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Mack E7 User Manual

Mack E7
303 pages
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E7 ENGINE
OVERHAUL
AUGUST 1997
ENGINE 5-101

Table of Contents

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Mack E7 Specifications

General IconGeneral
Engine TypeDiesel
Displacement12.0 L (728 cu in)
AspirationTurbocharged and Aftercooled
Bore4.875 in (124 mm)
Stroke6.5 in (165 mm)
Fuel SystemElectronic Unit Injection (EUI)
ConfigurationInline 6-cylinder
Torque1, 060 to 1, 660 lb-ft

Summary

SAFETY INFORMATION

Advisory Labels

Defines cautionary signal words and their meanings for safe service.

Service Procedures and Tool Usage

Guidelines for safe use of service procedures and tools.

EXPLANATION OF NUMERICAL CODE

EXPLANATION OF 3-DIGIT NUMERICAL CODE

Explains the 3-digit code system for manual content organization and component identification.

ABOUT THIS MANUAL

CHANGES FROM THE EXISTING E7 MANUAL

Details improvements and changes in content from the previous E7 manual.

200 GENERAL INFORMATION

INTRODUCTION

Assists technicians in overhauling E7 engines, emphasizing tools and knowledge.

ENGINE MODEL IDENTIFICATION

Explains how to identify E7 engine models using the information plate and serial number.

LUBRICANTS AND SEALANTS

Lists recommended sealing compounds and lubricants for engine assembly and service.

200 SPECIFICATIONS

SPECIFICATIONS

Provides general specifications and features of the E7 engine.

FASTENER TORQUE

Details the importance of fastener selection, installation, and proper torque application.

TORQUE SPECIFICATIONS

Lists torque specifications for critical and non-critical fasteners.

FITS AND LIMITS

Provides standard sizes and fits for engine components for proper assembly.

METRIC MISMATCH

Highlights incompatible metric/English fastener combinations that may cause failure.

SPECIAL TOOLS

Special Tool List

Lists all special tools required for E7 engine disassembly, assembly, and related procedures.

200 ENGINE REMOVAL

Vehicle Preparation

Guidelines for preparing the vehicle and engine area for safe and efficient removal.

Engine Removal

Details the step-by-step procedure for removing the E7 engine from the vehicle.

200 ENGINE DISASSEMBLY

MOUNTING ENGINE IN STAND

Instructions on safely mounting the E7 engine in an engine stand for disassembly.

[211 DB] CYLINDER BLOCK

Details procedures for cleaning and inspecting the cylinder block, including counterbore work.

[212 HP] CRANKSHAFT

Covers the inspection and installation procedures for the crankshaft, ensuring proper assembly.

[213 CH] CAMSHAFT

Explains the inspection, removal, and installation procedures for the camshaft and its gears.

[213 EV] CYLINDER HEADS

Details the inspection, removal, and installation procedures for the E7 cylinder heads.

[219 MU] OIL PUMP

Covers the disassembly, inspection, and installation of the engine's lubrication oil pump.

[221 GP] INJECTION PUMP

Provides procedures for removing and installing the fuel injection pump and its related components.

200 BENCH PROCEDURES

[211 DB] CYLINDER BLOCK

Details procedures for cleaning and inspecting the cylinder block, including counterbore work.

[212 HP] CRANKSHAFT

Covers the inspection and installation procedures for the crankshaft, ensuring proper assembly.

[213 CH] CAMSHAFT

Explains the inspection, removal, and installation procedures for the camshaft and its gears.

[213 EV] CYLINDER HEADS

Details the inspection, removal, and installation procedures for the E7 cylinder heads.

[213 FB] INLET AND EXHAUST VALVE SEAT INSERTS

Describes dimensions and procedures for installing inlet and exhaust valve seat inserts.

[213 LV] VALVE ROCKER ARM SHAFT

Covers the inspection and installation of the valve rocker arm shaft assembly.

[219 MU] OIL PUMP

Covers the disassembly, inspection, and installation of the engine's lubrication oil pump.

[221 GP] FUEL INJECTION PUMP

Provides procedures for removing and installing the fuel injection pump and its related components.

200 SETUP AND ADJUSTMENTS

VALVE YOKE AND VALVE LASH ADJUSTMENTS (NON-JAKE BRAKE ENGINE AND DYNATARD EQUIPPED)

Details procedures for adjusting valve yoke and valve lash on non-Jake brake and Dynatard engines.

Slave Piston, Inlet Valve and Exhaust Valve Lash Adjustments

Provides procedures for adjusting slave piston, inlet and exhaust valve lash on Jake Brake engines.

[221 GP] INJECTION PUMP FIXED-TIMING PROCEDURES

Explains the fixed-timing method for setting injection pump-to-engine timing for optimal performance.

Locating Piston Top Dead Center (TDC)

Provides instructions for locating piston TDC for timing inspection and adjustment procedures.

200 ENGINE INSTALLATION & TESTING

Engine Installation into Vehicle

Provides general guidelines for installing the MACK E7 engine into the vehicle.

Filter Element Installation

Details the correct procedure for installing air, oil, and coolant filter elements.

CMCAC Troubleshooting

Provides troubleshooting steps for Chassis-Mounted Charge Air Cooling system issues.

200 TROUBLESHOOTING

ENGINE WILL NOT CRANK

Troubleshooting steps for diagnosing and resolving engine failure to crank.

ENGINE CRANKS — WILL NOT START

Troubleshooting steps for diagnosing and resolving engine starting issues.

ENGINE MISFIRES

Troubleshooting steps for diagnosing and resolving engine misfires.

LOW COMPRESSION

Troubleshooting steps for diagnosing and resolving low engine compression issues.

Cylinder Head and Cylinder Block Leak Test Procedure

Provides procedures for pressure testing cylinder heads and blocks for leaks.

200 APPENDIX

E7 ENGINE SERIAL NUMBERS, JACOBS BRAKE APPLICATION

Lists E7 engine serial numbers and their corresponding Jacobs brake application details.

E7 LUBRICATION SYSTEM

Diagram and description of the E7 engine's lubrication system components and flow.

E7 COOLING SYSTEM

Diagram and description of the E7 engine's cooling system components and flow.

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