from the hose, through the cylinder block, and out of the This section presents standalone replacement internal passages.
Page 386: Tappet Guide Pin And Tappet Bore Inspection
5-111.bk Page 373 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 12. Remove the roller tappet from the EUP bore by hand. Do not use a tool as it could damage the bore. Place the roller tappet in a A small amount of scuffing or foreign particle clean area and cover it to prevent the entry scoring in a lifter bore can inhibit static-free...
Page 387: Tappet Installation
O-ring (Figure 448) of clean engine oil to allow oil to fill the is available through the MACK Parts System. passage to the roller axle. Remove the roller This seal should be used in the lower O-ring tappet and while holding it vertically, spin the position when necessary to correct leakage.
Page 388 5-111.bk Page 375 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 2. Generously lubricate EUP O-rings with clean 3. If not previously done, inspect each EUP engine oil and install the EUP into the hold-down bolt hole in the engine block for cylinder block (Figure 449).
Page 389: Camshaft Replacement (In-Chassis)
5-111.bk Page 376 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 CAMSHAFT REPLACEMENT Camshaft/Lifter Removal (IN-CHASSIS) [213 CH] When removing or installing the camshaft, first remove the idler gear and hub. It is Preliminary Steps easier to remove the camshaft guide from the camshaft (after installation) when the idler gear has been removed and alignment of the timing marks is not being attempted at...
Page 390 5-111.bk Page 377 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 Figure 450 — Valve Lifter (Tappet) Holder Tool J 37720-C 3. If not previously done, rotate the engine in direction of normal rotation so that the cam timing marks are positioned at approximately the 1–2 o’clock position.
Page 391: Cleaning And Inspection Of Cylinder Block
5-111.bk Page 378 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 6. After installing the removal/installation tool 2. Trial-fit a lifter back into its original lifter bore J 41682, remove the idler gear and hub. by aligning the lifter flats with the H-ring flats as shown in Figure 453.
Page 392: Camshaft Installation
5-111.bk Page 379 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 A lifter that does not move freely in the lifter bore Ceramic lifter rollers will not tolerate high impact can be impacted by the cam lobe during engine loads.
Page 393: Camshaft Idler Gear Installation
5-111.bk Page 380 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 4. Secure the lifter in the UP position with grommets provided with the tappet holders. The holding tool shafts of two adjacent valve lifters can be prevented from dropping by wrapping a rubber band around the two shafts.
Page 394 5-111.bk Page 381 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 1. With the engine in an upright position and the hub correctly aligned with the mounting bolt holes, place the idler hub against the There are 45 gear teeth on the crankshaft gear, block and verify proper alignment of the 90 teeth on the camshaft gear and 48 on the idler mounting holes.
Page 395: Exhaust Valve Yoke Pin And Valve Rotator Inspection And Replacement Criteria (In-Chassis)
5-111.bk Page 382 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 EXHAUST VALVE YOKE PIN 3. Perform the following inspections to determine the likely locations for damaged AND VALVE ROTATOR valve rotators: INSPECTION AND Inspect and record the locations where REPLACEMENT CRITERIA the cam lobes (both inlet and exhaust) (IN-CHASSIS)
Page 396 ® XADC-ARMOLOY coating is available through the MACK Parts System to update the engine brake units with new and improved component. Always verify that the engine is not already equipped with these new components.
Page 397: Valve Lifter H-Ring Dislodgement And Alignment Inspections (In-Chassis)
5-111.bk Page 384 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 VALVE LIFTER H-RING 4. At the locations recorded in steps “a” and “b” above, the rotators must be replaced. Be DISLODGEMENT AND sure to use a magnet to clean all the pieces ALIGNMENT INSPECTIONS of broken rotator springs from the valve (IN-CHASSIS)
Page 398: H-Ring Dislodgement Inspection
5-111.bk Page 385 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 H-Ring Dislodgement Inspection If the H-ring at the failure cylinder is 1/16–1/8 inch (1.587–3.175 mm) higher than that of an adjacent OK cylinder, Dislodging of the H-ring from its bore results from the H-ring position is OK.
Page 399: H-Ring Dislodgement Check And Alignment Verification
5-111.bk Page 386 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 H-Ring Dislodgement Check and Alignment Verification Requires Removal of Cylinder Head(s) If the H-ring dislodgement or alignment checks performed previously reveal that an H-ring is dislodged or out of alignment, the cylinder head(s) must be removed, and the position of the H-ring verified with the H-ring installation tool (tool No.
Page 400: Eecu And Sensor Service Procedures (In-Chassis)
5-111.bk Page 387 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 EECU AND SENSOR SERVICE PROCEDURES (IN-CHASSIS) Engine Electronic Control Unit (EECU) and Cooling Plate Removal [230 EA] The following procedure applies for an EECU mounted to the cooling plate at the front left side of the engine.
Page 401 5-111.bk Page 388 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 6. Disconnect the two harness leads from the EGR MASS Flow module mounted to the back side of the cooling plate (Figure 463). Figure 462 — EECU Removal/Installation 1.
Page 402: Eecu And Cooling Plate Installation
5-111.bk Page 389 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 7. Disconnect the fuel lines at the inlet and 8. Loosen the two retaining nuts securing the outlet ports at the top of the cooling plate plate support bracket to the mounting studs (Figure 464) and position the lines on top of the coolant manifold.
Page 403: Sensors Installation And Adjustment
5-111.bk Page 390 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 Sensors Installation and Adjustment Make sure that the seals are firmly seated on the connectors and that the EECU terminal pins are ASET™ AC ENGINE SENSORS straight and not damaged. The engine speed and engine position sensors EJ2 (89-pin connector) —...
Page 404: Cooling System Service Procedures (In-Chassis)
5-111.bk Page 391 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 COOLING SYSTEM SERVICE PROCEDURES (IN-CHASSIS) Thermostat Replacement [215 NU, NG & LD] The EGR mixer tube must be removed to gain access to the thermostat housing for replacement of the thermostats.
Page 405 5-111.bk Page 392 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 5. Remove the thermostat housing assembly COOLANT BYPASS TUBE AND Y-HOSE (Figure 466). With the EECU, cooling plate and thermostat housing removed, the bypass tube and Y-hose can be removed from the oil cooler if required.
Page 406 5-111.bk Page 393 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 3. Loosen the clamp securing the Y-hose to the 7. Slide the bypass tube into position between oil cooler inlet port and remove the hose and the water pump housing and the inlet filter screen (Figure 468).
Page 407 5-111.bk Page 394 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 Press the barrel seal into the housing bore by applying smooth, uniform pressure with a press fitting tool. Press When replacement is required, always replace fitting tools are available through the thermostats in pairs.
Page 408 5-111.bk Page 395 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 The seals attached to the thermostats provide total sealing for the housing-to-coolant manifold joint. No other sealant is required. Figure 473 — Thermostat Positioning on Dual Figure 472 — Thermostat Positioning Thermostat Housing 1.
Page 409: Water Pump Housing Assembly Removal And Installation
5-111.bk Page 396 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 For problems with the water pump, DO NOT replace the entire water pump and housing assembly. Replace only the water pump cartridge if the problem is in the impeller unit. PUMP REMOVAL Refer to Figure 477 as required to identify parts referenced in the steps below.
Page 410 5-111.bk Page 397 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 3. Disconnect the coolant supply hose to EGR cooler from the fitting on the water pump. 4. Disconnect the coolant inlet tube from the inlet port at the back of the water pump on the left side of the engine.
Page 411 5-111.bk Page 398 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 Figure 477 — Water Pump Installation 1. Engine Lifting Bracket 6. Water Pump Assembly (Housing and Cartridge) 2. Threaded Inserts and Upper Mounting Bolts 7. Water Pump Stiffening Bracket 3.
Page 412 O-rings in the grooves at the coolant inlet and outlet flanges, respectively. Use MACK Code 442 grease or any quality O-ring grease to hold the O-rings in place for The water pump cartridge assembly and water assembly.
Page 413 5-111.bk Page 400 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 7. Push the housing against the block and 15. Install a new O-ring on the pump cartridge hand-tighten the mid-position mounting bolts housing mounting flange (Figure 480). (item 4 in Figure 477).
Page 414: Coolant Conditioner Adapter Removal And Installation
5-111.bk Page 401 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 FINAL ASSEMBLY 1. Place a suitable container below the coolant filter area to catch any spilled coolant. Complete the procedure by installing the radiator, charge air cooler and hood and fender assembly, 2.
Page 415: Egr System Service Procedures (In-Chassis) For Aset™ Ac Engine
5-111.bk Page 402 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 EGR SYSTEM SERVICE COOL TUBE REMOVAL (ONE-PIECE ASSEMBLY) PROCEDURES (IN-CHASSIS) 1. Disconnect the turbocharger oil supply line FOR ASET™ AC ENGINE and the air line to the VTG actuator at the turbocharger (Figure 483).
Page 416 5-111.bk Page 403 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 Figure 484 — Cool Tube Clamps 1. Clamp Bolts 2. Clamp, Upper and Lower Sections 3. Loosen and remove the clamps from the 4. Remove the cool tube and coupling hoses coupling hose at each end of the cool tube from the engine (Figure 486).
Page 417 5-111.bk Page 404 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 Early-production engines will use coupling adapters in combination with the one-piece cool tube assembly. On vehicles so equipped: Loosen and remove the clamp from the cool tube coupling hose adapter at the EGR cooler tube mounting flange.
Page 418 5-111.bk Page 405 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 4. Loosen and remove the clamp connecting the hot tube-to-EGR valve outlet flange. The hot tube also is fitted with wire-mesh seals in the flanges at both ends. Remove and discard the seals.
Page 419 5-111.bk Page 406 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 COOL TUBE INSTALLATION (ONE-PIECE 3. Place the cool tube assembly in position on ASSEMBLY) the engine between the EGR mixer tube and cooler ports (or coupling adapters). Slide the Early-production engines use flange-style coupling hoses onto the ports/adapters and coupling adapters at both the EGR cooler and...
Page 420 5-111.bk Page 407 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 Figure 491 — Cool Tube Clamp Installation 1. Mounting Bolts 2. Clamps, Upper and Lower Halves 5. Start the engine and allow it to warm up. Check for leaks in the EGR system. 6.
Page 421: Egr Cooler Removal And Installation
5-111.bk Page 408 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 EGR Cooler Removal and Installation REMOVAL PROCEDURE 1. Drain the cooling system in preparation for removal of the EGR cooler. A petcock is located at the lower rear corner of the cooler to drain coolant retained in the cooler (Figure 492).
Page 422 5-111.bk Page 409 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 4. Loosen the clamps and disconnect the 5. Remove the four retaining nuts, two at each coolant inlet and outlet hose connections at side, attaching the cooler assembly to the the front side of the EGR cooler cylinder block and remove the assembly (Figure 495).
Page 423 5-111.bk Page 410 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 INSTALLATION PROCEDURE 4. Slide the coupling hose onto the cooler port/adapter and secure with the hose clamp (Figure 497). Clamps used on the hot-side tube are prone to corrosion and damage and should be replaced.
Page 424 5-111.bk Page 411 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 If alignment of the EGR hot tube is difficult, complete the following: Remove the clamps from the EGR hot tube and remove the tube. Remove the mounting nuts and remove the EGR valve and gasket from the exhaust manifold.
Page 425: Egr Valve Removal And Installation
5-111.bk Page 412 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 EGR Valve Removal and Installation 1. Remove the one-piece EGR gas cool tube following the instructions covered earlier in this section. REMOVAL PROCEDURE 2. Disconnect the oil supply and oil return lines at the EGR valve (Figure 499).
Page 426 5-111.bk Page 413 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 Figure 501 — EGR Valve Gaskets 3. Install a new gasket on the EGR valve assembly mounting surface of the exhaust manifold (Figure 502). Figure 500 — EGR Valve Removal 1.
Page 427 5-111.bk Page 414 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 Beginning with March 2004 production, a filter screen has been added to the oil inlet port on the EGR valve. It is retained in place by a wave washer and inlet hose fitting (Figure 504).
Page 428 5-111.bk Page 415 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 Figure 505 — EGR Valve, Installed 1. EGR Valve 4. Mounting Studs/Nuts 2. Electrical Connection 5. EGR Hot Tube 3. Oil Return Line Page 415...
Page 429: Egr Valve Heat Shields Removal And Installation
5-111.bk Page 416 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 EGR Valve Heat Shields Removal 1. Remove the three retaining nuts and remove the two outer EUP heat shields. and Installation 2. Remove the four capscrews retaining the inner EUP heat shield and tilt the shield up All ASET™...
Page 430: Egr Gas Mixer Tube Removal And Installation
5-111.bk Page 417 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 EGR Gas Mixer Tube Removal and INSTALLATION PROCEDURE Installation Refer to Figure 506. 1. Place the EGR valve heat shield in position over the front section of the exhaust REMOVAL PROCEDURE manifold.
Page 431 5-111.bk Page 418 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 4. Remove the capscrew from the support bracket at the side of the EGR gas mixer tube. The bracket is attached between the mixer tube and the coolant manifold. 5.
Page 432 5-111.bk Page 419 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 3. Place the mixer tube in position on the inlet manifold (Figure 511) and install the two mounting capscrews. Tighten the capscrews to specification, 40 lb-ft (55 N m). Figure 512 —...
Page 433: Mass Flow System Replacement Instructions
(EECU) cooling plate. To replace the module, it is connector also facing the rear. Depending upon necessary to disconnect the EECU and mass the availability of parts through the MACK Parts flow system module connectors, then to remove System, it is acceptable to use either wire length the EECU, cooling plate and MASS flow system MASS flow system in place of the other.
Page 434: Final Assembly
5-111.bk Page 421 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 4. Reinstall the non-current design EECU For the non-current cooling plate cooling plate as follows: design, upper isolators are secured with flanged nuts only; washers are not Non-Current Cooling Plate Design used.
Page 435: Vtg Turbocharger Service Procedures
5-111.bk Page 422 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 VTG TURBOCHARGER On early-production engines (prior to May 4, 2004), supply air enters the control valve directly SERVICE PROCEDURES from the chassis air system. As a result, small ASET™...
Page 436 5-111.bk Page 423 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 REMOVAL AND INSTALLATION PROCEDURE 6. Place the control valve assembly in position on the inlet manifold and install the two Refer to Figure 513 for reference in removing and mounting capscrews.
Page 437: Turbocharger Removal
5-111.bk Page 424 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 Turbocharger Removal 1. Disconnect the air inlet and outlet ducting DO NOT let the exhaust pipe drop onto the from the turbocharger compressor housing. bellows of the EGR hot tube as the exhaust pipe 2.
Page 438 5-111.bk Page 425 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 4. Disconnect the oil supply line from the fitting in the turbocharger center housing. 5. Remove the two capscrews securing the oil The turbocharger is heavy, weighing drain tube at the bottom of the turbocharger approximately 76 lbs.
Page 439: Turbocharger Installation (Includes Pre-Lubing Procedures)
5-111.bk Page 426 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 Turbocharger Installation (Includes Pre-Lubing Procedures) 1. Inspect the intake and exhaust systems leading to and from the turbocharger to ensure absence of foreign material, including burrs and loose lining fragments. A thorough inspection is required as even small particles can cause severe rotor damage if inducted during high-speed operation.
Page 440 5-111.bk Page 427 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 7. If the V-band is loosened for angular 11. Install and adjust the VTG actuator (if orientation of the compressor housing, removed) using the procedure under “VTG ensure that the mating flanges are tightly Removal and Installation”...
Page 441: Vtg Actuator Removal And Installation
VTG actuator kit is available through operating lever clevis (Figure 521). the MACK Parts System. Use the following procedure to reinstall the original actuator or to install a new unit. Page 428...
Page 442 5-111.bk Page 429 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 7. Remove the three 6 mm Allen-head bolts and washers that secure the position sensor connector and thermal isolation plate assembly to the compressor housing. Figure 521 — Vane Operating Lever Connection 1.
Page 443 5-111.bk Page 430 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 VTG ACTUATOR INSTALLATION 1. Place the VTG actuator assembly in position on the mounting flange at the center of the turbocharger. Make sure the alignment pin is positioned in the hole on the flange (Figure 524).
Page 444 5-111.bk Page 431 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 2. Using spanner wrench J 47019, install the spanner nut securing the actuator assembly to the mounting flange. Tighten the nut to specification, 92 lb-ft (125 N m). To ensure that the spanner nut is tightened to the proper torque value, spanner wrench J 47019 (Figure 525) is required.
Page 445 5-111.bk Page 432 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 Step c must be completed or the actuator will be out of range and cause a fault to be logged in the ® V-MAC system. Using an open-end wrench on the two flats on the rod end, tighten the jam nut.
Page 446 5-111.bk Page 433 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 6. With air pressure applied and the actuator rod extended, move the lever arm clevis to align the hole in the clevis with the hole in Use care in applying air pressure to the actuator the rod end and insert the clevis pin assembly.
Page 447 5-111.bk Page 434 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 15. Connect the vane position sensor harness connector to the engine harness connector, then secure the connector to the isolation plate mounted on the turbocharger compressor housing. Use the existing washers, spacers and bolts previously removed.
Page 448: Vtg Actuating System Calibration
5-111.bk Page 435 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 VTG Actuating System Calibration problem with the vane operating lever, actuator, control valve, etc., that must be resolved. Verify that air system pressure is at least 110 psi (95 psi The VTG actuating system must be recalibrated delivered to the actuator), and check the actuator for proper open and closed vane position...
Page 449 5-111.bk Page 436 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 4. With the actuator rod extended, remove the C-clip from the clevis pin, then remove the pin from the clevis. At no time and under no circumstances should 5.
Page 450 5-111.bk Page 437 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 Figure 535 — Install Air Pressure Gauge in Air Line 3. Turn the ignition key switch ON, then note 4. If full stop-to-stop rod travel occurs with the reading indicated on the pressure 100 psi shop air applied to the actuator, gauge.
Page 451 5-111.bk Page 438 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 If a VTG control valve is installed for Under no circumstances should the actuator lever troubleshooting purposes and the problem is not stops ever be adjusted. These stop screws are resolved, the original control valve is to be adjusted to provide proper travel of the vanes reinstalled.
Page 452: Turbocharger Wheel Speed Sensor Replacement
The turbocharger wheel speed sensor is located is required, a pin and clip kit (part No. near the top of the VTG turbocharger bearing 7536-174126) is available through the MACK housing, between the oil inlet port and the VTG Parts System. When removing the existing pin vane actuator.
Page 453 5-111.bk Page 440 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 2 Complete diagnostic procedures for wheel speed 2. Disconnect the sensor harness connector. ® sensor faults are outlined in the V-MAC The connector is located at the front of the Service Manual, 8-311.
Page 454: Repair Instructions, Part 3
5-111.bk Page 441 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 3 REPAIR INSTRUCTIONS, PART 3 Page 441...
Page 455: Engine Setup And Adjustments
5-111.bk Page 442 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 3 ENGINE SETUP AND LOCATING AND MARKING FLYWHEEL VALVE ADJUSTMENT MARKINGS ADJUSTMENTS Fuel Injection Timing Some engines may be equipped with flywheels that have missing or illegible valve adjustment There is no need to set injection pump-to-engine markings.
Page 456: Valve Adjustment Procedure
5-111.bk Page 443 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 3 There are 12 clutch mounting bolt holes in the 5. Permanently mark the flywheel at this flywheel, but only 8 of these holes are used to location for cylinders 1 and 6. To gain mount the clutch.
Page 457 5-111.bk Page 444 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 3 Valve adjustments must be made in firing order Valve adjustments are made in two stages. The sequence (1-5-3-6-2-4) with the engine cold exhaust valve yoke is adjusted first, and then the (coolant temperature below 100°F [38°C]), and valve lash.
Page 458 5-111.bk Page 445 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 3 4. Exert moderate force on the valve yoke by pressing on the rocker arm slipper end. Turn the yoke adjusting screw clockwise until it Valve lash must be set using the valve makes solid contact with the outboard valve adjustment marks on the engine flywheel, which stem tip (a light drag should be felt on the...
Page 459 5-111.bk Page 446 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 3 6. Hold the valve yoke adjusting screw in this Inlet and Exhaust Valve Lash Adjustment position and tighten the adjusting screw jam (Non-Brake Engines) nut to the specified torque, 33 lb-ft (45 N m), using torque wrench J 24407, or equivalent.
Page 460 5-111.bk Page 447 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 3 4. Continue tightening the adjusting screw until the torque screwdriver clicks. At the exhaust locations, the push rod spring seats are now in contact and the push rod is solid and the valve lash is now properly set.
Page 461 5-111.bk Page 448 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 3 When exerting pressure on the rocker arm to keep the push rod spring compressed, drag on the thickness gauge should feel normal, as when performing an adjustment on an engine that is not equipped with spring-loaded push rods.
Page 462 5-111.bk Page 449 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 3 Inlet and Exhaust Valve Lash Adjustment for Non-Brake Engines (Alternate Procedure) If an oz-in or lb-in torque screwdriver or torque wrench is not available, valve lash can be adjusted (for both brake and non-brake engines) in the same manner as described above (by installing the appropriate thickness gauge and...
Page 463 5-111.bk Page 450 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 3 VALVE YOKE, VALVE LASH AND BRAKE LASH ADJUSTMENT FOR J-TECH™ BRAKE-EQUIPPED ENGINES For clarity, most of the illustrations in this section Valve Yoke Adjustment Procedure (J-Tech™ show adjustments being performed without the Brake Engines) Jake brake units being installed.
Page 464 5-111.bk Page 451 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 3 4. Exert moderate force on the valve yoke by pressing on the rocker arm slipper end. Turn the yoke adjusting screw clockwise until it makes solid contact with the outboard valve stem tip (a light drag should be felt on the adjusting screw).
Page 465 5-111.bk Page 452 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 3 The J-Tech™ exhaust rocker arm adjusting screw spherical jam nut is a through-hardened nut. When tightening these nuts, be aware of the following: Always use the proper 20 mm size wrench to tighten the spherical jam nut.
Page 466 5-111.bk Page 453 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 3 Brake Lash Adjustment (J-Tech™ Brake 2. Place the appropriate 0.021-inch Engines) (0.533 mm) thickness gauge between the slave piston stem and the top of the actuator The engine brake lash specification is based on pin in the yoke adjusting screw.
Page 467 Continuation of Adjustments for Remaining VALVE YOKE, BRAKE LASH AND VALVE Cylinders LASH ADJUSTMENT FOR ENGINES EQUIPPED WITH MACK POWERLEASH™ 1. Using a barring socket, manually rotate the ENGINE BRAKE engine crankshaft (Figure 560) in normal rotation direction 120 degrees until the...
Page 468 5-111.bk Page 455 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 3 Valve Yoke Adjustment Procedure 3. Exert moderate force on the exhaust valve (PowerLeash™ Brake Engines) yoke by pressing on the end of the exhaust rocker arm above the yoke. Turn the yoke adjusting screw clockwise until it solidly contacts the outboard valve stem tip (a light drag should be felt on the adjusting screw).
Page 469 5-111.bk Page 456 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 3 5. While holding the valve yoke adjusting 7. While exerting a moderate force on the screw in this position, tighten the adjusting rocker arm end above the yoke, check that screw locknut to 33 lb-ft (44 N m).
Page 470 REPAIR INSTRUCTIONS, PART 3 It is mandatory that the T-handle torque screwdriver (tool No. J 29919) be used to adjust the MACK PowerLeash™ engine brake hydraulic actuator. The engine brake hydraulic actuator must be adjusted prior to adjusting the exhaust valve lash.
Page 471 5-111.bk Page 458 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 3 The torque screwdriver may allow the adjusting screw to loosen slightly when it “clicks” at the pre-set torque. It is important to develop a “feel” for when the screwdriver click occurs and feel for the actual setting of the lash.
Page 472 5-111.bk Page 459 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 3 2. Holding the adjusting screw in position, use Inlet Valve Adjustment (PowerLeash™ Brake an accurately calibrated torque wrench to Engines) tighten the jam nut to 45 lb-ft (61 N m). Inlet valve lash is adjusted in the same manner as non-brake engines.
Page 473: Electronic Unit Pump (Eup) Calibration
SHIM SELECTION CHART FOR ENGINE SPEED AND same location on the data plate (next to the word ENGINE POSITION SENSORS MACK), only the identification letters “CAL” have Use the Following been eliminated to provide room for larger bar Depth as Measured P/N 505GC28 Shims codes.
Page 474: Engine Position Sensor
5-111.bk Page 461 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 3 Other Engine-Mounted Sensors The remaining engine-mounted sensors are thread-mounted and are not adjustable. Mounting torque values for these sensors are listed under “Torque Specifications for Engine-Mounted Sensors” in the SPECIFICATIONS section. Fuel Temperature Boost Air Temperature Boost Air Pressure...
Page 475: Engine Final Preparation And Operational Check
COMBINATION spin-on fuel filter element All filters and coolant conditioners must meet with clean No. 2 fuel oil through the small MACK specifications. Prime oil filters before holes at the perimeter of the element. Do not installation using the correct specification engine fill the filter element through the center hole.
Page 476: Turbocharger
1. Fill the engine crankcase to the specified 5. Install the turbocharger air inlet duct and capacity with the recommended reconnect the oil supply line at the MACK-specified EO-N PREMIUM PLUS ’03 turbocharger. engine oil. 2. Fill a pressure prelubricator (J 39258-A) with...
Page 477: Fuel System
5-111.bk Page 464 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 3 Fuel System 4. Hand-prime the system until fuel is seen at the disconnected hose fitting for the applicable engine. This should take GENERAL INSTRUCTIONS approximately 50 hand pumps. 1.
Page 478: Engine Operational Check
5-111.bk Page 465 Monday, July 10, 2006 2:26 PM REPAIR INSTRUCTIONS, PART 3 Engine Operational Check Run-In Check 1. Remove all tools from the engine compartment. 2. Connect the battery cables (negative cable Install any additional instrumentation needed for last). the run-in method selected.
Page 479 5-111.bk Page 466 Monday, July 10, 2006 2:26 PM NOTES Page 466...
Page 480: Specifications
5-111.bk Page 467 Monday, July 10, 2006 2:26 PM SPECIFICATIONS SPECIFICATIONS Page 467...
Page 481: Aset™ Ac Engine Mechanical Specifications
5-111.bk Page 468 Monday, July 10, 2006 2:26 PM SPECIFICATIONS ASET™ AC ENGINE ASET™ AC-380/410 (CEGR) MAXICRUISE MECHANICAL — Speed Range — 1100–1800 rpm SPECIFICATIONS — Power at Governed Speed — 380 hp (283 kW) at 1800 rpm Performance Specifications —...
Page 482: Material And Dimensional Data
5-111.bk Page 469 Monday, July 10, 2006 2:26 PM SPECIFICATIONS ASET™ AC-460(E) (CEGR) ECONODYNE ASET™ AC-460(P) (CEGR) ECONODYNE — Speed Range — 1200–1800 rpm — Speed Range — 1200–1800 rpm — Power at Governed Speed — 460 hp — Power at Governed Speed — 480 hp (343 kW) at 1800 rpm (359 kW) at 1800 rpm —...
Page 483 5-111.bk Page 470 Monday, July 10, 2006 2:26 PM SPECIFICATIONS Item Description Cylinder head cover Casting is changed to allow space between the front and rear cover assemblies, to accommodate the upper EGR gas tube Cylinder sleeve Wet/dry, replaceable, centrifugally cast, alloyed cast iron Cylinder heads Alloyed gray cast iron, two per engine, four valves per cylinder.
Page 484 5-111.bk Page 471 Monday, July 10, 2006 2:26 PM SPECIFICATIONS Item Description Piston ring — oil Dual chrome-faced rails, conformable with coil spring expander Piston pin Full-floating, 2.25-inch (57 mm) diameter, full-pressure lubrication through rifle-drilled holes in connecting rod ® Oil filters Two spin-on disposable, one Centri-Max Oil pan...
Page 485 5-111.bk Page 472 Monday, July 10, 2006 2:26 PM SPECIFICATIONS Tolerances Are Shown Low to High Standard Size or Fit Component English Metric Bushing Press-Fit in Bore 0.004–0.007 in. 0.102–0.178 mm Bushing ID (installed) 3.8188–3.8213 in. 96.998–97.061 mm Cam Journal Diameter 3.8150–3.8160 in.
Page 486 5-111.bk Page 473 Monday, July 10, 2006 2:26 PM SPECIFICATIONS Tolerances Are Shown Low to High Standard Size or Fit Component English Metric CYLINDER BLOCK Deck Flatness (across one cylinder head) 0.002 in. 0.0508 mm Deck Flatness (across both cylinder heads) 0.004 in.
Page 487 5-111.bk Page 474 Monday, July 10, 2006 2:26 PM SPECIFICATIONS Tolerances Are Shown Low to High Standard Size or Fit Component English Metric Valve Guide Ream ID (after installation, inlet and exhaust, 0.3745–0.3755 in. 9.5123–9.5377 mm used with 3/8 valve stem) Top End of Valve Guide-to-Valve Spring Seat 0.857–0.937 in.
Page 488 Note: End gap checked in 4.875 gauge diameter. For every 0.001-inch (0.0254 mm) increase in gauge diameter, ring gap will increase by 0.003 inch (0.076 mm). Refer to a MACK branch or dealer for specifications for piston ring part numbers not listed above.
Page 489 * Note: Valve Yoke Setting must be completed at each location with the respective piston at TDC firing position prior to setting the (cold static) rocker arm lash. (See procedure for engines with J-Tech™ or MACK PowerLeash™ engine brakes.) Valve Face-to-Deck (inlet) 0.047 + 0.009/−0.007 in.
Page 490 5-111.bk Page 477 Monday, July 10, 2006 2:26 PM SPECIFICATIONS Tolerances Are Shown Low to High Standard Size or Fit Component English Metric VALVE SEAT ANGLE 30° 15′ ±15′ Exhaust 20° 30′ ± 15′ Inlet VALVE SPRINGS Outer Spring: Free length (approximate) 2.89 in.
Page 491: Engine Component Torque Specifications
5-111.bk Page 478 Monday, July 10, 2006 2:26 PM SPECIFICATIONS Engine Component Torque Specifications All components are to be clean and free from foreign material or corrosion. Assemblies are to be made using suitable tools and procedures so that no permanent damage will occur as a result of the assembly.
Page 492 SPECIFICATIONS Torque Fastener Name Lb-Ft BRAKE COMPONENTS — MACK POWERLEASH™ Engine Brake Hydraulic Actuator Jam Nut Rocker Arm Adjusting Screw Nut Rocker Arm Shaft Locating Screw (1 Per Shaft Assembly) Rocker Arm Bracket-to-Rocker Arm Shaft Screw (2 Per Shaft Assembly)
Page 493 5-111.bk Page 480 Monday, July 10, 2006 2:26 PM SPECIFICATIONS Torque Fastener Name Lb-Ft FAN DRIVE Fan Drive Pulley-to-Hub Screw Poly-V Belt Tensioner Mounting Screw FLYWHEEL, FLYWHEEL HOUSING AND CLUTCH Flywheel Housing-to-Cylinder Block Screw Flywheel-to-Crankshaft Screw Clutch-to-Flywheel Mounting Screw Transmission-to-Flywheel Housing Screw: 10 mm 7/16-inch FUEL SYSTEM...
Page 494 5-111.bk Page 481 Monday, July 10, 2006 2:26 PM SPECIFICATIONS Torque Fastener Name Lb-Ft OIL PUMP Oil Pump Cover-to-Housing Screw Oil Pump-to-Cylinder Block Mounting Screw Oil Pump Shaft Driven Gear Retaining Nut Oil Pump Inlet Fitting-to-Oil Pump Housing Screw Oil Pump Pressure Relief Valve Cap PISTON COOLING Piston Cooling Nozzle-to-Cylinder Block Screw SENSORS (FOR DASH GAUGES)
Page 495 5-111.bk Page 482 Monday, July 10, 2006 2:26 PM SPECIFICATIONS Torque Fastener Name Lb-Ft VALVE ROCKER ARM Valve Rocker Arm Bracket-to-Cylinder Head Screw Valve Rocker Arm Adjusting Screw Jam Nut Valve Yoke Adjusting Screw Jam Nut (See “NOTE 5 — VALVE YOKE SETTING”...
Page 496 5-111.bk Page 483 Monday, July 10, 2006 2:26 PM SPECIFICATIONS TORQUE SPECIFICATIONS FOR HOSE CLAMPS HOSE CLAMPS (SEE “NOTE 6 — HOSE CLAMP INSTALLATION POSITIONING INFORMATION” ON PAGE 489.) Torque Fastener Name Lb-In For Standard SAE J536 Type F Hose Clamps: Air Inlet Systems Oil Drain Systems Water or Coolant Systems...
Page 497 5-111.bk Page 484 Monday, July 10, 2006 2:26 PM SPECIFICATIONS TORQUE SPECIFICATIONS FOR ENGINE-MOUNTED SENSORS ASET™ AC ENGINE-MOUNTED SENSORS Description Sensor and Sensor Mounting Hardware Sensor Threads Mounting Torque Air Temperature Sensor 64MT450 sensor only; sensor is used in three locations: 23 lb-ft (31 N m) (wide range and fast Compressor discharge temperature...
Page 498 5-111.bk Page 485 Monday, July 10, 2006 2:26 PM SPECIFICATIONS TORQUE SPECIFICATIONS FOR NON-CRITICAL FASTENERS PROPERTY CLASS 8.8 Tightening Torques Size (mm) Pitch Lb-Ft 0.75 1.00 1.00 1.25 1.25 1.50 1.25 1.75 1.50 2.00 1.50 2.00 1.50 2.50 1.50 2.50 1.50 2.50 2.00...
Page 499 5-111.bk Page 486 Monday, July 10, 2006 2:26 PM SPECIFICATIONS PROPERTY CLASS 9.8 Tightening Torques Size (mm) Pitch Lb-Ft 0.75 1.00 1.00 1.25 1.25 1.50 1.25 1.75 1.50 2.00 1.50 2.00 1.50 2.50 1.50 2.50 1.50 2.50 2.00 3.00 2.00 3.00 2.00 1005...
Page 500 5-111.bk Page 487 Monday, July 10, 2006 2:26 PM SPECIFICATIONS PROPERTY CLASS 10.9 Tightening Torques Size (mm) Pitch Lb-Ft 0.75 1.00 1.00 1.25 1.25 1.50 1.25 1.75 1.50 2.00 1.50 2.00 1.50 2.50 1.50 2.50 1.50 2.50 2.00 3.00 2.00 1250 3.00 1159...
Page 501: Specification Footnotes
5-111.bk Page 488 Monday, July 10, 2006 2:26 PM SPECIFICATIONS SPECIFICATION FOOTNOTES NOTE 3 — CYLINDER HEAD TORQUING Cylinder head assembly and torquing is to be performed as follows: NOTE 1 — AUXILIARY SHAFT GEAR RETAINING NUT INSTALLATION 1. Oil all cylinder head capscrew bosses, capscrew threads and washers with clean A new nut has pre-applied thread locker.
Page 502 5-111.bk Page 489 Monday, July 10, 2006 2:26 PM SPECIFICATIONS Figure 578 — Exhaust Manifold Tightening Sequence NOTE 5 — VALVE YOKE SETTING NOTE 7 — PIPE PLUG SEALING ® 1. Push down on the slipper face of the yoke. All pipe plugs must be sealed using Loctite ®...
Page 503: Aset™ Engine Assembly Lubricants And Sealants
5-111.bk Page 490 Monday, July 10, 2006 2:26 PM SPECIFICATIONS ASET™ ENGINE ASSEMBLY LUBRICANTS AND SEALANTS All genuine MACK cylinder head gaskets are Use only the following recommended sealing precoated and do not require any type of sealing compounds and lubricants.
Page 504: Aset™ Ac Engine Drive Belt Specifications
5-111.bk Page 491 Monday, July 10, 2006 2:26 PM SPECIFICATIONS ASET™ AC ENGINE DRIVE BELT SPECIFICATIONS Fan Drive Belts Tensioner Mounting Ratio Length Part No. (HL No.) Part No. 10-Rib Poly-V Belt (Main Drive) High 1.68:1 — 67.8 in. (172.2 cm) 88GB449P678 (HL62-87) 87GB41 1.68:1...
Page 505 5-111.bk Page 492 Monday, July 10, 2006 2:26 PM NOTES Page 492...
Page 506: Schematic & Routing Diagrams
5-111.bk Page 493 Monday, July 10, 2006 2:26 PM SCHEMATIC & ROUTING DIAGRAMS SCHEMATIC & ROUTING DIAGRAMS Page 493...
Page 507: Aset™ Ac Engine Systems Schematics
5-111.bk Page 494 Monday, July 10, 2006 2:26 PM SCHEMATIC & ROUTING DIAGRAMS ASET™ AC ENGINE SYSTEMS SCHEMATICS Cooling System Flow Diagrams Figure 579 — ASET™ AC Cooling System Flow Diagram Page 494...
Page 508: Lubrication System Flow Diagrams
5-111.bk Page 495 Monday, July 10, 2006 2:26 PM SCHEMATIC & ROUTING DIAGRAMS Lubrication System Flow Diagrams Figure 580 — ASET™ AC Lubrication System Flow Diagram Page 495...
Page 509: Fuel System Flow Diagrams
5-111.bk Page 496 Monday, July 10, 2006 2:26 PM SCHEMATIC & ROUTING DIAGRAMS Fuel System Flow Diagrams Figure 581 — Fuel System Flow Diagram, ASET™ AC Engine Standard Fuel Filter Arrangement with Chassis-Mounted Primary Filter (December 22, 2003 and Later Production) Page 496...
Page 510 5-111.bk Page 497 Monday, July 10, 2006 2:26 PM SCHEMATIC & ROUTING DIAGRAMS Figure 582 — Fuel System Flow Diagram, ASET™ AC Engine Standard Fuel Filter Arrangement with Pre-Pump Filter (Production Prior to December 22, 2003) Page 497...
Page 511 5-111.bk Page 498 Monday, July 10, 2006 2:26 PM SCHEMATIC & ROUTING DIAGRAMS Figure 583 — Fuel System Flow Diagram, ASET™ AC Engine with Optional Fuel Filter Arrangement Page 498...
Page 512: Accessory Drive Belt Routings
5-111.bk Page 499 Monday, July 10, 2006 2:26 PM SCHEMATIC & ROUTING DIAGRAMS Accessory Drive Belt Routings Figure 585 — Accessory Drive Belt Routing without AC Figure 584 — Accessory Drive Belt Routing with AC Page 499...
Page 513 5-111.bk Page 500 Monday, July 10, 2006 2:26 PM NOTES Page 500...
Page 514: Special Tools & Equipment
5-111.bk Page 501 Monday, July 10, 2006 2:26 PM SPECIAL TOOLS & EQUIPMENT SPECIAL TOOLS & EQUIPMENT Page 501...
Page 515: Aset™ Engine Special Tools
5-111.bk Page 502 Monday, July 10, 2006 2:26 PM SPECIAL TOOLS & EQUIPMENT ASET™ ENGINE SPECIAL TOOLS Special Tools for Engine Overhaul Tool No. Description Midget Seal Tool HT77136 Valve Seat Insert Counterbore J 2619-01 Slide Hammer J 5347-B Dial Bore Gauge J 5853-C Torque Wrench (3/8 DR, 0–600 lb-in) J 5902-01...
Page 516 5-111.bk Page 503 Monday, July 10, 2006 2:26 PM SPECIAL TOOLS & EQUIPMENT Tool No. Description J 35529 Wear Ring and Seal Installer J 37077 Position Sensor J 37093 Injection Nozzle Puller J 37481 Valve Guide Reamer (3/8-inch diameter) J 37482 Valve Guide Remover (3/8 inch) J 37712 Flywheel Housing/Timing Cover Locating Pin Driver...
Page 517 5-111.bk Page 504 Monday, July 10, 2006 2:26 PM SPECIAL TOOLS & EQUIPMENT Tool No. Description J 42639 Fuel Injection Nozzle Tester Adapter Set (use with J 29075-B Nozzle Tester) J 42678 Fuel Injection Nozzle Sleeve Puller (use with J 2619-01 Slide Hammer) J 42680 Fuel Injection Nozzle Combustion Gasket Seat Carbon...
Page 518: V-Mac Iii Special Tools
5-111.bk Page 505 Monday, July 10, 2006 2:26 PM SPECIAL TOOLS & EQUIPMENT V-MAC III Special Tools Tool No. Description J 37490 Diesel Electronic Connector Replacement Kit 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...
Page 519 5-111.bk Page 506 Monday, July 10, 2006 2:26 PM NOTES Page 506...
Page 520: Appendix
5-111.bk Page 507 Monday, July 10, 2006 2:26 PM APPENDIX APPENDIX Page 507...
Page 521: Fastener Identification
5-111.bk Page 508 Monday, July 10, 2006 2:26 PM APPENDIX FASTENER IDENTIFICATION Equally important as the selection of the correct fastener is its proper installation. Improperly installing a correct fastener is just as bad as using Fastener Selection and Installation an incorrect one.
Page 522: Fastener Sizes And Types
5-111.bk Page 509 Monday, July 10, 2006 2:26 PM APPENDIX Fastener Sizes and Types The pitch of metric fasteners is measured by determining the millimeters per thread. For example, a bolt with 0.8 pitch would have The first and most important fact that the 125 complete threads in a 100 millimeter section mechanic must know about a fastener is whether (100 mm divided by 125 threads equals 0.8), and...
Page 523: Torque Wrench Use
5-111.bk Page 510 Monday, July 10, 2006 2:26 PM APPENDIX TORQUE WRENCH USE Using an Adapter in Combination with a Torque Wrench When tightening a fastener, it is important to use a steady pull on the torque wrench. Only in this It is sometimes necessary to use an adapter at way can accurate torque values be achieved.
Page 524: Turbocharger Failure And Actions Required To Avoid Repeat Failure
5-111.bk Page 511 Monday, July 10, 2006 2:26 PM APPENDIX TURBOCHARGER FAILURE 2. Multiply the dial reading times the Quotient found above to determine the torque at the AND ACTIONS REQUIRED TO end of the adapter. AVOID REPEAT FAILURE Example: —...
Page 525: Cleaning Oil From The Charge Air Cooler
No. 6. If enough oil enters the cylinder, hydraulic contact the Mack Trucks, Inc. Warranty lock could occur and result in severe damage Department to authorize replacement.
Page 526: Cleaning The Turbocharger Oil Supply Line, Changing The Engine Oil And Pre-Lubricating The Turbocharger Following A Failure
appendix.fm Page 513 Tuesday, July 11, 2006 11:18 AM APPENDIX 3. Mount the turbocharger on the exhaust manifold, install the oil drain tube and connect the exhaust pipe. Do not connect To check the intake air ducts and air cleaner the oil supply line or the inlet air duct to the canister, carefully wipe the inside surfaces with a turbocharger.
Page 527: Pre-Lubricating A Turbocharger After Sitting Idle For An Extended Period Of Time
5-111.bk Page 514 Monday, July 10, 2006 2:26 PM APPENDIX 9. Again, pour clean engine oil into the Before starting the engine on a vehicle that has turbocharger oil inlet port until overflowing, been sitting for an extended period of time and then install the oil supply line.
Page 528: Index
Index.fm Page 515 Monday, July 10, 2006 2:48 PM INDEX INDEX Page 515...
Page 529 CAMSHAFT REPLACEMENT (IN-CHASSIS) ..... 376 ABOUT THE MACK ASET™ AC DIESEL CAMSHAFT TIMING AND LOBE LIFT ENGINE ......9 CHECKS .
Page 530 Index.fm Page 517 Monday, July 10, 2006 2:48 PM INDEX CRANKSHAFT DOWEL PIN REPLACEMENT ....213 DIPSTICK TUBE INSTALLATION ..366 CRANKSHAFT FRONT SEAL DIPSTICK TUBE REMOVAL .
Page 531 GLOSSARY OF TERMS ....80 MACK ASET™ ENGINES ... . .88 ENGINE WIRING HARNESS INSTALLATION .
Page 532 PERFORMANCE SPECIFICATIONS ..468 PIPE PLUG REPLACEMENT ... . 194 MACK FUEL FILTRATION SYSTEM ..41 PISTON AND CONNECTING ROD MACK POWERLEASH™...
Page 533 VALVE ROCKER ARM SHAFT OVERHAUL ..... . .502 REASSEMBLY (WITH MACK SPECIAL TOOLS REQUIRED ..185, 230 POWERLEASH™...
Page 534 Index.fm Page 521 Monday, July 10, 2006 2:48 PM INDEX VTG POSITION CONTROL VALVE REMOVAL ......162 WATER PUMP HOUSING ASSEMBLY VTG POSITION CONTROL VALVE REMOVAL AND INSTALLATION .
Page 535 Index.fm Page 522 Monday, July 10, 2006 2:48 PM NOTES Page 522...
Page 536 ASET™ AC DIESEL ENGINE SERVICE MANUAL for Engines with Exhaust Gas Recirculation (EGR) PRINTED IN U.S.A. ENGINE 5-111 © MACK TRUCKS, INC. 2006...