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Page 340
SPECIAL T
OOLS & EQUIPMENT
8511137
7
F
eeler Gauge
Set
8511246
0
V
alv
e Stem Seal Ins
tallation T
ool
8511246
1
V
alv
e Stem Heig
ht Measurem
ent Gauge
8880001
1
V
alv
e Stem Seal Protect
ion T
ool
(Essential)
T
ool No.
Description
Image
350
352
Table of Contents
Main Page
Default Chapter
5
Table of Contents
5
Introduction
12
Safety Information
13
Advisory Labels
13
Service Procedures and Tool Usage
14
Explanation of Numerical Code
16
Conversion Chart
17
About the Mack Mp7 Engine
20
Service Precautions Summary
24
Visual Identification
26
Mp7 Engine Model Identification
27
Engine Information Plate
27
Engine Serial Number Identification
28
Description and Operation
30
Mp7 Engine Design Features
31
Engine Variants
31
Engine Components
31
Lubrication System
43
Crankcase Ventilation
45
Fuel System
46
Powerleash™ Engine Brake
51
Exhaust Gas Recirculation System
53
Exhaust Aftertreatment System
55
Variable Geometry Turbocharger
60
Cooling System
61
Engine Management System
62
Glossary of Terms
65
Component Locator
68
Mp7 Engine Component Location Views
69
Troubleshooting
74
Engine Symptom Diagnosis
75
Troubleshooting Technique
75
Noise and Vibration
76
Engine Checks and Tests
77
Special Tools
77
Camshaft Sensor Depth, Check
80
Camshaft Timing, Check
81
Crankcase Ventilation, Check
81
Cylinder Head, Pressure Test
82
Cylinder Liner and Piston Wear, Check
83
EGR Cooler, Pressure Test
85
Engine Compression, Test
86
Flywheel Housing Runout, Check
88
Oil Cooler, Pressure Test
89
Rocker Arm, Check
90
Thermostat, Check
93
Valve Guide Wear, Check
94
Maintenance
96
Lubrication System Maintenance
97
Oil Level Check
97
Special Tool
97
Oil and Filter Change Procedure
98
Crankcase Ventilation System
99
Fuel Filter Replacement
100
Fuel Filter Change
100
Cooling System Maintenance
102
Coolant Drain Outlets
102
Coolant Filter
102
Special Tool
102
Exhaust Aftertreatment System Maintenance
103
Special Tools
103
Diesel Particulate Filter
104
Aftertreatment Fuel Injector (AFI)
109
Drive Belt Replacement and Tensioning
112
General Information
112
Automatically Tensioned System
113
Repair Instructions, Part 1
114
Engine Removal
115
General Instructions
115
Special Tools
115
Removal
116
Engine Disassembly
119
Special Tools
119
General Instructions
122
Mounting the Engine on a Repair Stand
122
Cylinder Head (Valve) Cover Removal
123
Engine Wiring Harness Removal - External
123
Camshaft Gear and Vibration Damper Removal
124
Engine Wiring Harness Removal - Internal
124
Timing Gear Cover Removal
124
Rocker Arm Shaft and Engine Brake Removal
125
Valve Yoke (Bridge) Removal
126
Camshaft Removal
127
Unit Injector Removal
128
Starter Removal
133
EGR Hot Pipe (Cooler Inlet) Removal
134
Turbocharger Removal
134
EGR Valve Removal
135
EGR Cooler Removal
136
Exhaust Manifold Removal
137
Oil Filter Housing Removal
138
Coolant Pipe Removal
139
Cooling Duct Cover and Oil Cooler Removal
140
Fan Drive, Idler and Fan Bracket Removal
142
EGR Crossover (Cooler Outlet) Pipe Removal
143
EGR Mixer Removal
143
EGR Venturi Housing Removal
143
Fuel Lines and Fuel Filter Housing Removal
144
EECU and Cooling Plate Removal
145
Inlet Manifold Removal
146
Tandem Pump (Fuel and Power Steering) Removal
147
Air Compressor Removal
147
Flywheel and Pilot Bearing Removal
148
Power Take-Off (PTO) Assembly Removal
148
Flywheel Housing Removal
149
Crankshaft Rear Seal Removal
150
Timing Gear Train Removal
150
Timing Gear Plate Removal
152
Alternator and Refrigerant Compressor Removal
152
Thermostat and Cover Removal
153
Coolant Pump Removal
153
Cylinder Head Removal
154
Crankshaft Vibration Damper and Fan Pulley Removal
157
Crankshaft Front Cover Removal
157
Crankshaft Front Seal Removal
158
Oil Fill Pipe and Dipstick Retainer Removal
158
Oil Pan Removal
158
Front Engine Support Removal
159
Oil Pump and Valve Housing Removal
159
Block Stiffener Plate Removal
161
Piston and Connecting Rod Assembly Removal
162
Main Bearing Cap Removal
163
Crankshaft Removal
164
Cylinder Block Reconditioning
165
Tools and Equipment
165
Cylinder Liner Removal
166
Piston Cooling Spray Nozzle Removal
166
Cylinder Block Cleaning and Inspection
167
Cylinder Liner Height Measurement
168
Cylinder Liner Installation
169
Flywheel Bench Procedures
170
Flywheel Ring Gear Replacement
170
Connecting Rod and Piston Bench Procedures
171
Connecting Rod - Piston Disassembly
171
Piston Inspection and Cleaning
173
Piston Ring Inspection and Replacement
174
Connecting Rod - Piston Assembly
175
Cylinder Head Overhaul
177
Tools and Equipment
177
Inlet and Exhaust Valve Removal
180
Cylinder Head Cleaning and Inspection
181
Valve Guide Replacement
182
Valve Spring Inspection
183
Injector Sleeve Replacement
184
Expansion Plug Replacement
191
Valve Inspection
192
Valve Installation
192
Rocker Arm Shaft Bench Procedures
194
Description
194
Inspection
195
Rocker Arm Shaft Assembly
195
Rocker Arm Shaft Disassembly
195
Camshaft Bench Procedures
196
Camshaft Inspection
196
Cooling System Components Bench Procedures
197
Special Tool
197
Oil Cooler Reconditioning
198
EGR Cooler Cleaning
199
EGR Cooler Pressure Test
201
Engine Reassembly
203
Special Tools
203
General Instructions
206
Crankshaft Installation
207
Main Bearing Cap Installation
208
Piston and Connecting Rod Assembly Installation
210
Block Stiffener Plate Installation
214
Oil Pump and Valve Housing Installation
215
Front Engine Support Installation
216
Crankshaft Front Cover Installation
217
Crankshaft Front Seal Installation
218
Timing Gear Mounting Plate Installation
219
Cylinder Head Installation
220
Camshaft Installation
223
Unit Injector Installation
225
Valve Yoke (Bridge) Installation
228
Rocker Arm Shaft and Engine Brake Installation
229
Timing Gear Train Installation
232
Flywheel Housing Installation
235
Oil Pan Installation
236
Oil Filler Pipe and Dipstick Pipe Installation
238
Power Take-Off Installation
238
Timing Gear Cover Installation
238
Crankshaft Rear Seal Installation
240
Flywheel and Pilot Bearing Installation
240
EGR Crossover (Cooler Outlet) Pipe Installation
242
Fan Bracket Installation
242
Coolant Pump Installation
243
Oil Cooler and Cooling Duct Cover Installation
244
Thermostat and Cover Installation
244
Coolant Pipe Installation
248
Exhaust Manifold Installation
249
Oil Filter Housing Installation
249
EGR Valve Installation
250
EGR Cooler Inlet Pipe Installation
251
EGR Cooler Installation
251
Turbocharger Installation
252
Starter Installation
253
Air Compressor Installation
254
Tandem Pump (Fuel and Power Steering) Installation
255
Inlet Manifold Installation
256
EECU and Cooler Installation
257
EGR Mixer Installation
257
EGR Venturi Housing Installation
257
Intermediate and Mixer Inlet Piping Installation
257
Fuel Lines and Fuel Filter Housing Installation
259
Crankcase Ventilation Separator
260
Alternator and Refrigerant Compressor Installation
261
Crankshaft Vibration Damper and Fan Pulley Installation
262
Wiring Harness Installation
262
Cylinder Head (Valve) Cover Installation
263
Filters and Miscellaneous Components Installation
264
Removing Engine from Engine Stand
264
Engine Installation
266
General Instructions
266
Installation
266
Special Tools
266
Repair Instructions, Part 2
270
In-Chassis Part/Component Procedures
271
Oil Pump Replacement (in Chassis)
271
Oil Pump Removal
272
Oil Pump Installation
272
Crankcase Ventilation (CCV) Separator Replacement
274
CCV Separator Removal
274
CCV Separator Installation
274
Turbocharger Smart Remote Actuator (Sra) Replacement
274
Preliminary Steps
274
Turbocharger SRA Removal
275
Turbocharger SRA Inspection and Installation
276
Final Assembly
279
Unit Injector Cleaning
279
Preliminary Steps
279
Cleaning and Inspection
280
Final Steps
280
Injector Copper Sleeve Replacement
281
Tools and Equipment
281
Preliminary Steps
283
Copper Sleeve Removal
283
Copper Sleeve Installation
287
Final Steps
290
Valve Stem Height Measurement Procedure
290
Valve Stem Seal Replacement
293
Special Tools
293
Preliminary Steps
294
Seal Removal
294
Seal Installation
294
Final Steps
295
Repair Instructions, Part 3
296
Mp7 Engine Setup and Adjustment
297
Special Tools
297
Valve and Unit Injector Adjustment
298
Checking and Adjusting Timing Gear Backlash
302
Engine Final Preparation and Operational Check
305
Filter Element Installation
305
Engine Lubrication System
306
Fuel System
306
Engine Operational Check
308
Rebuilt Engine Run-In Procedures
308
General
308
Run-In Check
308
Specifications
310
Mp7 Engine Mechanical Specifications
311
Material and Dimensional Data
311
Engine Component Torque Specifications (Standard Fasteners)
316
Engine Component Torque Specifications (Critical Fasteners)
317
Engine Gaskets, Lubricants and Sealants
340
Gasket and Seal Reuse
340
Lubricants and Sealants
341
Special Tools & Equipment
342
Mp7 Engine Service Tools
343
Special Tools for the MP7 Engine
343
Index
358
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