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ASET™ AC ENGINE SERVICE

MANUAL

OCTOBER 2006

(REVISED — SUPERSEDES ISSUE DATED JANUARY 2005)

ENGINE 5-111

View of ASET™ AC Engine

5-111.bk Page i Monday, July 10, 2006 2:26 PM

Main Page

Table of Contents7
Introduction14
Safety Information15
Advisory Labels15
Service Procedures and Tool Usage16
Explanation of Numerical Code18
Conversion Chart19
About the Mack Aset™ Ac Diesel Engine22
Heater Core and Optional Fuel Heater Hose Connection Revisions22
Visual Identification24
Engine Model Identification25
Engine Information Plate25
Engine Serial Number Identification27
Description and Operation28
Engine Design Features29
ASET™ AC Engine Technologies30
ASET™ AC (CEGR) Engine Features and Components32
MACK Fuel Filtration System54
Electronic Unit Pumps (EUP)55
Engine Brake56
Camshaft66
Valve Train66
Low-Pressure Fuel System73
High-Pressure Fuel System76
High-Pressure Fuel Injection Lines77
Fuel Injector Assemblies77
Cylinder Block78
Crankshaft80
Block Heater80
Cylinder Head81
Cylinder Head Gasket82
Gear Train83
Air Compressor84
Power Steering Pump84
Vibration Damper Hub84
Front Cover85
Lubrication System86
Glossary of Terms93
Component Locator96
Component Location Views97
ASET™ AC Engine97
Troubleshooting100
Engine Symptom Diagnosis for Mack Aset™ Engines101
V-MAC III Diagnostics101
Camshaft Timing and Lobe Lift Checks112
Camshaft Timing Check112
Camshaft Lobe Lift Check112
Chassis-Mounted Charge Air Cooling Tests113
General Information113
Special Tool Required113
CMCAC Troubleshooting113
CMCAC Pressure Test114
Restriction Pressure Test115
Core Inspection116
CMCAC Preventive Maintenance116
Cylinder Head and Cylinder Block Leak Test Procedure117
Cylinder Head and Head Gasket Check - in Chassis117
Cylinder Head Fuel Passages Leak Check - in Chassis118
Cylinder Block/Cylinder Head Coolant Passages Leak Check - in Chassis118
Cylinder Head Oil Passage Leak Check - out of Chassis120
Cylinder Head Coolant Passage Leak Check - out of Chassis121
Cylinder Block Coolant Passage Leak Check - out of Chassis122
Engine Brake Tests (Mack Powerleash™)124
Operational Tests124
Electrical Troubleshooting125
MACK Powerleash™ Checks (Hydraulic/Mechanical)126
MACK Powerleash™ Troubleshooting Guide128
Removal and Inspection of MACK Powerleash™ Engine Brake Components130
Engine Brake Tests (J-Tech™)132
Operational Tests132
Electrical Troubleshooting133
J-Tech™ Checks (Hydraulic/Mechanical)134
J-Tech™ Troubleshooting Guide137
Maintenance140
Lubrication System Maintenance for Aset™ Engines141
Crankcase Breather Element Cleaning141
Oil Level Check142
Oil and Filter Change Procedure143
Fuel Filter Element Replacement for Aset™ Ac Engines147
Primary/Secondary Fuel Filter Change147
Coolant Conditioner Element Replacement for Aset™ Engines150
Coolant Conditioner Replacement150
Oil Coalescing Air Filter Replacement150
Drive Belt Replacement and Tensioning for Aset™ Ac Engines151
General Information151
Automatically Tensioned System152
Repair Instructions, Part 1154
Engine Removal155
General Instructions155
Removal from Vehicle155
Engine Disassembly158
General Instructions158
Filter Element Removal158
Dipstick Tube Removal159
Oil Cooler and Oil Filter Mounting Bracket Assembly Removal159
Oil Coalescing Air Filter Removal160
Mounting Engine in Stand161
Alternator Removal163
Engine Electronic Control Unit (EECU) and Cooling Plate Removal163
EGR Gas Tube Removal165
EGR Cooler Removal167
EGR Mixer Tube Removal168
Thermostat Housing Removal169
Oil Supply Lines Removal170
EGR Valve Removal172
Water Pump Housing Removal173
VTG Position Control Valve Removal175
Coolant Manifold Removal176
Air Inlet Manifold Removal176
Turbocharger Removal176
Fuel Nozzle Inlet Tube Assembly Removal177
Exhaust Manifold Removal178
Engine Wiring Harness Removal178
Electronic Unit Pump (EUP) Removal179
Air Compressor Removal180
Cylinder Head Cover and Spacer Removal182
Rocker Arm, Valve Yoke and Push Rod Removal183
Revised Rocker Arm Shift Mounting Bolts185
Nozzle Holder Removal186
Cylinder Head Assembly Removal186
Vibration Damper and Crankshaft Hub Removal188
Oil Pan Removal188
Oil Pump Removal190
Front Cover Removal191
Auxiliary Shaft Removal191
Camshaft Removal192
Piston and Connecting Rod Assembly Removal193
Flywheel Removal195
Flywheel Housing Removal196
Main Bearing Cap Removal196
Crankshaft Removal198
Cylinder Block Reconditioning198
Special Tools Required198
Piston Cooling Spray Nozzle Removal198
Cylinder Sleeve Removal199
Cleaning and Inspection200
Cylinder Sleeve Counterbore203
Cup Plug Replacement207
Pipe Plug Replacement207
H-Ring Replacement208
Camshaft Bushing Replacement210
Auxiliary Shaft Bushing Replacement214
Cylinder Sleeve Installation218
Piston Cooling Spray Nozzle Installation221
Cylinder Block Dowel Pin Replacement224
Crankshaft and Flywheel Bench Procedures226
General Information226
Crankshaft Inspection226
Crankshaft Dowel Pin Replacement226
Crankshaft Gear Replacement227
Crankshaft Wear Ring Installation228
Flywheel Inspection and Resurfacing230
Auxiliary Shaft and Camshaft Bench Procedures232
Auxiliary Shaft Inspection232
Camshaft Inspection232
Connecting Rod and Piston Bench Procedures236
Connecting Rod Inspection and Reconditioning236
Piston Inspection and Cleaning239
Piston Ring Replacement239
Assembling Connecting Rod to Piston242
Cylinder Head Overhaul243
Special Tools Required243
Inlet and Exhaust Valve Removal243
Cylinder Head Cleaning and Inspection247
Fire Ring Groove Cutting248
Valve Guide Replacement251
Valve Seat Insert Replacement254
Valve Spring Inspection260
Injection Nozzle Holder Insert Replacement261
Valve Yoke Guide Pin Replacement263
Cylinder Head Cup Plug Replacement264
Cylinder Head Pipe Plug Replacement265
Inlet and Exhaust Valve Inspection266
Inlet and Exhaust Valve Installation267
Valve Rocker Arm Shaft Bench Procedures273
Rocker Arms273
Valve Rocker Arm Shaft Disassembly (With/Without Engine Brake)275
Inspection276
Valve Rocker Arm Shaft Reassembly (Without Engine Brake)277
Valve Rocker Arm Shaft Reassembly (with J-Tech™ Engine Brake)279
Valve Rocker Arm Shaft Reassembly (with MACK Powerleash™ Engine Brake)281
Lubrication System Bench Procedures286
Oil Cooler Assembly Reconditioning286
Oil Pump Reconditioning286
Cooling System Components Bench Procedures292
Oil Cooler Reconditioning292
EGR Cooler Reconditioning292
Water Pump Reconditioning292
Fuel System Component Bench Procedures293
Electronic Unit Pump (EUP) Inspection293
Installation of Electronic Unit Pump Plunger Spring and Seat293
Fuel Injector Nozzle Cleaning296
Vtg System Bench Procedures297
VTG Control Valve Solenoid Replacement297
Engine Reassembly299
General Instructions299
Crankshaft Installation299
Main Bearing Cap Installation300
Piston and Connecting Rod Installation306
Flywheel Housing Installation311
Crankshaft Rear Oil Seal Installation314
Flywheel Installation317
Valve Lifter Installation318
Camshaft Installation320
Camshaft Core Plug Installation321
Camshaft Idler Gear Installation321
Auxiliary Shaft Installation322
Oil Pump Installation323
Front Cover Installation324
Crankshaft Front Seal Installation325
Crankshaft Hub Installation326
Vibration Damper Installation326
Oil Pan Installation327
Cylinder Head Installation329
Exhaust Manifold Installation332
Nozzle Holder Assembly Installation333
Push Rod Installation336
Valve Yoke Installation337
Rocker Arm and Engine Brake Installation341
Cylinder Head Cover and Spacer Installation347
Oil Fill Tube/Dipstick Installation349
Air Compressor Installation349
Electronic Unit Pump (EUP) Installation351
Engine Wiring Harness Installation352
Fuel Nozzle Inlet Tube Assembly Installation352
Turbocharger Installation355
Coolant Manifold Installation356
Air Inlet Manifold Installation357
VTG Position Control Valve Installation357
Water Pump Housing Installation358
EGR Valve Installation361
Oil Supply Lines Installation363
Thermostat Housing Installation366
EGR Mixer Tube Installation369
EGR Cooler Installation370
EGR Gas Tube Installation371
EECU and Cooling Plate Installation373
Coolant Conditioner Installation375
Alternator Installation376
Removing Engine from Engine Stand376
Oil Coalescing Air Filter Installation377
Oil Cooler and Oil Filter Mounting Bracket Assembly Installation377
Dipstick Tube Installation379
Engine Installation379
General Instructions379
Engine Installation into Vehicle379
Repair Instructions, Part 2384
In-Chassis Part/Component Procedures385
Electronic Unit Pump Replacement (In-Chassis)385
Unit Pump Removal385
Tappet Guide Pin and Tappet Bore Inspection386
Salvaging a Damaged EUP Tappet Bore386
Tappet Installation387
Unit Pump Installation387
Camshaft Replacement (In-Chassis)389
Preliminary Steps389
Camshaft/Lifter Removal389
Cleaning and Inspection of Cylinder Block391
Camshaft Installation392
Camshaft Idler Gear Installation393
Exhaust Valve Yoke Pin and Valve Rotator Inspection and Replacement Criteria (In-Chassis)395
Valve Lifter H-Ring Dislodgement and Alignment Inspections (In-Chassis)397
H-Ring Dislodgement Inspection398
H-Ring Alignment Inspection398
H-Ring Dislodgement Check and Alignment Verification399
Eecu and Sensor Service Procedures (In-Chassis)400
Engine Electronic Control Unit (EECU) and Cooling Plate Removal400
EECU and Cooling Plate Installation402
Sensors Installation and Adjustment403
Cooling System Service Procedures (In-Chassis)404
Thermostat Replacement404
Water Pump Housing Assembly Removal and Installation409
Coolant Conditioner Adapter Removal and Installation414
Egr System Service Procedures (In-Chassis) for Aset™ Ac Engine415
Preliminary Steps415
EGR Gas Tube(S) Removal and Installation415
EGR Cooler Removal and Installation421
EGR Valve Removal and Installation425
EGR Valve Heat Shields Removal and Installation429
EGR Gas Mixer Tube Removal and Installation430
MASS Flow System Replacement Instructions433
Final Assembly434
Vtg Turbocharger Service Procedures435
Preliminary Steps435
VTG Position Control Valve Removal and Installation435
Turbocharger Removal437
Turbocharger Installation (Includes Pre-Lubing Procedures)439
VTG Actuator Removal and Installation441
VTG Actuating System Calibration448
Turbocharger Wheel Speed Sensor Replacement452
Repair Instructions, Part 3454
Engine Setup and Adjustments455
Fuel Injection Timing455
Valve Adjustment455
Valve Adjustment Procedure456
Electronic Unit Pump (EUP) Calibration473
Engine Speed and Position Sensors Installation and Adjustment473
Engine Speed Sensor473
Engine Position Sensor474
Other Engine-Mounted Sensors474
Engine Final Preparation and Operational Check475
Filter Element Installation475
Engine Lubrication System475
Turbocharger476
Cooling System476
Fuel System477
Engine Operational Check478
Rebuilt Engine Run-In Procedures478
General Instructions478
Run-In Check478
Specifications480
Aset™ Ac Engine Mechanical Specifications481
Performance Specifications481
Material and Dimensional Data482
Engine Component Torque Specifications491
Specification Footnotes501
Aset™ Engine Assembly Lubricants and Sealants503
Aset™ Ac Engine Drive Belt Specifications504
Schematic & Routing Diagrams506
Aset™ Ac Engine Systems Schematics507
Cooling System Flow Diagrams507
Lubrication System Flow Diagrams508
Fuel System Flow Diagrams509
Accessory Drive Belt Routings512
Special Tools & Equipment514
Aset™ Engine Special Tools515
Special Tools for Engine Overhaul515
V-MAC III Special Tools518
Appendix520
Fastener Identification521
Fastener Selection and Installation521
Fastener Sizes and Types522
Torque Wrench Use523
Using an Adapter in Combination with a Torque Wrench523
Turbocharger Failure and Actions Required to Avoid Repeat Failure524
Cleaning Oil from the Charge Air Cooler525
Cleaning the Intake Air System525
Cleaning the Turbocharger Oil Supply Line, Changing the Engine Oil and Pre-Lubricating the Turbocharger Following a Failure526
Pre-Lubricating a Turbocharger after Sitting Idle for an Extended Period of Time527
Index528

Mack ASET AC - Page 4

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