Mack E7 - 200 BENCH PROCEDURES

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200 BENCH PROCEDURES

Page 5-1

BENCH PROCEDURES

5-101.bk Page 1 Friday, March 17, 2006 11:05 AM

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Safety Information7
Explanation of Numerical Code11
Explanation of 3-Digit Numerical Code12
About this Manual13
Table of Contents16
200 General Information25
Introduction26
Engine Model Identification27
Engine Information Plate27
Lubricants and Sealants29
Overhaul Part Replacement30
200 Specifications31
Improved Design32
Engine General Specifications32
Engine Features32
Good Shop Practice - Fasteners34
Performance Specifications (Oil Pressure and Intake Manifold Temperature)34
Fastener Torque35
Fastener Selection and Installation35
Fastener Sizes and Types36
Torque Specifications37
Torque Specifications for Critical Fasteners37
Torque Specifications for Hose Clamps40
Torque Specifications for Pipe Plugs41
Torque Specifications for Non-Critical Fasteners41
Fits and Limits44
Metric Mismatch50
Inch Thread Vs. Metric Thread Fastener Combinations Contributing to Thread Stripping50
Inch Thread Vs. Metric Thread Fastener Combinations Contributing to Assembly Weakness51
Incompatible Metric Vs. Metric Fastener Systems51
Conversion Factors51
Special Tools52
Special Tool List52
V-MAC Tools54
200 Engine Removal55
General56
Vehicle Preparation56
200 Engine Removal56
200 Engine Disassembly59
General60
[219 Ev] Centri-Max™ and Spin-On Filter Elements60
Mounting Engine in Stand61
Special Tools Required61
[271 Cb] Alternator63
[215 Hb] Fan Assembly63
[231 Pb] Fuel Filter Adapter Assembly64
[215 Ld] Coolant Conditioner Element65
[215 Nu] Thermostat66
[214 Hd] Air Inlet Manifold67
[215 Nk] Coolant Manifold67
[215 Dw & 219 Ep] Oil Cooler and Oil Filter Housing Assembly68
[215 Sw] Water Pump69
[214 Sd] Turbocharger69
[222 Kd] Fuel Nozzle Inlet Tube Assembly70
[214 Eg] Exhaust Manifold71
[213 Jb] Valve Cover and Riser71
[213 Lp, Nv & Lh] Rocker Arm, Valve Yoke and Push Rod72
[222 Kg] Nozzle Holder73
Special Tool Required73
[213 Ev] Cylinder Head Assembly Removal74
[212 Rb & Rh] Vibration Damper and Crankshaft Hub75
[261 Ck] Air Compressor75
[221 Gp] Injection Pump77
[221 CD] Econovance78
V-MAC Equipped Engines78
[211 Nb] Oil Pan78
[219 Mu] Oil Pump80
[211 Rp] Timing Gear Cover81
[212 CV] Auxiliary Driveshaft82
[213 Ch] Camshaft82
[212 Np & Lq] Piston and Connecting Rod Assembly83
[212 Uc] Flywheel85
[211 Hd] Flywheel Housing86
[211 Ja] Main Bearing Cap86
[212 Hp] Crankshaft88
[219 Rv] Piston Cooling Spray Nozzle88
[212 Nc] Cylinder Sleeve89
Special Tool Required89
200 Bench Procedures91
[211 Db] Cylinder Block92
Cylinder Sleeve Counterbore92
[212 CV] Auxiliary Driveshaft95
Description95
Inspection95
[212 Lp] Connecting Rods95
Special Tools Required97
Inspection97
Wrist Pin Repair97
[212 Hp] Crankshaft99
Description99
Inspection100
[212 HA] Crankshaft Dowel Pin Replacement100
[212 HV] Crankshaft Gear102
[212 Ub] Flywheel103
[212 Np] Pistons103
Description103
Special Tools Required104
Disassembly104
Inspection105
[212 Nv] Piston Rings105
Keystone Ring Groove Check105
Ring Installation107
[212 Lp & Np] Connecting Rod Assembly to Piston107
[213 Ch] Camshaft108
Description108
Disassembly108
Inspection110
Assembly110
[213 Ev] Cylinder Heads112
Description112
Special Tools Required114
[213 NB] Inlet and Exhaust Valve Removal115
[213 EX] Cylinder Head Inspection117
[213 EH] Fire Ring Groove117
[213 EP] Valve Guides120
[213 FB] Inlet and Exhaust Valve Seat Inserts123
[213 MB] Valve Springs128
[213 GB] Injection Nozzle Holder Insert128
[213 FH] Valve Yoke Guide Pins129
[213 FP] Cylinder Head Cup Plugs131
Cylinder Head Pipe Plugs132
[213 Nb] Inlet and Exhaust Valves133
Inspection133
Valve Identification133
Inlet and Exhaust Valve Installation135
[213 Lv] Valve Rocker Arm Shaft137
Inspection137
Rocker Arms137
Valve Rocker Arm Shaft Assembly (Except Jacobs Engine Brake)137
Valve Rocker Arm Shaft Assembly (with Jacobs Engine Brake)139
Dynatard Engine Brake Solenoid141
[266 Kd] Dynatard Engine Brake141
Dynatard Overload Protection (E7 Engines with Dynatard)141
Jacobs&#X80; ENGINE BRAKE143
Engine Brake Switch and Bracket Assembly143
Description143
Adjustment (E7 Mechanically Governed Engine with Engine Brake)143
[215 Dw] Oil Cooler Assembly144
Description144
Disassembly145
Inspection146
Assembly146
[215 Sw] Water Pump147
[219 Mu] Oil Pump147
Disassembly147
Inspection148
Improved "Fast Ratio" Auxiliary Driveshaft151
Assembly152
[221 CD] Econovance152
Econovance Control Valve Assembly152
Econovance Disassembly153
Cleaning and Inspection154
Econovance Assembly154
[221 Ku] Injection Pump Drive Hub154
Description154
Special Tools Required154
Cleaning155
Installation of Drive Hub (Mechanically Governed Engines)155
Installation of Drive Hub (V-MAC Engines)156
[222 Kg] Injector Nozzles157
Nozzle Cleaning157
Engine Assembly159
General160
[211 Db] Cylinder Block160
Special Tools Required160
Cleaning and Inspection160
Cup Plug Replacement161
Pipe Plug Replacement162
[213 CC] Camshaft Bushings163
[212 CB] Auxiliary Driveshaft Bushing Replacement167
[212 Nc] Cylinder Sleeve169
Description169
Special Tools Required169
Installation169
[219 Rv] Piston Cooling Spray Nozzle172
Description172
Special Tools Required172
Installation172
Piston Cooling Nozzle Spray Positioning173
[211 Ha] Cylinder Block Dowel Pins175
Description175
Special Tools Required175
Removal175
Installation175
[212 Hp] Crankshaft177
Installation177
[212 Hh] Main Bearing Cap178
Special Tool Required178
Installation178
[212 Np & 212 Lp] Pistons and Connecting Rods181
Description181
Special Tools Required181
Installation182
[211 Hd] Flywheel Housing184
Description184
Inspection184
Dowel Pins184
Capscrews (Flywheel Housing)185
Installation187
Runout188
[212 Jh] Crankshaft Wear Ring189
Special Tools Required189
Removal189
Installation189
Wear Ring with Double-Lip Teflon Seal (Automatic Transmission)190
[212 Jh] Crankshaft Rear Oil Seal191
Installation191
Description193
Installation194
[213 Ch] Camshaft195
Description195
Special Tools Required195
Inspection195
Installation (Engine in Stand)196
Installation (Engine in Chassis)197
[212 CV] Auxiliary Driveshaft199
Inspection199
Installation199
[219 Mu] Oil Pump200
Description200
Installation201
[211 Rp] Timing Gear Cover202
[211 Sb] Timing Gear Cover Seal203
Special Tool Required203
Installation203
[221 Gp] Fuel Injection Pump Installation203
[212 Rh] Crankshaft Hub203
Inspection203
[212 Rb] Vibration Damper204
Description204
Inspection204
Installation204
[211 Nb] Oil Pan204
Description (Isolating Oil Pan Gasket on E7 Engines)204
Oil Pan Installation208
[213 Ev] Cylinder Heads209
Description209
Installation210
[222 Kg] Nozzle Holder Assembly213
Description213
Special Tool Required213
Installation213
[213 Lh] Valve Lifter Push Rods215
Inspection215
Identification215
Installation216
[213 Nv] Valve Yokes216
Description216
[213 Lp] Rocker Arms217
Description217
Installation (Non-Brake and Dynatard Equipped Engines)217
Installation (Jake Brake-Equipped Engines)217
Brake Housing Installation218
[213 Jb] Valve Cover219
Description219
Installation219
[214 Eg] Exhaust Manifold220
Description220
Installation220
[215 Nk] Coolant Manifold222
Inspection222
Installation222
[261 Ck] Air Compressor223
Installation223
[221 CD] Econovance224
Installation224
[221 Gp] Fuel Injection Pump224
[222 Kd] Fuel Nozzle Inlet Tube Assembly228
Installation228
[214 Sc] Turbocharger230
Installation (Includes Pre-Lubing Procedures)230
[215 Nu, Ng & Ld] Thermostat, Thermostat Housing, Thermostat Seal and Coolant Conditioner231
[214 Hd] Air Inlet Manifold233
[231 Pb] Fuel Filter Adapter Assembly233
Installation233
[215 Sw] Water Pump234
Installation234
[215 Dw & 219 Ep] Oil Cooler and Oil Filter Head235
Assembling a New Oil Filter Adapter235
Installation236
[271 Cb] Alternator238
Installation238
Fan Belt(S)238
Setup and Adjustments241
[213 Nb] Valve Yoke and Valve Lash Adjustments (Non-Jake Brake Engine and Dynatard Equipped)242
Description242
Special Tool Required242
Locating and Marking Flywheel Valve Adjustment Markings242
Valve Yoke Adjustment243
Inlet Valve Adjustment245
Exhaust Valve Adjustment245
Continuation of Adjustments246
[213 Nb] Valve Yoke, Valve Lash and Slave Piston Adjustments (Jacobs Brake Engine)246
Description246
Housing Identification247
Special Tools Required248
Valve Yoke248
Slave Piston, Inlet Valve and Exhaust Valve Lash Adjustments249
Inlet Valve Adjustment249
Exhaust Valve Adjustment249
Slave Piston Adjustment250
Continuation of Adjustments251
[221 Gp] Injection Pump Fixed-Timing Procedures251
Description251
Special Tools Required253
Setting Static Fuel Injection Pump Timing253
Fuel Injection Pump Driven Gear Installation255
Checking Pump-To-Engine Timing258
Fuel Injection Pump Access Cover Installation258
Fuel Injection Pump Pre-Lubrication259
Timing Event Marker (TEM) Installation260
[212 Np] Locating Piston Top Dead Center (Tdc)261
E7 Series Engines with Front Timing Indicators261
Special Tool Required261
Locating Piston TDC261
200 Engine Installation & Testing263
Installation264
Description264
Removing Engine from Engine Stand264
Engine Installation into Vehicle264
Filter Element Installation265
Final Preparation266
Lubrication266
Engine Operational Check267
Rebuilt Engine Run-In Procedures267
Description267
Run-In Check267
[233 Fa] Chassis-Mounted Charge Air Cooling268
Description268
Special Tool Required268
CMCAC Troubleshooting268
CMCAC Pressure Test269
Restriction Pressure Test270
Core Repair271
CMCAC Preventive Maintenance271
Troubleshooting273
Camshaft Timing Check282
Camshaft Lobe Lift Check282
Proper Fire Ring/Cylinder Sleeve-Top Combinations283
General Information283
Engines Built Prior to 1993283
Engines Built from June 1993 to Present (3L Serial Number and Later)284
Cylinder Head and Cylinder Block Leak Test Procedure285
200 Appendix293
E7 Engine Serial Numbers, Jacobs Brake Application294
E7 Lubrication System295
E7 Cooling System296
Index297

Mack E7 - 200 BENCH PROCEDURES

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