Professional Documents
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MACK MP8
DIESEL ENGINE
$ERUIIt frliltltllt
!,(EUR0 3 EMISSI0NS REGULATI0NS)
MACK@ MP8 DIESEL ENGINE
SERVTCE MANUAL (EURO 3
EMTSSTONS REGULAT¡ONS)
ól;;;*;r-.. .. .. .......
lnspéclion
Focker Arm Shatt A*ehbly . . . . 1,15
CAMSHAFI BENCH PBOCEDURES
TABLE OF CONTENTS
EXHA!Sf PFESSUBE GOVERNOR, OVEBHAUL
Disá*émbly .. .
Assombly .. ... .... .... ..... 150
COOIING SYSTEM CO¡'PONENTS BENCH PROCEDIIFES 152
Oil Cooler ñecondilionlng 152
ENGINE FEASSEMBLY ,.. 153
spectatToots .. ... .... 153
Geneallnslruclions.... 154
cr¿nkshan lnbtrllalion
Main Bea ng cap hstallalon .159
Pdon át Corneclrg Fod Assenb y lnralar o. . .. .161
O,lPuúp ¡nd B ocl $ rener Plale lnralanon
OlPuúpPpesandSrar.erlrsialalion . .. .165
F onrtrq ne suppofl l¡slallaro .166
LÉnkshafl Froñl cde.a¡d seal lnslallaxon .165
I nngcea Pl¿le lnslallarlon
Cylité¡He¿d lnsl¿l dlion .169
Cdmsh¿n lnslaldlion
InngCFd l€n lrsÉllaron .173
Unh ln;€nor lnsra l¿rion
Valve Yoke (Bndse) hstalLalion
Bockér a¡m shaft ánd Eñgi.e BÉié lnstállá1ion. -.
Flwhgél Housino lnslállalion . . .142
c¡anksh¿ft Rear seal lnslallalio _144
Flwheel and Pilot Bearinq lnslallalion . . . . . . . . .135
oilPán lnslallalion ...... .. .. .137
oil Filler Pip6 md Dipslick Pip¿ lnsiallárion .......
Power Tak8'Of lnsla lalion . . . . . . . . . . 139
Timing G€arcovér lnslaLhnon........
coolant Pump lnslslblion . . . . . . . . . . . 192
193
coolaff Pipe lnsral¡aron 193
Otl Cool6r and Cooling Ducl Cover lnstallation _ .,._. .
Oil Fillér Housing lnsrallalion ,.
.,.,............... -... -.
tx¡ausl Manfold rnslallalloñ
Turbtrh¿rqér'n,lelláro. .198
ErhdJsl PrFs,Jré Góvernor (EPO) l-slal'¿trol ....... ... .199
Sr¿rrér lnrGl aiion
An CompFsor lnstallaho. ,201
-dndén oJrp (rue ¡.d Power Sr"e ,ns) lr\ralrarion ,202
lnlér Manfotd tretattattoh .203
Tngir Eehea€rsp¿Fr lnsr¿Ia.on...
EECU and Cool€r ,rr¿llalion
FuelLnes ard TillérPousi! lnsalal'on ... ... ... .205
Cr¿nlcdse Venlil¿ on Sepd6lo
Cr¿nkshaf Vb?ronOamper ¿nd.ánPul€ylnq¿ll¿don .
alemalor and Feilqe'anr Corpressor lnslall¿dor
Wting Hame$ lnsrafálioñ . . . . . . . . . .
Cfinder Head (Varv€) cov€r lmral]á on .210
Fa. Hub a¡d Dnv6 aéft lnsiallalion .... .211
TABLE OF CONTENTS
Fenoving Engine fom Engin6 Stand . . . . . . . . . . .212
Filte6 and Mis@llaneoos compo¡ents lñslá talion .213
ENGINE INSTALLATION
SpaialTools.......
GeneE¡ l¡slrucüo¡s . .
lnstallalion .. .... .
To 5c@mñodate thé low cab lomard design, lhe On some engi¡es, ih¿ EPG éxhausl brake is
inlel ma¡itold is oo¡ligured dife€nl¡y lor the used in @mbination wnh üe PN€rLéGhfr
convénliona¡ véBUs th¿ lM cab loNád chassis. énqine b6ke. Wilh lhis conigu6llon,lhe eñqhe
The ai¡ lnlél ibm ihe charge air c@ler is at the cañ háve thre6 or four €ms Jbf ea6h cylinder
font ol lhe inlet ñan¡lold on the @n@ntional dependlng on the P@erleashrM ant €
ch6sis, bú near the rear of the manifo d on lhé
Engine Components
rwp;
F¡quEs_cal¡nd8lalo<*an¡lsüfl€mlPlds
| 3 cyfidef Brod
AcaurtoN
fhe head ¡s al¡gred wílh lhe tiñ¡ng gaar plale by
súaws passed lhough the naunl¡ng plale ¡ñlo
lhe húd and t¡qhlúe¿ swely. I is ertrcnely
¡npanañl lo rcñúe lhe* súews befoÉ
aÍúpüng b tma|e lhe cyl¡ndet head hon lhe
blóck. Fá¡lué fo h@d th¡s Édian nay rcsu¡t k
swrc danage lo ¡he tiñing geat pkte and orhét
DESCBIPTION AND OPEFATION
CYIINDERIINEBS OILPAN
The ctinder block lses repla@able wel cyl¡nder The oil pán is pláslic or s1e€l wilh a lhrca¿ed pluq
d€€@, The lower end ot e&h de* is sealed lor dEinino. fhe plaslic pán has á grco@ i¡ lhe
againsl rh6 block wilh lh€é élaslomár dngs. Thé mounnng ilange which accepts a molded
úpper end ls sealed wllh a rlng ol EPDM olastomér g6ker for a 6eal, The sleel pan is
elasromer siruared di€.ily under rhe slede eded wlh a gaskel on lh€ oil p llange.
collai This desiqn cools lhe upper seclion oa lhe Trenty-lwo spnng-loaded *rews clámp lh6 pan
sle@ beter be@u6e lhe arca of @olanl
F¡gol.14_cFnish:rt¡9al¡43'f
NOTE
Whenever the krer main bea ng caps aé
inslalled in lhe enqlne block,6nsu@lhe owe¡
nain bea nq cap is installed iñ lh€ samé l@alion
ól lhe 6nqiné bl@k as remored, Ats, ensure lhai
the arrani¡q hafk (boss) on lhe b€ring Ép
aliqns wilh lhe ñark (bos) on rhé engine block.
DESCRIPTION AND OPEBATION
PÉ.TONS AI{D COÑÑECÍING FODS
| 6 cü dne RodBo\:
| 7. conEüis Rod&ariñs cap
¡'droBcf chs RodB€'rc'
I a LrPPe
I ,Oe co1€.ú0 Fod
i WÉ.P¡1
6Po€fstsúc]FuelPlmDGéf
e. P.*efráéofr Ga (opriondJ
fhe pwer sieerhg/luél pump gáar, rhe air fhe camshaft oear faslens lo lhe hub oñ thé énd
mmpe$orqeerandlhe PTo oearafe no iminq ol lhe shaf- A vlbdtion damper also athches ió
¡€Is. The pump¿ndcompressorqeaÉlaslen tó thá hub oulboad ol lhe 96ár Téeth on the
$en @specliE @mponéñts. rhé pump qed is dañp6r acluale lhe Émshafr positión sensór
d wn by lh€ áuxiliaryidlergear The mmpressor The geaf ¡s drivén via rhé adjustable idter
qear is driven by lhe double idler geai
There are lhree lih€G, oné by-pa$ and tvo The Educing vdw maintalns @nstanl sysl€m o I
lu l-llow, atached lo a hous¡ng mounted al lh¿ pressu¡e. Thé sisly mlvá p@venls excessi@
lo@rrightsid¿ ollhéengine. Oilllowlhóughthe p€ssu G d uring pef¡ods ol h io h viscosiry. The oil
lillers ánd lhé lubri€lion syslem is @nlro led by cooler lh6rmoriái v¿lve prMntsof Írom €nrennq
the @oeru¡rrL rMms rothe setpont.The
overllow valw all@s o'l to by-pss the flter il it
becomés clogqed. T¡e openins valve prsenls oil
ton mwing lo lhe piston @ot¡nq oultels unli the
. OilCool€r fhemostal Valve syslem eaches the sl prssue The conlol
valve @qulales Ihé oil llow lo lh€ pisron cooling
. Owrl N Valre. Full-Flów Fillé¡
. OpeninS Valve, PislonCoor¡ng
. conlrolva@, Piston coolins
DESCRIPTION AND OPERATION
Crankcase Vent¡lation opén spaces are ducred iho;h á pipé üal
opens to thá almosphere ¡ear thé bottom ol the
l-ubri@nl becomes a ñisl in many arcs ol the
e¡giné as rhe @su I ol lhe motlon of the parts
(e.s., bcker ams, pisrons, c¡ankshatt, €mshaft ThB c€nkc4é renlilaiio. (ccv) slslém
and rocker shalt). Ihé misi ridés the dctts ot alr sepafát* lhe oily m sl t@n lhe gases by
and olher g4es lhal circútate in thé open spaces cefnrifugal lorce. Thé oil €lurns to the oil pan.
in lhe engine. To praent pressure buildup, th€ Thé rémainder e$apes lo the álmosphárá.
A iurbine ih the CCV separaior, drive¡ by a smat Thé opéñ port conrecls to a lube leadinq lo lhe
sl@am ot oll slr kino its lins, spins ár high speed. bottom ot the onqine where bad d6lt draws lhé
The mixturé óf g4es ard o¡ y mlst lbpped in thé qases inlo lhe alñosp he fé.
€lve evef andihetming gear.ovef dElns onlo
lhé lop ót lhe center ol lhe lurbine and ru¡s down
onlo sd6Éldis rolaling w¡lh1he tuóine.
Separal¡on occú6 as lhe nixlure, tlu¡g outward
bylhé luóine, slikes lhe wa ls ol lhe ccv The
drop ¿ls ol mist c@les@ nlo a liquid ánd d@in
back inlo lhe oil pan along wilh lhe o¡¡ lhai dnv€s
lhe luróine. Thé q6€s aré lree lo leaE via a.
DESCRIPTION AND OPERATION
Fuel System
FislE22_Fú.lsyd.ñDl.qÉn
t,3.FadP,npHdrdF
'5 wbré oir es cord i*ú \ (rnrd- ér, %eD
7 Ai BÉdv¿tls(!ro*skháfré.HMo,
's ^j@rn
seD(. Pod (P *uc cdussr
¿ s@ndaryüain) Fiher je supprPresu€s€ner
20 rp
Pad6, (oprioÉ)
e. un rni.dor 2r. shüon valv€ (dos úM
sdi@ rl€f Gnr@d)
22. On*w4 vár@ (Hand Prminq)
r r. Pmp sábry vd€ {P@uÉ R@utab)
R@
F¡ll phasé (A): Ouringrhel¡r¡nq phasé,lhe pump Sp¡ll phase (B): The spill phase beqins when the
piunqer is on ils way up, lhe @mshan bbe is camshall obe ior@s ihe rocker árm lo pu€ h the
pa$inq its hiohesl poinl md rhe @cke¡arm is on pump plungardown, The tuel€. n@ llow
its My loward lhe €dshaft báso circl€. fhe luel thouOh thé luel E vá, lhmugh lhe holes h lhe
El€ is open, allowi¡g luello llow lnto the unii unil injeclo¡ and out ihóúqh lhe luel gallery. fhe
iñjdlor Jrom lhé lówer luel gallery Fuel ft@s ¡nto spill p hass conlinues as long ás the tuelúh€ is
ihe cylinderhead and lhe unil inieclor pump
6flinder Filliñg conti¡ues until lh€ pump plunge¡
reach4 irs upper posrrlon.
DESCRIPTION AND OPERATION
horGml svdsm
The qhausl pE$ue @gulalor (EPG) is placed To meel ihe uryhg corfól áir n¿6d3 of the
h dlrect @nnecton with the tuóiho housi¡g of áxhausl brake, lhe engine electronic conlol unil
lhe tuóocharqer, and has lwo tasks: sénds a Puh6 widlh Modurated (PwM) signalo
. when idlinS, lhe engi¡e ls kept warm by the AVU valve, wheré lhe siqnál pulsá w dth (s a
p€rcénlage) deremines Ihe oulpú ai prosufo lo
créannq a báck péssu.6 in thé qhausl
. when lhe a@e eElor pedal ls eleased, lt Figuc 27 shM lhe silualion du ng normál
ácts ás an dhausl bBke. d vi¡g. Wh€nñe AVU vdre is ¡ot receMnQ
elecric curenl, ihe shdl6r (2) is complete y open
The qiausl pre$u€ regulalor conslsis ol a and lhe qhausl is f@ to pass.
shuiérhoúsing (1). a shdrér (2) and ap¡eunallc
cylinder (3) as sh@n in Fisuro27. Compre$ed
an is bken lom lhe veh¡cte aar system and
@nroned by án air valvé unit lAvU), which is
ávaiable in lrc ÉÍants lorlurbocha.qeFwith
or wilhout wasle gares {acruaroF) respecrtuéry.
The avu válvé consisls básically ot a solenoid
Elve, an air €lÉ dd a p¡inl€d {i@uil boad. h
@gulales lhe pessure sleplessly wlhin lh6 0.5 ro
7.5 bar Éñgé. Th€ EN€ has a bulll-ln reducing
€tue, which rol€s¿s ditfeern pB$ures ior the
respeclive anoúnts ol bdking.
DESCBIPTION AND OPERATION
Powef Leashrr Eng¡ne Brake
POWEFIEASH {3-FOCKER)
Witi lhe s-rccker P@é €6hüd6¡gñ,the
dhausl rokér ams @nla¡n a power pi6lon and
non reiufn Elve lo acluale rhá dháusl €l@s iof
e¡gine braking. Th€ lh@ rocker a¡ms ae
posíionéd on the shalr (fbnt ro ba6k) in the odér
ol ¡nlel, injeclor and exhausl. Bolh lhé in el añd
éxhaust rcck€r srms éach dri@ the vdre paks
Fiqu6 23
-P 6l€a3h'¡ Í3.F.cbr) comDonsr3
via a pinless yoke (bridse).
L Adiudñañr shin
lil 6é ahácr va c
. T€nsm¡sslon ln 9€r
r oilrempeÉtuÉ ábo@ 60'c (1,ro'F)
. chafse aúpfessúe berow50 kPa (7.25 psD
3 Déómpresrdlóbá I L Serinq
I ii E,h¿!dLobe
FicuE3l_c'¡inddH¿ado[Pf8J6^6$Pod
DESCRIPTION AND OPERATION
Turbocharger A housins conta¡niño animpelür, shadseats.
bsa ng ánd pulley anaches lo lhé móuntinq
The lurbocharQe¡ ls ol Map Widlh Enhancement
plale. Thé bean nq is a pe rmanently lub ¡icaled
d¿sign, which ñeanslhatthe alr iñ1ak6 is dividád combinallon óll€rand ba lbearing. Betwe¡ lhe
inlo trvo áBas (an inne¡ and an ouler afeaJ shafr sels and lhe bearino, lhe€ is a ventiláted
connecied by a ring-shaped gap. Thls spacewhich le¿ds ¡lo a ducil behind rhépulev
lurtocharqer d4ion eñsur€s eficiéncv al bolh fhis állówq inr.'n'l lé'k< r. hé dprédéd
ow and hioh rolallon speeds.
e,
t-i.t-.t
NOTE
For rh€ 6nvénlion.! ch*sis, lhé áir inlol is ar rhé
loht ol the i¡let manifold which Is lhe
con,iguElion shown ¡n F gure 33. For lhe low cab
loBard (LCF) chssis, lh6 ai¡ inl6l s local¿d néar
TBOUBLESHOOTING
ENGINE SYMPTOM DIAGNOSIS Beforé Troúb¡éshool¡ng Beglns
WrhapJddlJspedrudure
Special Tools
PG*uEc oe¿dHG6s(a4rd'l
@@ s@
@a
TROUBLESHOOTING
Camshaft Sensor Depth, Check Trql_'lén lhe thumb $rew to ¡scur6 the
innerpart ollhe gauqe.
The siqnalfoñ üle cámshaft sene¡ musl Caelu¡ly Gm@ the galge lrom rh6
dceed 0.5 rcll in ofder to slart lhé éñgin6. ll the canshall señsor bor¿ and obsefve lhe
slgñal is l@, chéck üe deplh sefling ol lh€ localion ot sieps belwéeñ lh€ innér and
sensof lofowina lhis p¡ocedu€, outer pódions ol rhe gauge (Fisurs 40):
1 . Réñóvé thé plug fom lhe lltryheél housins . Bolh steps be ow lhe surfacé ot
ánd instal th6 approp ale tlywheel tur¡¡ng ihe gaug6 = no shins Equired.
lool, 39S6356 (MP7) ó¡ 43400014 {¡lPg and
. Oné slsp below lhs sulace ot the
gauge = o.e sh¡m fequ¡red.
2. Check lor proper camshán position sénsor
. Bolh geps ab@ lhe sulae ol
d€ance using lhe $reor deplh gauge,
48400031- lo dálamine if shims áre ths qauq€ = lso shims @quircd.
fequÚed ior sensor depf..
@
@
@
3- hst6ll th6 emshatl posilion sen$r with thá
a. Rótáté thé €ñginé until a looth ol lhé appfopriate shim(s) and ns ojing, seure
Émshait ioohed whéel is aligned wilh lh€ sénsorwith a boll and plug ln lhá
NOTE
ll lhé camshál is oné roólh oul ól limé, rhá diál
ihdicator eadinq wll beapprdimably0.T62 ñm
{0.030 ¡¡ch) oul ol speclicalion and should
qpe¡ ene a Jáull code lor üe camshall sensoi
6 lnsl¿llrhecylinderhead(v¿lve)cóEr
THOUBLESHOOTING
4- Check the oil nozlé in lhe CCV base lo¡ d¡rl
and any a@uñuláed oily d6posils. clean
lhe nózle as required. ll unáble to cléañ lhe
nozl6 suficiénllyj repla@ lhe complete
CCv *paÉlór assombly.
Ac^urtoN
usé úté
úilh lhe fúel paseg¿s lo tuké M
that tu diñ qte6
the f@l 6ramels. Dht ún
@u@ the unl ¡nj@¡ots to be damged.
NOTE
A dop in pressure and ihe appearance or alr
bubblés indicalés a Leak(s) in rhe ñolanl, luel ot
oil passaq€s. Thá surce ol lhe leak(s) musl be
tound and lhe cyl¡nder head éoaired o¡ rcplecéd
TROUBLESHOOTING
CYLINDER LINEñ
1. Check lhe cy inder liner lo¡ cácks, páying
special ánenlion lo lhe liner tlange. The
siandard dy6 pérelEnl or Maqnallu¡d
melhod en bé used tot ch€cking.
2. Meásúre th6 cylinder linér wea. wilh a
cylinder bore qauqe. Th€ origi.al bore size
ot lhe cyli¡der liner€n be used as a
Eferene meásurémé¡l
.-815."
&
,4,
4. ll wear is gealer thañ 0.05, o.1 0 mm
(0.002-0.004 in.h), use a coñplete ri¡e¡kll
(cylinder liner, pislo¡, piston rings, piston pin
and cylindei l¡ner seals). Also considé.
énqine oil corsumDtion 10 deterhihe wh€n
to rep aca lhé cylinder liner
NOfE
Pislons and cyliñdér lin€B áe ava lable fom
slock only as malched pans and should noi be
PlSTOl,l
F¡qq€47_Mgsuinqcvl¡nderLlnelws¡
lnspect the pislon ring qrcoves, lands, skirt and
3. Measu¡e the cyJind6r lin$ al Top Dead comblslio¡ bowl lor w6ar, sufi ma*s, deep
Cenler (TDC), at Borom Dead céñér scralch6s. c.acks and blow-by. P slons are NOT
(BDc)and ala colple ol pos¡tio.s in repai€ble. Discard wórn ordamaoéd p¡slons.
belween. al each poinr, méásue in lwo
dtections engine crosswise and Bngine AcaurtoN
Do not stanp ot ügÉve an the fOP of the
pislan, Failue la h@d rhb caut¡on ñay esul k
| 7. eees333
NOIE
A slream ol bubbles seen cominqf@m aound
the pluos in e ther ot lhe coolant ports lnd¡cales
lhal lhe Oiinqs may be damaqed. flhis islhe
casé, GmoB lh€ pluqs, inspecl tho Ojings and
. using a lolque wfeneh, fqtfeñ the Remove lhe J 473&3 adapteÉ lfom all ol lh€
atláching scrss accotding lo
lnstálrlhé unil inje.lo6 using nd O rlngs
ánd new séáling washéB.
9?
*Fto
Connecl the wiÍng hámésslólhe unil
.f-
I ii" It ls very
assñbv m¡¡otñtv
Í@ker am shaft
AcaurroN
inpodanl to t¡ghlen lhe rccket atñ
¿crass the @nD¡ete shat
T¡ghtú¡nq Mevent ñn @use danage to the
assúw
úaft
!9--5'
Frsues Túd¡ns Frywh4r (üPa shom, ryprc.D
TBOUBLESHOOTING
5. To chéck bd¡ál ruñour, pcilion lhe lip oi
the dial gauqe againsl ths inner llange ol lha
ilywheel housinq. Rotále the fyrvheel añd
nole lhe indi€led ru¡oul, again al a
minimum ot lour lmarions aróurd lhe inner
llanoe ol th€ hous¡na. Comparé lhé nol€d
fuñoú wlh the sp¿cifed adial rúnout
| 2. Máon¿r c Sráñd,
7. Bemo@ the ilylheel turninq lool a¡d 5. lnc€as¿ lhé pEsure to 250 kPa 135 psi)
@inslall rhe pllg in theiywheerhousinq. usinq ihe reduclion valve knob and check lbr
airbubbles emerqrnslmmlheoilcoolei The
iósl peiod should lar lor al leasl oná
O¡l Cooler, Pressurc Test
L Cleanlhecoolanlsideoilheoil.oolerwitha
NOTE
watéFsoruble de greasing llu id. F lush lhe oll
side of the oo ¿r with degrcasing solvenl.
Air bubblés emelging l¡om lhe oil cooler andicate
2. lnsiall rhe c amp lools, 9996a45, making a leak. The oi coolgrshould bé replaced,
sure thev aré pmperlv sealed,
TROUBLESHOOTING
Rocker Arm, Check 3. Push down on lhé rdkér ;rm so $at any o¡t
iilm is iorced olt of thé upp€r side ot the
NOTE
Sél thé dial indl@1or to éo.
Make slre lhere is clea€nce béh!één lhé rdké. Posllion a pry bar di@lt u.d€r lhé rmker
áñ tolléE and l¡e camshan whe. peformins afm inüe sháll a@a. Pry lhe fockéf áfñ úp
th6 follMlng r@ker am bshing and rol er and nole the readiño on lhé dial indiGtor
Thé naximum clea€nce állów€d b6¡r¿én
lh€ rockér arm a¡d shafl is 0.1 mm
(0.0039 ¡nch).lflhe cloa.ancB is a€alér,
ROCKEF AFM BUSHINGS réplacé lhe @ker arm and check thé shalt
1. lñslalllhe approplale llywhée¡ tuñlng tool,
9S96956 (MP7) or 88300014 (MPB and
MP10), and lurn lhe enoine unlillhe
camshan b h a postlion whére lhe óckér
am tol er being 6h4ked is on the b4e
circlé of lh€ camshaÍ lobe. Make sure lhat
there ls cleÉnce ben eeñ thó roll6r ánd
NOfE
lh€ rockér árm @l er musl
ol lhe emshaf lobe and
6crew backed of (p¡eload
Ac^urroN
l,se @e whén prykg or prñ¡ng on lhé allér ¡o
aw¡d danage lo the suna@ ol the roler
Spiclal Tool
Ac^urroN
Failurc to M¡t a su4¡ciút añomt al t¡re (2 hoüs
¡f éngire oít tenpéntuE js betow 80r [175'F])
ot 15 ñkulés I o¡l ranpantu6 is above gA'C
[175"FI w¡n t$un k añ k&tuhte d]pslJck
NOTE
Usé of ánylhing other than genu¡ne MACK titl€6
ñáy €us6 damage and vo d rhe engine Mranly-
Change liliers amording lo lhe rccomñended
MAINTENANCE
FUEL FILTER REPLACEMENT FUEL FILTER REPLACEñIENT
FuelF¡lter Change
NOfE
Becaus€ of ie buildup or tuel Mxing shich €n
[231 BA] cloO luelfilt€6, il may bé necessary during
4iremely @ld wealher to rcduce thé limé or
FILTER DESCBIPTION mileage inleNal belween luelflter chañaos.
Be carelul lo pre@nl lore¡gn matter ol any kind
Two lilleB ensurelhal cean, waleness tuel
ircm énlá nq lh€ lillác du rg5eruice,
rcaches lhe €lecl@nic unil inioclors. Oná is a
lu |-llow fitér, thé olhér is a wáler sepahtlno lnsralLn tu€llillers dry
pfe-ilter with á ttuspafent cúp lo collecl and
dEi¡ lhe walei A walerin-luel sene¡ inrorms lhe
d wr of dcéssi€ áccumulalion iñ ihe cúp. The w'térSépár.i¡ng PéF¡herReplaceme.l
war€r s6pará11ñg preiiltef is in the'sucllon side'
ol the luel circuil, ll is a spln-on lype wllh one end To replace the waler separa¡ing pre-lilter:
ol ils @sing lhréáded lo !éceiB lhé cup. 1. Disconnecl the eleci¡¡€l €ble.
Thetullll@ main tiller is on lhe hEssure side" 2. Make sure lhe lllter casing is thoroughly
ot lhé circuil. ll is álso an éasily r6pláced spiñ-o¡ 6leaned. ll nor a¡@ady done, wash rhe afea
Iilter fhe €sing complelely enclGeslhe lller abund thófit6rñóunting adaplé! wilh a
elémenl. This li rer is Bred ár 3-s micons. su¡lable elÉ¡n and blów dry with
NOTE
Alt€r lill€r inslallalion, operate the háñd p¡iñ6r to
1¡ll lhe tuel tllteG b6loré anámpli¡g to starl the
4 Dr.in Assmbt
MAINTENANCE
Fu¡l-Fl@ Ma¡n Filler Báphc;eñ¡ :
NOTE
To épla€ th6 tull-llow main li¡ter:
fhere is a new styte prej¡ner with a
repped4@n diamerer ar rhe botom lirte.
of rhe L Maks su@ lhe liller esing ¡s thoóughty
The ¿adi¿FsMe lille¡ has st€ight sides with a cleaned. ll nol ak6ády done, wash lhe a€a
la€er bottoñ diám6t6r which rcqun6s an adaple¡ arcundlhe liller ñounting adaplér wlh a
to atiach lhé luelÁ@tér sspaÉtor b@l lo lhé suilable elrenl a¡d bld dry wlth
li[er W¡en reptac¡nq ihe pB¡ous stÉ]ghtstded
tiller with lhe cwe¡t slepped-down @rsion, the 2. Put a suilable conlainer in p áce to coltect
adapler is nol usd. Hower, do nol discad lhe
adáptér ás it €n b6 u*d sho¡ld iMntory ol tho
€arlle Éstb n ler slill be ava¡lable. Using a lille¡ wrench, remde lh€ ñltsr
cdinq rom lhe mounlinq brackel and
It nse$ary replaco ¡he lul -flow main lihe¿
See lh€ follNing instruclions. Apply a ihin lilm ol cl€an 6nQin€ o¡l lo lhé
sealing qasker ol the new lirrer
Connécr lhs €l€ct cál cáb 6.
5. Scrw lhe n4 dry llller ln place añd tighlen
11, Slal lh€ €naine and run al idls lor fiw an addilional 14 lo 1 lum by hand aner $e
m¡nutes to fll lhe l¡llef wi¡h tuel. gasket @ntads lhé b¿ss.
ll necésary bp ms lhé wal€r 6epaBlinq
pE-nlei see rhe preced¡nq instfucrions.
Siarlhe engine and run át ldle lorfw
mintfes lo lill t¡e liller wilh tuel.
^caurroN
sewe enghé .kñage nay be caused by
atenpl¡.@ lo piñe ¡he tuel sysm using an
auxitiary pmp ü by app¡y¡ng at vessurc h the
f@l knk. Ihese téchnk@s nay .le6tfoy @a¡s
¡hat pt*n¡ l@¡ hóñ leák¡N kto ¡|E úank@se,
MAINT.ENANCE
COOLING SYSTEM MAINTENANCE
Special Tool
Coolant Filter
REMOVEAND REPIACE
The 6ólaft lilter áttachés to lhé back of rhá 1, c¡ose the shut-oll Etve on the cootant puñp
c@lanr pump housiñg. lr fesembles a spin-on oir
lill€r The lill¿r elenenland c6inq a@ rcpla@d
NOIE
positon.lhe pin on lhe shul-olf
MAINTENANCE
Thé 6ndilion of lne bell and iensioner should be
checked ahen Pelo¡ñing ptMrfi v¿
mainlenance inspeclions. Belt lenslon ldels
nééd not bé chécked as long 6 lhe lensioner ls
h qood 6nd¡tioh añd theb is no did6ncé ol a
sÉdd Tools
REPAIR INSTRUCTIONS, PART 1
14. Fem@ lhe radiator ánd charq€ án mobt 16, It equipped, rem@ ihé éxháu$ bÉdiet
f.om lhe fwh@l housiro.
NOTE NOTE
The fan assembt ls h4W áñd dificull ro handl¿. P@vide a conlainer to collecl powér stéé ¡g
obtai. ssistance to support ¡t salely dúdnq
l)
tkih"
W q. Hydaulic hoss or lubing
a Ac^u¡toN
: Cow the @|ve ñé.Í¡aniú and gear ta¡n w¡¡h a
.-__-_J_
l \_!\\_J _]_
(' su¡table .lolh ot
and debis f@n
stnlat @wríng
qlehg
ta
the enake.
p@ent .litt
BqJ673_vl'cou.F¡nonrcft3¿mblysbhge NOIE
ProvidÓ a tansmissjon ja6k lo supporl trté
lEnsmiss¡on when disonnécted lom the englñ6.
REPAIB.INSTRUCTIONS, PABT 1
22. wilh lEnsmisslon jad< ¡¡ place, r6mwé lhé Femo@ i¡s scrM that s;cuie lrie rear
srews afla.hing ihe lEnsmission to the engire support bdcké1s ló rhe fame
a. ll a manual lEmmis6ion. make @rtaiñ 25. Remove lhe bolts thal $cu€ t¡é lont
the clutch linkaq€ and bBckets have enqine support lo lhe fame cGsm€mbér
ENGINE DISASSEMBLY
MACK MP8 Euro 3 Engine
[200 EAI
Spec¡al Tools
0 )
FoddshaftAssmblvLihingT@l
camcapuamoElTool'8.{!h3|d6
nr
@1
ú ii'
H€lr.Dúry uni hiádof Pur ar
tlprár
REPAIR INSTRUCTIONS, PART 1
lñ ordár to atlach lh6 mounlinq plale, J 48662, lo Locen lhe luél liné banjo liíings. Femore
the ¡ell s¡de ol lhe engine, thé iollowiñg the banjo tlnlngs, clamps ánd the ro¡l@ ng
componenrs musr de be femoved il presenr. tue line fom lhe side ol the eñginé.
l. Femde lhe dipsuck a¡d o¡llll plp€. . FuelElurnline EEcucoolins
plár€loji ler valve hous¡ng
2. Feñde thé cankcásé wnlilalion (CCV)
sepafalor and tub¡ng. . FuélErurn line
-cylinder
heád (ar
3. Tag thé el€c1ri€l cón¡scroE on lhe lsft sidé
ló )-lojill¿r valv€ housirg
ol lhe enq¡¡e lo lac¡lllale fecoóneci¡on upon . Fuélsupplyliné
- lifter Blve
housl¡g-lo-cylinderh€ad (ál r¿ar)
4- Unlock and femore lhe hafness end . Fuelsupplyand relurn lin6 fúel
@nne.lo6 arlached lo lhe EEcu. FemoE pumpro-Íiher Elve housing
the scr€ws fom the harn€ss €láin€r
9, Femrye lhe iiler housing a$embly,
clamps. The¡, push lhe conneclor locks
i¡ward and olale oulward lo diwnnel 10. F€mde the @oling plate and the EECU
bolh wnino ham@s€s fDm lh€ EECU.
11. anách lhá 6nginé mounr ng pláre, J 48662,
ioihe lelt side oi the engin6.
llsing a su¡lable hoist and the ápp¡opiátd
liting dsice, aliach lhe englne lo lhe épak
^c^uÍtoN
use @e to a|oid dañaging lhe letñkal pks.
NOTE
¡ags ánd conlainére lor collecling
ddináqo al €ach ol th6 fol¡owinq
BEPAIR INSTRUCTIONS, PART 1
2. R€mm and sl aside lhé sp ng-loaded 5, A1 lhe top ol thé cylinde. head, disnnet
scr4s atiachhq the cyllnder hoád (@lvél úe wning hames at €mh unir.injector
c@r lo lhe cylinder head.
Flqorc77_cyn¡ddH¿ad6v¿r
3. Femow lhe der lom lhe cylinde¡ h@d.
lhecamshatlpcilionsensrlbmtheliminq
NOfE
on e¡qines withoulrhé engine b€ke, an oilflow
adapler s used in place of lhe oil ó¡trol varre. n
is mounled ln lhe sane loeiion on lha cylindér
head and provid6s oi 10 the focker shaft.
REPAIR INSTBUCTIONS, PART 1
^caurtoN
The laslereB tusI be loo@red eveñly, ln stages
and in @qu,@ to ptevat búd¡.g ü danagiñg
(1Fe0 (4tuD
3. It equipped wilh an engine bEke. ecu6 lhe
pislons in tho dhausl mk6r arms using
fubbef b€nds (or r¡e srhps) ro p@enr
*qen¿e
5. Alrach the lifting too , a5109250, ro fie
6. Wilh lhé áid of an a$ista¡l, caélully
Ém@ lh€ shafi a$embly using the t¡li¡nq
1@1, Place ihe shaft assombly in a s€ure
REPAIR INSTRUCTIONS, PART 1
Camshatt Removal
[213 CH]
Nj
S*
M
-*fur--
S+
tr€E9EFae6FE
h¿ r;- eó
| 2 Fodc' a'n shar'
S¿ tv ! |
3. Usélh6 cam ca! cmMl lool, 85109980. in 6. Remove the bearinq ins¿ns {shérls) túi üe
comb¡nallon wÍh slldé hanñ6r¡ 9990013, lo camshafi lorer bearinq suppórG {saddles)
femove lhe upper beanng caps. fhé uppér andlhe upperbea ng eps. hspet ihé
bearing caps and l@er suppo¡ls (saddres) bea ng i¡séns¡ béa ng supporls and 6aps
m6t bé k€pr in séls and i.lheir respaí@ lor wear or danagé. R6plaÉ ú16 parrs ir
localions at reas6mbLy. excssive wear or damaqe exlsls.
4. Al€ch lhé riiling bar, S5109034, ro rhe
€mshalt bá¡réén lhé lobés and €¡étully
Éno€ lhé Énshalt fbm lhe cylinder head.
NOTE
This prccedure preslnes thát lh€ camsháf lower
5. Ca€lully lift lho c¿mshaft and €€l il aside in bearing suppo s (saddle) aE in pla@ on the
a secue local¡on bl laler inspe{flon. crlinder head, h6ld ¡n posilton by guide sleeves. li
removed, lhe supporls ñust b6 mafk€d añd
LcaurtoN @luned lo lheironginal local¡o¡s alonq wlh lhé
6spectiw béa ñg .aps. ll ¡eqlired, fem@ thó
ll the @ñshah ¡s hol belnq reda@d, stand the beariñg súppons usins a pry bai Rem@ the
mshaft on and and stute ¡l ia pla@ t t No 7 reamosl support usino a sólt-fac€d mallel
sL.Ege. Use carc to aeoid .latugé Lt tE guida
REPAIR INSTBUCTIONS, PART 1
1221 GP1
/AcaurtoN ^caurtoN
Use hand toals to túove the klectatt Do NoT
Do NOT us a sleel tuapér or a sreel w¡té btush use ait trds d
the ¡rja.tot pu et shak. uskg an
lo clean ¡nje.:lot l¡ps. u@ deaning kiI J 42aa5. laols nay rcsúl ¡n damoe to canpmnE.
F¿ilúa to hée¿ thk @u¡ion nay Bult in evéE 4. P ace a pry baf, lool 999a511 of equiúleñ1,
iñ posilion underlh€ hold-down yoke or
lnieclor l¡p and prv up lo reñ@ the iniector
Fisurc s4
- Benovins h¡dof y[h Pry er
'
NOfE
Use care when rem ovin o lhá u¡ il ir ieclor
bé@use lhe ¡njeclor hold down is ¡or seuréd
and mu d láll óf il not held i¡ p ace.
1. hjedo' Hord Dokñ Yob | 2 unl ñJeróf
5. lfthé inFcror cannol be remded us¡no ihe
pry bar, ¡nsialllh€ heavy.duly u¡it injecto¡
I fho¡oughly cean aroundihe unir ini€clors pullér, J 43922, oñlo á unl ini€clol Posilion
and chéck lo ensufe thal lhe engine ls lhe pulJet lolks i. the grc@s on the únn
coñPletelY dráined ol lué|. inteclor Secu16ltu pullé.by slidinq the lock
Tag lhe injectoG wilh lh6 cllinder number
collar down over the lorks holding lhe unil
belb¡e lheir removd lrom the cy inder h6ad. injeclor Rémove lhe inlector lrom th6
ll new injecrorc are nor belng insralled, ir is eyllnde¡ head bore usifg hand t@ts. The
esseñtial lhal rh6 onginal injecloB be iniectors musl be lifted our w¡th thet
€inslalled ir ihe cy lnde6 lDm which lhév
REPAIR INSTRUCTIONS, PART 1
NOTE
Í rhe nozle qasker (tlar washer) ¡s atrached ió
lhó iñiector, looson t wilh génrle pMng tfom a
lhin llal gaskel s¡apper blad€. ll lh6 gsk¿r is in
$e bonom ol lhe injecro¡ sreeve, ¡¡¡trarry allémpl
lo rámd¿ it wilh a nagnéi. ll lhis i5 unsu@eslul,
use á slandá¡d nd blád€ scr€wdriwr ülh a ong
ihin shanka¡d narow wldth blade to l@senihe
ga6kel. Lo€1e thé blade in lhe @cess be¡@en
th€ oulsid6 ol lh€ gask€t ánd lh6 inj€clo¡ d6M.
use the blade lo apply 1orce on lhe ouls¡de ol the
gaskel al ditte¡enl locálions abund lhé qaskái.
Coffinua lhis unlilth€ g6kel sepaales lDm lho
FieuEe5-unn hj..¡or Pun.4J 13s2
NOTE
lf án inj¿ctornozlé gskér oal washe4 had been
used lor lhe seal joinl betw6en th€ inj€clof mppér
slese and rhe injector, discafd rhe used gasket
iññediátely after lha inj4lor s rém@d A used
gaskel must noi be reused. when lh6 ini€clor is
@novedi lhis qaskel may @me oul altached lo
the injector or il may Gmain in lhe bofion ot lhe
l2 a''.hiñq Nub
3. Loosen thé clámp and r€mm lh6 dhá@l 5, Separate lhe EPG hoúsins rron thé eihausr
pipe iom lhe EPG hoúsinq pipé and ubochaEer; lifi a¡d remólr th€
EPG unil from lhé engine,
1214 SCI
/AcaurroN
fhotough cleañl¡ness ¡s rcgu¡rc.¡ snall patliclés
@n @ue severe b¡ü damge and @ñpúút
damge ¡l ¡nduc¡ad dunng hbh-speed opeat¡M,
B-p sute ¡a ptug lhe ¡nlet and tullel pot¡s úhile
handlkg ¡he t¿ó@haryef, A¡@, ap the o¡l lke
aqeninss to prcvent @ntankation.
FsuE ro5 Túrbo oir supet lins
1. FemoÉ lhe clamp t¡om lhe EPG -
the lurbocharq6r, f nol p@viouslv 3. Femovelheo rerurnlne(l@et.
*:.--=
REPAIR INSTHUCTIONS, PART 1
4. Bemow lhe lorer oharge an pipe lom lhe Exhausl Mañifold Removál
turbocharg€r and midpipé suppon hslener
5. RémoB lhe luóocharqer llange moun¡nq
l t + t t !
Oil Filler Valve Housing Removal Coolant and Pump lnÉt Houi¡ngs
t2f I EPI
[215 SW]
NOTE
Póvid6 suiláb e €$ and coniaiñers lor collect¡ng NOIE
o¡l dÉhaqe al éách stéD.
Pbv¡de s¡itáb é cóntái¡á6 to @llecl coolant thal
mY es€Pe dulng removál pm€du@s.
1 . Rémo@ lhé scrss and €mow lhé oil lube
lrom lhe fonl ol lhé oil iillor housing and rh€ 1. B€nNé thé la6tene6 and €m@ lhe
c@llno ducl covei oisÉrd the oaskets. coolánt pips (byp6s) hoGing rrom lhe
.ylinder head, D¡scafd the fanqe seál dno.
ñsuE11o orfrb¿(arHochsFfo )
2. Rsmov€ lh€ scr€re and emore lhe o¡l lube
FIsof.11 2-upFc@r¿ Prp€(Bypá33)H.chq
belween lhe valve hoúsinq át lhé Bár and
lh6 ducl cder Dis€rd the gaskéls.
2. Remove lhe kf6ws and emove the puñp
i¡larhousing at the reár ot lhs @otañl pump,
Diserd the llanqe seaL inq.
FisuE 1r 1
- of ftb (ar Houane ñaD
3. Fem@ lhe last6n€6 and .emore the oil
t ller valve housino lrom the cylind€r block.
REPAIR INSTRUCTIONS; PART 1
Cooling Duct Cover and Oil Cooler 2. Cárérully emow rhe edlom me pérr'ma*
qó@ i¡ thé.ov¿i D¡ead the seal h
Removal
[215 DW 2r9 EP]
To remde lhe oll c@let lhe c@ling ducl ¡:Mr
must be @m@d ñ6t, The oit c@ter ts aiached
lo lhe inside of lhe @oling ducl @@r
NOTE
Nólé lhé loÉtióñ óf all fásteñeb for @ssemblyj
diftéreñl lenglhs are used.
3, Femo@ and dis€rd lhe c@rlo pump
REPAIR INSTRUCTIONS, PART 1
F'uE121_[&río|dl¡ldAd'Pbl
2. Femow lh€ spácér block fon ihe lnlel air
manilold. o( il $
equ¡pped, €m@ ail
pMf and gound €bl€s lfom th6 ¡nlétá¡r
p.eheabr and r6m@e the p€healer trcm
NOTE
Bé sue lo capture the banjo séalinq washeb ánd
hollow s€ws while rcmoving lh6m.
L:-
3. Femove lhe luól I n€s lmm lhe cooling plate lnlel Manlfold Removal
1. FémoE rhe two rop inraká ma;ifotd
mounring f¿srenefs and lnslall rwo ál gnme¡t
pins lo suppor rhe manilold dunno rcmd?1.
2. FemoÉ the €maining i¡let manitotd
mounling lasteñors. Using a plaric mallet,
ca€tully iap lhe manitold loos6 and r6mwe
itifom lh¿ cylinde¡ head,
,\
& jl l
3, lóstall1rc l\¡10 x 100 screws in holes 1, ll equipped wilh lhe oplional PTO 6sembly,
opFosité éach oihér al thé outé¡ périmél€r of loosn and Gmdé lhé lasle¡eE se.u ng
.thé llywh€61- Thsss sc¡6m will b€ usd ás thá dsembly to lhe llywhe€lhousing.
handles to a¡d €mMl ol lhe fy{heel.
Rénów thé PTO ass€ñbly lom thé
Ilvwh eel ho usi¡ s and ser eide.
3. Bemove and d¡sÉfd the PTo houslno seal.
N
Frs!re 136 usdhsFV-h4l
Flywheel Housing Removal
Reñore lhe llywheel mounling fasléné¡6.
whlle suppo.ling the llywheel, ca@lully lap
1 . Feñove lhe tDvheel hous nq rasieneF
(iiem 2 i¡ FiquÉ 139) locared ar the lrcnl or
lhe illvheé|, all¿maling from side to side, lo lhe tinina qeáf plaie.
work it oí thé aligning dowel pin and €mo@
it lom lhe cBnkshaÍ llange.
I }F}!hs N sins
REPAIR INSTRUCTIONS, PABT 1
2. Supporl lhé i yvrheel housing ánd rémm Timing Gear Tra¡n Removal '
lhe lasleneÉ al lhe @. ol lhe ly{heel
housiñg sdunnq lhé housing to thecylinde¡
FrqrE 1r0
- Fhvh¿¿r Houinq F*mrc Íshom w¡h NOTE
TOqU¿ *qU¿E)
fo s¡mplit lhe re6smbly prcc6ss, awid roraling
3. Remóve lhe fwhed housi¡g. l! may be
lhe engine orliñi¡g ge6 whlle perfohiñg
ne@*ary to táp l¡ohlly on lh€ housing wilh ilñino oear 6ñ@ añd rcin6lallalion.
a solt mallel lo spa€le the housing ibm
lh€ liminq aáar plalé.
CFANKSHAFT GE:AF AND IDLEF GFARSET
Crankshaft Rear Seal Removal
I2't2 JHI 1. Réñow lh¿ ¡ro Allen-head scÉws thál
scur6 th€ aear toüe cÉnkshatl llanqe.
With lhe llywheel housing r6mmd, use a d¡¡fl 2_ Uslng a suitablé puller, ¡em@ lhe
and hammef lo femde lhe old seal ffom thé
cánkshafl bóré in thá housing,
3. Remove and $t ásidé lhe lower (auxil¡áry)
idl$ geai Bemo@ ft6 soal rins lrom lhe
| 5. FsrnF6d comp'sr
NOTE | 6. Frenr Ens¡re supFn
I Mou inq BEcker
when thé riming gear plare is beinq Éñded, il
músl be dawn slraishr oul to arcid m@inq or
damaqinq the at¡qnment dowets. NOfE
For lhis p@cedue, lhe eng¡¡e ls o1ll-ól'chssis,
4. Fémove lhe plate foñ |ne enqhe. the lan d wandame*oryd vebetsáré
fémoved, Ihe altefnalor ha.né6s wúing ls
disconn@red, and rhe ¡LlC compGsot
felf¡Qeánt lin6 áré €m@d
1, Whi e súpporing úlá ahe¡nator, rem@6 th€
tusléneB and €ú@ lhs allenalor iEm the
o
o
Flqul€117_cylhdslH€de.rinh
3, Fem@ lhe lour upper $r4s in lhe BEIMOVING THE CYLINDEF HEA;
ádjustáblé idlér géar hub.
Wñh rh6 tming qear mount ng plate to cit¡¡dér
¡ead *ras émowd (a, B and c in Figufe 147),
p@ceed 6 bll@s lo émds fto cyrinder head,
9996966
| 3 c6d3h'n fD
^cÁurroN
When hand¡¡ng a úbh¿on dañper. be @ratul nat
.knage ¡he h@siag. Oqts k the odet
to
housing ñav t
detthadañper¡neÍlec @,
auskg an hnbala@ ahd v¡btat¡m ¡n the eng¡ne.
The vjbhlbn danpq amo¡ be rcpahe.¡
+N>9,
Oil Fill P¡pe and Dipsrick Rerainer
d{5:
ÑOTE
P@vide suilable Eqs and coniaine6 ior @llecl¡ng
oildEináo€ al 6ách slep.
Fem@ lhe relainer sd* noñ lhé dipslick 1. lr fE whicle is equippéd iith an óflionál
pipe flange and Em@ lhe pipe lrcm thé lransmission oil c@ler and nol anéady don€,
reno@ ths lansmisoion @o¡ef line b€d<et
nuts and sepaÉte thó bmckáls fem the oil
3. R€mow rhe hsreneF fom lhe oiltillplpe
moúnti¡g llañgé áñd r€ñov€ thé olllill pipe.
Remove l¡e $rews a¡d sp¡l¡gs scuÍng
thé óil Pán lo lhe c6nkase.
NOfE
Thé oil lel ssns¡ néed nol b6 rcm@ed unl6ss
NOTE
li the eng¡ne is in lhe vehlcle, pdide a lilllng
device lo Gsume lhe weighl ot lhe oil pan du͡g
REPAIB INSTRUCTIONS, PART 1
C) 1\(]
6AC) O
rl
U
o
2 PlnpoursrPÉ
FquEre or Puñp ( cb||.d on No.7 seaine ca!) 3. Femove the lour boLls and rcnove the
3. Ca@lully remove ihé oil pump lrom lhe 4. D scadlhelowerbearino inse (shell)i¡the
NOTE
The connecli¡g rcd and bearinq €p á¡é a
mátchéd sét U6é care lo enslre lhal the
respeclive bé¿ring caps and mds a€ kepl
REPAIB INSTRUCTIONS, PABT 1
AcaurtoN
Ererci& extene cae when tiltkg atu novkg
lhe dantsháñ lo awjd str¡kkg ólher abj*ls. Nó
n¡cks, ffitch6, butÉ ot othet s¡gns ol d¡stess
@ ¡he burnb ot l¡ e¡s ate @ep¡able
NOTE
ln addition to ihe main beaÍnq inserts, lhe No. 4
crankshatl journal inclldes lour lhrusl washer
inserls, an upp$ and lMér al éach sid6 ol lhé
2.
ffi
F¡énóveanddisÉ¡d theuppermain béa ng
insens fron thá cylindef bl@k.
| 2. N0 4 eh Edrio cae
lhú
^caurroN
fo añ¡d dúág¡ng lhé suay nozlét reño@
beloe tñoving the l¡reb.
SERVICE HINT
l2 mm, 6-poinl sockel on a
a ¡s besl 10 use a
300 mm (12 inch) €ir€ñsion to remow lhe nozzle
FiEuE171_ca¡indÍliñ.iF.ú@l
Ae ^caurroN
te f,\e @gs oh ¡he pullét Leos dó nol
bét@d ¡he outs¡de d¡añetet ol the tker Fa¡|ue
qtend
to héad thís aúti@ nay resull ¡n @vere
NOTE
Cleaning the cyl¡nder b ock is iñporlanl. whilé Check thé crlind$ block lor indi€tions ol
cléáni¡g lhe cyinder blo6k, caretully hspéct lh6 c@cking or coolañt eakas€. ll any damage is
a€as around lhe cup p ugs and lhe @olant ducl suspecledj use a slandard dt€ péñélÉnr lo
cover ll cup pluqs or pips plugs shów 5¡g¡s of delémiñé il cadc exisl A cGcked eylind6r b ock
¡eaking,lhey sho! d be replac€d. musl be fepla.6d ¿nd n@r reused,
Clean¡ngthe cyliñderbock is a good 1imé lo
inspecl ll for ca.ks or olher pcsib e dolocls lhál
may be rc4on lor rejeclion. Fefer lo lhe
TROUBLESHOOTING seclion lor iniormalion o¡
leslino fo¡ l€aks in lhocvllndér head and cvllnder
block. lt damaoé is nól lbuñd urfil alter thó €noin6
isasseñbled,lhe engi¡e musl be drsasseñbled
REPAIR INSTRUCTIONS, PART 1
Counterbore lnspect¡on and 3. Feset th6 tp or rh¿ diar n¡icator ágainst rhé
hiqh poinl on the @nvd sufacé ot the
Clean¡ng cylinderliñer Measureánd record th6h€ight
12111
of lhélin ledqe above lhe cy úderbtoch
NOfE
Th€ prccédur¿ €n be péforméd eilhérin or oul
ot lhe chass¡s. ll pericfmlng lhe pro@due ¡n the
chassis, be sure lo @@r lhe cEnkshaf and any
hol€s in lh€ cylind€r block lo pt@nt
ontam¡nal¡on fon máchhlnq ch¡ps.
l.EPDM(Back) l3.YblPuDré)
t1 cyr¡&¡ LiEr
4 Seou¡e ihe ine¡ in placá using nro Iner
hold-down t@ts, 9996966.
/Ac^urtoN
fhe lneE rusI be ksla éd and secued in piae
w¡thin 20 nkules ahet appllcat¡on ol the séala¡n
REPAIR INSTRUCTIONS, PART 1
FLYWHEEL BENCH
PROCEDURES
AcauÍtoN
Use @¡lian mI to hat the hg geat de6¡@ly
ot danage wll o6ut to the new r¡ng gear
AcaurtoN
Do NOÍ 6e a preunattuj ¡npa.x wench to
t¡ghlen @nrectkg tod frew' ll will danage he
ñat¡ng suná@s. Fajlure Ío heed lh¡s úúl¡ú nay
rcsuft k sMte únpüút daÚage.
DISASSEMBLY
1. Usi¡g á suilablé pislon ring qpander,
rcmde the piston finqs.
2. C ean the plsloh ¡ing grooves, combuslion
bowl area and lhe s¡ap ring Oódés
AcauÍroN
Rmte a anbü. Ca¡ban leli in ¡he qrcoves
Ed@s tkg .leañtue and prcwnts praper
Th¡s n.y
^cau¡toN
Do nol l¡E ot a¡nd.hbñe-otatéd D¡stú mú.
cause ke ch@e b tl¿t¡e ¡ésuhkó in
ho fa¡luÉ. Fa¡lurc ro heéd th¡E ca
¡n @we ehgine ¡lamge.
BING INSIALLAÍION
NOTE
ldenrlñ@lion ma¡k'nqson thé ringsshoutd hce
lhe pislon lop Thé lteysion€ rinq qoes ú lh6 toD
AcaurroN
Ae b lhal the pÉ¡o¡ and rcd asseñbl¡es arc
clar¡y ñatued wfth thet cvlkdét loca¡io¡. nEv
nLet be rétut@d to lhe eñe ctt¡nde¡ fton which
they wee tmovad. Faílue to heed th¡s @ut¡an
ñay rcsú k sqerc enoine damase.
NOTE
Align lhe FRONT mark oñ lhe conhect¡ng rcd wilh
lhe ar@ on lhé p slon. Beler 1o Figure 140.
Fiq0Élaa_BinqG¿DLdlons
REPAIR INSTRUCTIONS, PART 1
Usinga g€néousámounlolclean e¡gineoi a scfs wrh rour punch malks (A) mui b¿
oñ ihe wrisl pih and rod beárlno, préss lhé epla@d wilh a ns sc@.
AcaurtoN
Come.xitg tud @psctws an mly be rc-u#d
foúr t¡nes. Suew f@ds nüsl be pun hed at
each oveñaul to ¡ndiate ¡he nurnbe. ol tins
used, Fa¡tute b heed thís aur¡on nay t6ulf in
ñvére cmporent danaae.
,AcauÍtoN
lf theÉpsctws ate ¡n@teclly as@ñtled ú
t¡ghtúed to an imct toque, lhe a*nb¡y
tusl be d¡$aded. Failuté to haéd th¡s @u¡bn
may etuu in sewe @ñponenl danaqe.
REPAIB INSTRUCTIONS, PABT 1
resphscoñp'Nd (Eseúd)
REPAIB INSTRUCTIONS, PABT 1
lel€s9dnqco@ÉslAd¡ol¿f
il
úñ' r'ldd P6i*úñ she (ked d)
0) ))l ll)
NOfE
Wor¡ Etu€ guides may result in poor
valve lo seal conlacl, válv6 dámage or excessive
NOTE
When recondilloning the cylindér head, it is
reohmoñd€d lhal all vdre quides be réplaced,
¿ Hyd,a! ic F¿m $0e72e I essP63
VALVE GUIDE FEMOVAL
Pessoll the old va ve guides irom lhe lop
SEFVICE HINT orthá rylinder head usinq the press.
Clean lhe exhausr válve guide Cl€an all surfaces thomuqhty.
b6lore emoval, wilh th6 guidé
rctary brúsh lo p@enl sco¡lng
dhausl val@ guide boG.
Assemble ihe hydEul¡c Em, 9409729, press ll spring siEnqrh is norwithin spe.ilicarions, ir
1ool, 99901 76, pum p 99996222, an d lhé
appbpriale €lve guide inslállér (33300062
lor inl€l ánd dhaúst) on lop ol the c.yl¡nder Fo¡ indicalions ol oroovino or rouohness:
FEII]IOVAL PROCEDUBE
1. Removetheirjetorortheplug,9s93251,1o
a@ess the iniecrof s ee@ botron.
2. Fem ove and dis@fd rh e seallng washef in
lh€ bollom ol lhe @pper slewe.
3, lnsall lwo s4linq Ínqs lo prweni dúl fom
enle nqih6lu6l aallervwhén lhé mppér
FigúB1a_copFsledefapp¡nqfool
NOTE
This ensues lhal thenp ol lh6 copper slerye is
lappéd all the way lhrcuoh.
Fqu€ 1e4
- ad¡usri4 copFr sr4€ frrdor Bolr
REPAIR INSTRUCTIONS, PART 1
/AcaurroN
DoNI u* at loo¡s ¡o eñM @Wet sleMg at
dana@ to lhe iniedot bare @n t$ull.
BEPAIR INSTRUCTIONS; PART 1
it!2,-r
fr' \/
16. Usi¡g lhe bru6h. .lean lhe cylinder head F¡qum d - chn¡nq rñlebr np BoE
inieclor boré walls for lh€ copp€r d€M.
NOTE
The injector bore sealino tool ñust be used to
pr4¡t débris lrom enle ñq lhe luel passaqe.
Wh€ñ €placing lhé coppe¡8ledes, il is
iñponañt to ch4k lhal lho dewé boG in lhe
cylinder head ¡s l@ foñ any caóon deposits or
olhár rásiduá (i.e., piéc* oi G¡ing, et6.) beiore
instálling a ne mpp€r dá@. Reclean ¡f
SEFVICE HINT
Do nol ¿tl€mpl lo bl@ away debris usanQ
compressed air Dóing só €n rasull in eye iniufy.
NOfE
Swaging bil @n bé ordé€d s a spáF p.rt if thé
/AcaurtoN
Fa¡ture to l@en the eagkg b¡t cú É ]t iñ the
bi¡ bako twisled ot baken.
NOIE
Remow any oll fom rhe iniecior ho d dowñ bort
holes to arcid hydÉulic loc* lor this step and
when lhe injector is inslall€d.
NOTE
Thá smging lip has lhree secrions ol mcreasi¡g
diamels R€sisrañe increases ás the Morna
lip adÉnces ihrouqh lhá holé. Cóntinue to pull
lhé lip lrtil il ¡s lee ol th€ hol6.
REPAIR INSTRUCTIONS, PART 1
NOTE
Thé p ug shoúld be iGlalled llush to 0.503 mm
(0,020 iñch) bdethe sul¿ce.
REPAIR INSTRUCTIONS, PART 1
ffi
rb d
€o
AcauÍtoN
fhe klel and dhaus¡ valw h&d dianelets are
dtfetút Take ate when inslall¡ng Íhe valves,
lncone¿¡ ¡ns¡a¡la¡¡on nay e
lt in eng¡ne Íailurc
The MPB ocker arm shatl assembly i6 held in 2 Slid6lhá ro.k€r off rh. shelr
"ms
place by lhe same $rss lhal ho d lhé inbootd
ends of lhá .arehált béáring €ps. A spec¡flc
s€qu6n@ lor iqhiénino lhese screws is
desr¡bed ¡n lhe ENGINE TOROUE
SPECIFICAÍ IONS 8éctióñ.
REPAIR INSTRUCTIONS, PART 1
AcaurroN 1. Pov¡de
and g€r
m€ñs ol @nto linq lhe damp€r
when lhe atehinq $r4s a€
Handle lhe @nshal¡ @teluly to awid béndkg ¡¡.
Sl¡ght but hanlul bendsm go mno¡¡ced. 2. R€move lh€ atl¡chinqscws.
Fáilue lo heed ds ñut¡ú coúd t$ull ¡n
üetutúE qsine h¡lúe. S6t ás dé lhé damp$ trd 96ár in a safá
Sp;c¡al Tools
il
REPAIR INSTRUCTIONS, PART 1
REPAIR INSTRUCTIONS, PART 1
Disassembly
1. Rémow the end @Er lrcm abde lhe
NOTE
Do nol pr€ss mo€ lhan néés*ry to remdé the
k€6p6rs- Coñpr€ssing thé spnng lully en
Assembly
1. l¡6rá I rhe plunqer rod into
b€hind so a c6nlér lhe
10
¡¡slalla ¡s seal wlth thé
tacinq in6ide ihe housing.
and a n.w spnnq holder
FiluE2r9Hous¡nqAsmblv
REPAIR INSTHUCTIONS, PABT 1
I 2. sprho
COOLING SYSTEM
COMPONENTS BENCH
PNOCEDUBES
FicuE2_oilcool€rAgblv
t3 Frd PhE
@
ENGINE REASSEMBLY
REPAIR INSTRUCTIONS, PART 1
SERVICE HINT
F@ñ tenpealure vul@nizins (BIV) sgalanl
cures in 20 minules ol exposure lo lhe
ahosphere ll il should cuB béto€ assembly ol
maling componenls, reñó@ il and applv lresh.
| 2. Eeaíns
REPAIR INSTRUCTIONS, PART 1
NOTE
tüake suro lh€ beannq €ps aé @rdlv fined
(se malklnss oñ lh6 €p).
F¡ ] J
down unlil il conlacls Ihe mach¡¡ed
NOTE
Lub caré the b€d¡g tnsert súfaces with ctáan
r No 1M¿inssinscap I , capah¿óms
I c,rws
R6peal lhe abde stéps lo. lhe bea¡ng €p
Nc. 2.3,5,6 and 7. fhs c€nlér bearind
cap, No. 4, is insratted tate[
L Using a torq@ w@nch, tighten lhé bea nq
c.p.cras according lospec¡t¡€ttoñ.
lj"ffir
FiguE¿3_M3¡nBEin!c¡P,ftrudwÁhg
rñ
t2 No,4 Main Béa'iú Cao
(
11. us¡¡g a lorque wfench, tghlen lh6
cápsÉw6 ac@'ding ro speciti@r¡on.
Using a suilable pry bar, move lhe
cÉñkshafl towád thé lórf or Ear ol lhe
NOfE
R¿lár lo allo@ble c@nkshaft end ptay totehñcos
under F¡¡s a¡d ¿iñ¡ts in lh€ sPEclFlcalloNs
NOTE
Lub¡icate lhrusl Mshor seclions wfih engine oil
BEPAIR INSTRUCTIONS, PART 1
14 Usiñq á ñagn€t c bas indicalor lool wilh ils Piston and Connect¡nd Rod¡
lip agáinst a cÉnkshall euñtémeighl,
check cÉnkhatl end play as iollM. Assembly lnstallation
a, ser the dial indi@rof ro @ro. [212 NB 212 LP]
b. us¡ng the pry bar, mow lhe dañkshall
endwise and read lhe indicalor PISTON AND FOD ASSEMBIY
c. f eñd play is out ot specidcai¡on, 1. Rótáté lhé cÉnkshaft so lhat the ¡ournals 10¡
@m@ rhe rhrur washeE and insrall Ihe No. 1 ánd No 6 cylindéB ae al Botlom
w4he6 ot suilable lhickne$ lo meel Dead Ce¡ler (BDC),
AcaurtoN
fhe thi¿kné* oftha rtuus¡ washets k lhe búkg
cap ñúsl nalch the lh¡c*ñ$ al ¡he lhrus¡
MsheE ¡ñ ¡he blark. Be tuE to pul thé btunzé
beanrs óa@ asainst ¡he úankshalt. Falúe to
h@d th¡s aúuú nay resull ¡n @v* cñoúql
11. Whils Gina a hammer handle lo push lhe 13. Ensúr€ thal rhé .orcct €p É litrdd lo lhé
p¡slon lhrouqh the iool, ápply pEs6uré lo lhe @rect coñn€cliry rcd (reter rothe mafks).
¡ng comp@sso¡ l@l lo málrnáiñ conlacl wilh
the cyl nder linei Conli¡ue pushinq th e
plslon ontil thé top r ng hás pasáed into the
r1 /A
AcaurtoN
Do ñot lsee@¡ve fo@ o, lhé pistü. Hiü
rcsista@ ¡ndiates an ¡@tect¡y aüqñed rins.
Benaw tha p¡stm asnw cürcct the
prcélú, añd lhú elreeñ i¡. Máke ture the | 2. Atehiio cs.rews
úmp6sü túl rcñaire in @ntacl v¡lh lhe
cyhhdet sleM until ¡he pbton c¡eaB the toat. 15. Bepeat the above sleps to lnstalt the No 6
Failue lo heed lh¡s eu ón nay bsuft ¡n eree
16. Folate lhe cránkshaft so that the journats tor
lh6 No 2 and No. 5 cyllnders ac ar bonom
12. Lubf¡cale the cáñkshall b€a ngansensañd
dead cént€r and installthe No.2 and No. 5
cEnkshailioumals wilh €nqiné oil. pislons foll@ing lhe abo@ steps.
REPAIR INSTRUCTIONS, PART 1
2\X
o C
NOTE i\3 oI O
Clean lhe oilpump mounl¡nq surla@ ol lhe @ar
nain beáring cap béforo installino the ñéw oil
NOTE
Thé eng¡n€ sr¡íening |rame has sharp édgés
The cEnkshan may need lo be @lated io allow that car c¿us€ ¡njury. To p¡event ¡njury, wÉr
a@6$ lor lhe oil punp la6leñeG. protect¡ve gtoves whén handt¡nq.