Manual Mack 67515j

@

MACK MP8 DIESEL ENGINE $ERUIIt !,(EUR0 3 EMISSI0NS

frliltltllt

REGULATI0NS)

MACK@ MP8 DIESEL ENGINE SERVTCE MANUAL (EURO 3 EMTSSTONS REGULAT¡ONS)

JULY 2OO9 (REVISED _ SUPERSEDES ISSUE DATEOJANUAFY 2OO9)

@ T4ACK

TBUCKS, INC, 2OO9 ENGINE 5.116

TABLE OF CONTENTS ,,.,

¡NTFODUGTTON .., ,. SAFETY INFOFMATION advlsry Labels Seruice Pbcedúres ánd Tool Usage . EXPLANATION OF NUMERICAL CODE

.1

.2 .3

.

.5

.6 ASOUffHE MACK ['P3 (EUFO3) ENGINE setoice P€aullons summary . . . . . . . . . f1

VISUAL ¡DENTINCANON , , . , , , IüP8 EUBO3 ENGLNE MODEL Engi¡e lnlomalion Plale ,. Engina Sarial N únber ldentillcallon

12

't2 ,12

...... ine Com ponenls .,..,,

.13

DESCRIPÍIOIT AND OPEFATION MACK MPA EURO 3 ENGINE DESIGN En

q

Lubrication Sys1em . . . . . . cÉñkésé vénlilar¡ón

Fue|Syslem ..

.22 ,25 .26

.

... .. .........

.

Exháust P.esure Govemor IEPG) PowerLeashr* E.SlneaEke....

Ailrnake

.31 _32

Sysleñ.............

Tufbochafgef . ... ... .. -. .. .. cool¡nq system Engiñé i¡a.ágémenl sysleñ . . .

.35 .35 .36 .30

.

cofiltPoNENT LOCATOB .. . . MP8 EURO 3 ENGINE COMPONENT LOCATION VIEWS TAOUBLESIIOOTING cNciNE SYMPTOM D|ACNOS|S T'oubreshooli.g Tec ¡flque .. NoÉe and vrbÉfon ENCINE CHECKS Af\D ITSIS Spec¡al

Tools . . .

.

.......

.-. .. .. .. . .. .

Camshalt Sensor Oepth, Check

camshaftrhinq, check

.

.

.. ..

C€nkc¿se Venril¿lion, Ch¿.k CyllnderHeád, PréssurcTesr,.,.... Cyllndér Ljner and Pislon Wear, Check EGR Cooler Prcssu€ Tesl Enginé Comp.éñion, Tes1 . . . . . . . . . . FlywheelHousinq Funoul, Check .... OilCooler, PresuéTesl. .. .. ... -. . Focker arm, check

Th€moslai Chéck..... .... ..,..., Válvé Guidé Wéar. Chéck . . . . ...

.50 ,51

.52 ,57 .58 ,59 .61

TABLE OF CONTENTS MAI¡TENANCE

.63

LUBRICATION SYSf EM MA¡NTENANCE Spécial Tool . . . . . . . . . . . . - . . . - . . . Oil Level Chek . . . . . . . . . - . . . Oil and Fil¡er Cha¡ge Procedure C€nk€e Venlilation Sysl6m FUELFILTER REPLACEMENT Fuál Fille¡ Chanoe .. COOLING SYSTEM MAII\'TENANCE .

.

.65 .65 .66 .66

-.-.

......

.,...

_68

Speia|Too|,,,.,.,,,,,.,,,

.64 .64 .63

coolantD€in outtets.....,.. coolanl Filter . -. ... -.... ... DRIVE BELT FEPLACEII/IENT AND TENSIONING

Ge¡eal lñlomatlon

..... ....

Automalical y Tsnsjonéd Svslem

FEPAIF INSIRUCÍIONS, PAFT

71

1

FEMOVAL..,. ,., SpeclalTools...,.... GeneEllnstruclions...... Bémdd . . . . . . . . . .. . . .

.72 .72 .73 .73

ENGINE

ENGINE OIs,qSSEMSLY Speial Tools . . . . . . . . . . . . . .

/

G€neE nrlruqors Móurlirglhe F!'neona FepanSland ........ Cyhnder Head (Valve) Cover Fen@al . . . . . . . . .

..... ........

TnqineWinnq Harñess qemdd rimi.g Gea. Cover FemoEt Camshatl Gear a¡d Vibralion Damper Remdd FockerArñShafi Femoval ... va ve Yoke (849e) Fenoval Cdrshaf Femova Unil lrieior Fer oval S'anerFemoval rrhaJslP¡6sure Goveñor (EPC) Retrovd Turb@l^a'qe' Fenov¿l

. ...

.

.....

......... -. Tilter Oil Varve HousrnO Beño€t . . . . -rhaJslMa¡lold Bemoval

.

Coolañr

a.d PJrp l.rer Housmgs R¿noval

.00

.al

a2 a3

.83 .s5 .s5 .49 _49

.91

,93

Cool'nq DuclCover ¿nd OilCool€r RéFovár Dnve Be ls F¿n Hub B6mová1 . . .

at

nelA¡'Pehéal6/Sp¿cffFemovál .....

C6nkcae

.96

Ventirát on (cCV)

Sepa6to¡Femovat . Fue Linés ánd Filld valve Housinq Fem@d .. ..

FFCU ánd Cooling Pla,e Femoval...... nlér ¡rán''old Removal Tandem Pump (Fue and Power Sbonnal F¿movál Air Compresor B€moval . . . . . . . . . . . . Flywheeland Pilot B€arinq Removal Pow€r Take-Or (PTO) Assembly Removal . FrwheelHousing Femoval ,.,. ,... .... . Canksháft RearSeal Fémovál

..,...

.94 100 101

102 102 103

TABLE OF CONTENTS ...

Timinq G€arTrain Femoval Timinq Gear Plale Femoval . . . Allenalor and Feinoera.t Coñpressor R¿moval Thémosial añd Cóvér Féñd,l Coolarf Pump Removal . . . . . . .

103 104 105

.

Cyind€rHéad

106

Femoval....,.

C@nkshaft Vibra¡on Damper and Fan Puney Bemovar CEnkshaft Frcnl Cover Femovar . . . . . . . . - . . . . . . . cánkshait Front seal Rémovál ol Fill Pipe ánd Dipslick Réiaiñór R6ñoval . . . . . . . , oil Páñ Rérfóvál Fonl Engine Suppon Bemoval Block Sl¡ffener Plale Femoval OilPump Bemoval , P¡sion and Connecling Fod Assenbly Bemoval . . . . . Ma¡n Bea ng Cap FemMl . . .

C€nkshaft Feñoval CYLINDER BLOCK RECONDITIONING

Toolsand

Equipmenl........

..............

Plslon Cooling SpÉy No2zle Rem@d . . . . . . . . . - . cytinder Liner R€mMt Bl@k Cleanlng añd lrepecuon . Counleóore lnspelion and Creanins -... LiñerHelght M€asur€m€¡l....

.....

-........ -. BENCH PROCEDURES ...,...

.

-...

Cyllnderlinerlnstallalion... FLYWHEEL

Flwhesl Rinq G€ar Replacémenl .. CONNECIINO ROOAND OISTON BENCH PFOCEDURES Coñnedirg Rod - Pis'on Ois¿serbly , . , . . Piston lnspoclion áld Cleañi g Pdon Bng lnsp€clion€nd Beplacemear ,.. ..... Coñnectirg Rod Asembry., ,... .. -Pimn CYLINDEq HEAD OVCFHAUL Tml> ¿nd Equipner l ... lnlerand Ertuusl V¿ ve Bemoval ............

lrspecl'on Valv6Guid€ Feplacemen!.... Cylind€r Head Clean ng and

Valv€Sprino Inspeclion .,.... lnjoclor Sreeve Fep acement . . E-ap¿¡sion Plug Feplacement . Valv€ |nspection. .. .. .. .. .. .

.....

109 110 110 110 111

112 112 113 113 114 115 116 117 117

f1a 119 120 '121 121

122

122 '123

124 125 '127

lsl 132

135

..

Válvé lnstá lár¡6n FOCKER AFI\¡ SHAFI BENCH PFOCEDUFES

ól;;;*;r-.. lnspéclion Focker Arm Shatt A*ehbly . . . . CAMSHAFI BENCH PBOCEDURES

.. ..

....... 1,15

TABLE OF CONTENTS EXHA!Sf PFESSUBE GOVERNOR, OVEBHAUL Disá*émbly .. . Assombly .. ... .... .... ..... COOIING SYSTEM CO¡'PONENTS BENCH PROCEDIIFES Oil Cooler ñecondilionlng ENGINE FEASSEMBLY ,.. spectatToots .. ... ....

Geneallnslruclions....

cr¿nkshan lnbtrllalion Main Bea ng cap hstallalon Pdon Corneclrg Fod Assenb y lnralar O,lPuúp ¡nd B ocl $ rener Plale lnralanon

át

OlPuúpPpesandSrar.erlrsialalion F onrtrq ne suppofl l¡slallaro

.

o.

.

150

152 152 153 153 154

.159 .161

..

..

.165 .166 .165

LÉnkshafl Froñl cde.a¡d seal lnslallaxon I nngcea Pl¿le lnslallarlon

Cylité¡

.169

InngCFd l€n lrsÉllaron

.173

He¿d lnsl¿l dlion Cdmsh¿n lnslaldlion

Unh ln;€nor lnsra l¿rion Valve Yoke (Bndse) hstalLalion Bockér a¡m shaft ánd Eñgi.e BÉié lnstállá1ion. -. Flwhgél Housino lnslállalion . . c¡anksh¿ft Rear seal lnslallalio Flwheel and Pilot Bearinq lnslallalion . . . . . . . .

oilPán lnslallalion ...... .. .. oil Filler Pip6 md Dipslick Pip¿ lnsiallárion Power Tak8'Of lnsla lalion . . . . . . . . . . Timing G€arcovér lnslaLhnon........ coolant Pump lnslslblion . . . . . . . . . . .

.142 _144

.135 .137

.......

139 192 193 193

coolaff Pipe lnsral¡aron Otl Cool6r and Cooling Ducl Cover lnstallation

Oil Fillér Housing lnsrallalion tx¡ausl Manfold rnslallalloñ

,.

_

.,._.

.

.,.,............... -... -. ErhdJsl PrFs,Jré Góvernor (EPO) l-slal'¿trol ....... ...

.198 .199

Sr¿rrér lnrGl aiion An CompFsor lnstallaho.

,201

Turbtrh¿rqér'n,lelláro.

-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 ... ... ...

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 Fa. Hub a¡d Dnv6 aéft lnsiallalion ....

.205

.

.210 .211

TABLE OF CONTENTS Fenoving Engine fom Engin6 Stand . . . . . . . . . . Filte6 and Mis@llaneoos compo¡ents lñslá talion ENGINE INSTALLATION

.212 .213

SpaialTools....... GeneE¡ l¡slrucüo¡s .

lnstallalion ..

....

.

.

REPATR |NSTFUCT|ONS. PAFT

2

,. ,. .. .. .. .. . .. ..

_217

IN.CHASSIS PART/CO¡¡PONENT PBOCEDUBES ,. CA¡¡ISHAFT BEAFING BFACKETS REPLACEMENÍ

.214 .214

_/a

./a Ti.al Steps . . . . . . . . . . OIL THEBMOSTAT AND PFESSUFE SAFETY VALVE REPIACEMENT PÉssure Sdlory V¿lv" Ferov¡ O'l lherrosrarV¿rvé Rep'acemerr . CBANXSHAFT TFONT SIAL FEPLACEVfNT SpeL'dl lool\ ..

....

Se¿lBeno€|. Sedllnsll¿iior CBAI\hSHA- R|AB SFAI Spe( dl lool, ..

BEPLACLVT\T

S"¿lFemov¡|

. .. .. .. c"¿lllslall¡ibn .. .. I ellon@ S"¿l Feñoval ... .. .

NeoP FnP NeoP Fne

lel'or@S.¿rrnsrarr¡lon

.

..

...

.

. ....

.

INJECTOB COPbEB 5I I TVT F¡PLACTMTNT

CopperSleeve

...

,231 .231

.231 _231

.

O'lPurp l.sla4¡ion Tml, "rd FqJFns P€ im arySlep.

.222 .223 .223

.224

...

..

.221 .221

,224 ,226 .226 .224

.

CRANKCASE VENTILATION (CCV) SEPAFAfOR REPLACEMENT CCV Sep¿ErorFerov¿t CCV SFp¿Etor rns¡rt¿ oo1 otLPUMP R¡PLACFME\'(rN CHASSTS)

SpecEl loo s , OilPump Bemoval .

.119 .219 .220

.232 .232

I

RFmov¿l .... ..

Copoer Sreeve tTta t¿rio. . . . . . Tin¿lS eps UNIT INJIC IOR CITAÑ¡INC

....

.

236 ,236

..

Pekm'n¿.vStFps. specl'ol

Cle¿nrno and I'

Fin¿lcl.ps

VI VAIV' VAI

..

.

CTFM HEICFI MIASUFEI,IENI PBOCEDUBL .. STEM SEAL . .. .. ,

R|PIACEIT¡ENI AelrndrySleps ...... Spe('állool\

SedlR.móval . .. . Se¿lllsl¡llaxor Tin¿lS¡eps .. ..

.250 .250 .250 .251

TABLE OF CONTENTS _....... _......

FEPATR |NSTFUCÍ|ONS, PART 3 . . . . MPA EURO 3 ENGINE SETUP AND ADJUSTMENT

Sp€ci¿l l@|s ... .. .. .. .. .. . vatu€ ánd Unil lnielor Adius¡menl . . , , , , , , . , , , . , , , . . , . Chéclinq ano Adiubling TimiT Gear Bdck¿sh . .. .. .. .. .. ENGINE FINAL PREPAFATION ANO OPERATIONALCHECK Fi rer Elemem lnslarlaron . . . . . Eng'ne Lub c¿ron SysFm

TLóochárq ... .. .. .. ..

.253 .251

...,,

.254 . .

...

.256 .262 .265

.26s .265 .266

Cooling Sr€rém

TuélSysém... E.gi¡e Operalioral Clecl FEBUILT ENGINE FUN]\ PBOCFOUFFS OeneÉl Bunrn chek . .

.

.

.

SPECIF¡CATIONS MP8 EURO S ENGINE ¡'ECHANICAL SPECIFICATIONS . . . . . . Maleial a1d Dim¿ñsionaL D¿'¿ Ensin€ComponentTorqueSpocilicatiohs (C¡iücal F6lene6) St¿nd¡rd Bolland \ulToque V¿lues ENGINE GASKETS, LUBRICANTS AND SEALANTS Gasheldnd SeálFedce .. .. .. Lxb canN añd Sesl,nrs

...... ....... .... .......

SPECIAL TOOLS & EOUIPMENT MPA ENGINE SEFVICE TOOLS Speá Tools lo¡ Engine Overhául INDEX

.266 .264 .260 .263

...269 .. .270 .. .276 305

.307 .304

INTRODUCTION ABOUT THE MACK MP8 (EURO 3) ENGINE [200 EA]

Do NOÍ ús sta¡ing flu¡d (ethet) on engitus equ¡ppe.¡ wl¡h an inlét ñúilol.r aí¡ h@W éléñent. An exp¡oslon @uLr oeú. Faílure to ,@.1 lhis d¿nset my ¡eulI ¡r p@nal ¡nlury ú .r@b.

we

opl¡onál lan dn€s ar6 ailabls On/Of and eclonl.ally aclualed. The electrcn¡cally actuatad v sous rán d!ñé is precisely conlrolled by the Engine Electonic c¡nlrcrunil iEEcu).

frc e

Tlhing gears hount on lhé réár of thé M P8 improving lhe ll@ ot coo inq airarcund th€ lfo¡I. Special seruice inslruclions apply lo the €nshaf position sensor Thé nounling plale, ¡dle. and camshaft geá6 are mark€d to lacililal€ propér inslallalion. The ai comp€ssor dd@ qéar moshos wilh lh6 double idler inslead ot lhe aux¡liary idler as oñ lhe M P7 eno n6.

Thé ¡¡AcK MPB (Euo3) is a 13ljlér (800 CID) enginew¡lh eletronlc uñil i.jecto6 and an dhausl préssuré governor(EPG) ior engine b6kino. Thé oplionál Pow6rl6áshrM énginé compession b6ke ls available ln emblnalloñ wlhlhe EPG lor inc€4ád enqine bEking pelormance. The engi.e coñlbfms ro Euro 3 A wide range ol the

of6

cure¡n hnsmission

nqs, includ nq manual, auloñaied manúal and autoñatic, Én bé leamed wilh the MPa. Diaqnoslic héip can be lound inihe Premtúm To obtáin PTI, conlaot yo( local

Teh loor (PTr).

The enq¡ne weighs approximálély 1 145 kg (252a b,) dry (w¡th aú ómpressor. wirhout oil c@lánl srale r, ian, alternalo r ánd clutch). lls design inc udes a óne-piece cyllnde I head, a sinqle @ñead camshañ,1h€é orlour rocker arns pefcyllnde¡, unit injectore añd no push@ds. Monclee[¡ sleel pislons arc ñadé in one piécé.

Anolher feálub of thá MPo is the rear engine power lake oli {REPTo ready) lhal is géar dnwn lhmugh lhelminq gea¡lÉh. An optionalPTO with d ve gear, bea ng and housinq can bé Thé mkér

an

shalt is held in place by €mshaft beá no cápscrss. Thé€ are specialinstruellons lor inslalling the cmshatt beár nq caps and lhe rockér arm €han duinq sruice. A slifener plate lastens tó lhé bonom oi lhe cylind¿r block lo ensue block slrenqlh and rigidity. Th6 éngine can be used wnh axte fomrd or axle back vehiclos by virlue of optional oil pans. The e¡gine lan is ñounl€d high or low dependi¡g on v€hicle @nligu€lloñ.

Thé MPB uses unli njéciorc. rhé unit injector incorpoÉlés lhe pump, vdw and i¡jécloi lls inle mal solonoids pe.mit tast, precise conlotof luel delivery into the cylinder The unii injectors ár€ áncased by r¡e várve mvef and not qposed lo lhe hoal of éxhausl system ñmpon€nls. Fuel pases lhough two liltere, one of which sepaEtes waier iom lhe tuel. High pGssurc luál in the uñit injedofs is créáled via lhe rccker ams with rclle¡ toll@e6 in mnsla dned conracl

INTRODUCTION Beplacing i¡jeoloF Equ¡res a specilic pmédure, €nd iñstállalion @quires that lhe EECIJ b6 proqfaññed lo €6gnizé @da@menl iniecloB. Cleanino ¡niector boés réqúirés a special tool.

2.

lheir fespectire connécling rcds due to the 'l@clu@d ma¡uiacturhg"procáss used. Al$,lh¿ 6d caps can be inslalted onty one My becaus€ of lhé difeE.@ in spac¡ng belween scréw hórér ál éach siri. he

.

DO NOT use lhe liiting eye on ihe ttywhet houshg whén lilting lhá ánqine/lransmission assembly 10 an angle gÉater lhan

TheE ate mu l¡ple des¡qn vafial¡ons ol thé Powe[eash enSi¡e bEke ufl]zing a 3iocker válv¿ lÉin or a 4{dkér valvé Irain. The varialions fequie a d¡tbrent camshan, spedal éxhausl qlve rccker arms and yokes (bridges), an oil conlrolEtu6 and wning harne$. Exhausl valve clearance lor Powe[eash¡H equipped engiñes is

cy indér head instal ation reqlires t@e ng the head onlo lhe gaskel us ng the alignmenl screws and washéB al rhe sides of lhe head and bl@k. The heád musl b€ pulled back ro the mounting plale us¡nq scews ¡nsened lhrouoh ihé plale. Pressed bossés in lhe gasGi keep lhe head from making lull contacl wilh lhe qaskei slflace a¡d Pre@nl dámage lo lhe élasloner s6áLi¡g ri¡gs as lhe head slid€s inlo

Unique colors and lhe appearance ol thé Élvé filléG and ¡oqo labels distinqulsh the MPB ñom olher eñgines inrhe MACK lin¿.

dé(

PMntivé óainbna.cé

is imporranl lo gel lhe mosl fon lhe MACK túPa €ngin6 ¿nd lo ensu@ many yea6 of re iable, 1roubl+lree opeálióñ. Fefer lo the curerf TS494 Mainlénan.e and Llbri@lion manual lor ehedulos and

TheG ar€ reslriclions @ncerning lhe reuse of @ ain hsleners- Retur lo curBnr 6pecilicallo¡s bull6tins and lhe sPEclFlcaTtoNs s€clion ot lhls ñanual ior d€raibd inlormation.

Seruice Precautions Summery Followi¡q isá summarylistolthe DO añd DON'T issues apply¡ng ló MPa 6nqine seryice.

1.

DO NOT machine lhe cylinder head tor 6lean-up s¡nce this will chüge injector deplh, lhereby afecting €missions, lt wil also upser the abir¡ry ro oredry adjusl liming géar backl4h.

sblMs,

hslallthe cEnkshatt ma¡n béarino caps adodiñg lo ma¡ked assembty nuñbel Conneclino rod caps MUSÍ BE haled io

Slándard equipmenlon lhe engine hc¡udeslho exháust préssur€ gowr¡or (EPG) which ulilÉes a shutter in the oxhaust pip¿ aler lhe turbooharger Ior e nq¡ne bEk¡¡q. The EPG canbécombined wilh lhe oplional PowerLéashm ensins comp@ssion b6ke lor addilional G¡st ¡n d¿c¿l¿Elio¡ and bEking.

R¿pai inslruclions n lhis manual d6al wilh Éñoval, indanánon, disa$embly¡ assembly selup and adjuslments ól MPa mmponenls

DO NOT srind lhe injector coppei

Dó NoT use

sla ingnuld(erher)on6nsines at heaier

eqúipped wilh án inréi manilold

T¡É use o¡ sta lng 0ui.1 (et¡Et) on ensires equíp,ed with .n ¡nlet ñanllold ¿it h¿ál.¡

¡s prchibiléd- an *p¡osloi @ut.t tbllúe to t@d lhis dangs may resttt

e¡emút

ofur

ih $vere pe@na¡ lnluty or déáth.

A.

The MPgengi¡e usesá numbérólOfirgs lorseálinq v¿ ous lluidioinls andlubes ltis essenlial lhal o{ings ot the @recl málBrial be used whéñev6rioints a€ d¡sassembléd and reássémbr.d

.*

VISUAL IDENTIFICATION MP8 EURO 3 ENGINE MODEL IDENTIFICATION

.

¡raximumloque

Engine Information Plale The engire inlormarion plare is locared on th6 rop ol lhe 6ylinder head (El@) covei This prate lnclude6 inlormalion con@rning the foll@ing

.

Engine model and emisions

addilion to ihé iniormarion plate, lhere ls another labe ón the cylind€r h 6ad (vahe) @ve Th is add ilio¡a I label lists lhe chass¡s num bér, 6ñgine sé al numbér á¡d Especlire barcodes.

l@l

$n€ moP

Mooa

l¡

I ñ;;6;ñl

vssn, a mm- l

kffioú.

MrD PmER F -dro -

lh ".,^

Pes';;-r -* lb

Mm -q otsPúEM€ú L

rz! ssDu f #m]r €MsrswE, f E

Engine Ser¡al Number ldentificalioñ ln addilion 10 rhe engi.e inlo.mation ptate on lhe cylinder head cover, the enginá is also identilied by lhá énqine se¡ial number laúped inro lhe cyli¡der block. This seralnumber¡s located on lhe block lefr sde at thé lonr jusr bélów rhe lnlet

l

¡ il gl I

r

DESCRIPTION AND OPERATION MACK MP8 EURO 3 ENGINE DESIGN FEATURES [200 EAI

Main réalu€s ol rhe cylinder

.

lnle gEl th

e

had

are:

rmoslat housins

Sepahie chañbérs lor axháust and in¡et at each 'crosslloü d6sign. Th e luel cha¡nel, d lled ircm fonl10 rear, connects with gr@Bs máchinéd a@und each injalor openlng. A plug ál lh€ Éá¡ ot lh€ cy ind6r head seals lhis

cyllnde r make lhis a

CAMSHAFT AND VALVE TRAIN

fháéngin6 has án ovéñéad €mshaft and ockér am shalt in supporl oi lour valves p€r cylind€L fhe camshaft rides on seven journals w¡lh a béanng cap ánd suppoñblock (s.ddle) al each poinl. fh6 b€a¡inq inserls (sh¿llsi, beannocaps and suppo¡l blocks are replaceable.

lllhe ongine

exhausl b6ke thee cams for each cyliñde¡,

is €quipp€d wnh EPG

only, there arc

in.luding inréI, injeclion and qhacl, Each valve bcker ah drives two wlres via a pinles voke 5c@mñodate thé low cab lomard design, lhe inlel ma¡itold is oo¡ligured dife€nl¡y lor the convénliona¡ véBUs th¿ lM cab loNád chassis. The ai¡ lnlél ibm ihe charge air c@ler is at the font ol lhe inlet ñan¡lold on the @n@ntional ch6sis, bú near the rear of the manifo d on lhé To

On some engi¡es, ih¿ EPG éxhausl brake is used in @mbination wnh üe PN€rLéGhfr

énqine b6ke. Wilh lhis conigu6llon,lhe eñqhe cañ háve thre6 or four €ms Jbf ea6h cylinder dependlng on the P@erleashrM ant

€

Engine Components

F¡q!É4_cll¡nd4H..d'ilhv.lÉsandcanshaÍ

r

n

3'

\hi€

\br€ (s' dse) lr.adrusmen'shm | 4 sh m Feb nnq s.re*

DESCBIPTION AND OPERATION Exhausl valw yokes nclude a shim ór adjusrñenr. Fépraceábt€ vdw suidesand se¿ts are made of a lovéd esl kón ¡nd srpél €speclively, A¡li/álvé guides htu ot s@ts. Exhausl valres haw doublá vdre sprhgs.

Rolle6 in Ihe ends oflhe rocker arms enlact lhe c¿m shah The @nl¿cts wirh Lhe yokes h¿v6 ba

rhé Émshaft

s h;uclion-ha¡dened fm,nq m¡rks lor válve and qeclor ¿diuslméni ¿F

Jocaled on lhe llanqé

lotuad oi the No.

1

cáñshafi jóurna . Th€e mafks ae lor adiust¡¡s valve clearancé. They do not appty io cámshafi Cañshaft lhrusl w6heF are tnteqht on thá No 7 joumal bearng. sñoórh @talion ls ensu€d by m6áns ot a vibralloñ dampe¡ oñ ihe camshaf gear Téelh on lhe damper ¡f$eáct wilh the camshall pc¡lioñ sBnsor lo¡ input to th€ EEcu. .r

%M

Yoré (B' dss)

3. Lowsf Beainq

c4

6upood)

DESCRIPTION AND OPERATION Timinq ma¡ks on lhe cúshal p@ide lorBN€ ánd iniécior adlustmént. t¡oMrlóásh iñclúd6s ls owñ eleclron¡c conlrcl Oo@ned by divers c¡oi@ ihouqh a swilch ne4 lhe sleering wheel, This @nlrol mounls on lhe cy indér head be¡r¿én lhe No.3 and No 4 cylind€r rockBr ams Thé o¡í¡q hainess lncludes addll¡onal wlre

rwp; F¡quEs_cal¡nd8lalo<*an¡lsüfl€mlPlds | 2. 3ro.{ srirleE

CYLINDEBBLOCK The cyliñder bloc( is made ol casl lbn. For increased cylinder block rqidúy and noise a¡d vibdtion 6duction, a stéel sttfend plale atlaches The maln and p¡slon lub cal¡nq channels ae drilled longiludinally lhrcugh lhe block These a@ plugg€d ál lh€ lmnr ot lh€ block. Thé main chañnel opens ¡nlo a est ¡n channel lhat supplies oillorhelim¡ng geaB. The pislon eo ing channel is cover€d by lhe liming gea.

Pr#

Main bearing caps are made oi nodular casl úo¡ machined l€elhér wnh üe cylinder block. Car al¡q¡m€nl slols in lh€ block and tabs on lhe caps ensufe pre¡ alagnment at ¡nstallalion. Each cáp is marked wilh its localion beginning wilh No. I at lh€ lront. Cap Nos. 4 ánd 7 a@ unique and arc Th€ block includes cylinder line6 lhal @nlacl lhe coolarf dú4try (wet I né6). Th6 cásring shapé lollo@ lhe co¡lours ol lhe cyliñdeÉ lo inc€as riqidily and redu@ noise,

DESCRIPTION AND OPERATION H@d ro Bloct Arlgnmenl

CYLINDER HEAD GASKEI The cylinder head qasket is nade of on6 Di€ce oi s heel sr€é wirh vu l@ nized elaslomer séáls oh oil a¡d c@lant @ndufs. Thá des gn ót the engine a¡ d head gskel requires a u ñiqu€ pocédu € ror inslállar on ol ihé cylinder head,

fhe scrss a¡d MsheB

át the sid€ guidé rhé head inrosideto-side alig.ment as lt s tatd óh the gásket ánd block. Screws pased lhróuqh the 1lm¡n! gear mounling plale hto thé head pullthé head inlo alignmenl lore and ail. Small, slamped bosses on the g6kel hold lhé h€ad clear ol lhs seals and all@ [ lo glide a.curalely ¡nto position ágainst lhé mounling plale du ng i¡slallalion. Tightenihq lhe head bolis llatlens lhe bosses on lhe qaskel. For lhis reae¡, a nd head Aaskel musl be insralled whénévér thé héad is rémMd.

| 3 cyfidef Brod

Three eews a¡d washeF inslalled at the side (two inlhe bl@k and on6 in the head) allgn lhe head foñ side lo side al asseñbly. Fore and afl, rhé héad is aligned by co¡racl wilh the liming

AcaurtoN fhe head ¡s al¡gred wílh lhe tiñ¡ng gaar plale by súaws ed 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 The ctinder block lses repla@able wel cyl¡nder d€€@, The lower end ot e&h de* is sealed againsl rh6 block wilh lh€é élaslomár dngs. Thé úpper end ls sealed wllh a rlng ol EPDM elasromer siruared di€.ily under rhe slede collai This desiqn cools lhe upper seclion oa lhe sle@ beter be@u6e lhe arca of @olanl

OILPAN The oil pán is pláslic or s1e€l wilh a lhrca¿ed pluq lor dEinino. fhe plaslic pán has á grco@ i¡ lhe mounnng ilange which accepts a molded olastomér g6ker for a 6eal, The sleel pan is eded wlh a gaskel on lh€ oil llange. Trenty-lwo spnng-loaded *rews clámp lh6 pan

p

Thé lo@r seals afe litred ¡n gboves in the cylhder block, The botom seal ¡s ol a diltéEnl maten¡l and ll!órcsenl violél iñ mlorto dislinguish ir lóm lh6 interñed¡ale sels.

W

FrquE

Gh.$

12

-

o¡hder Li¡or.¡d

sat.

| 3. LMers.:rlnq uiiq I übn (PuDla)

The oil pan hcludes an oilleü/t€mpéEture sen6or wnh connecior fhe iillef túbe ánd dipsrick moun¡ng pons a@ also @mponenls ol lhe oil

NOTE Oll pans wilh lh€ sump al the

lont or at the rear a€ available io aeomhodal8 dré foMd or

DESCBIPTION AND OPEBATION The cEnkshan is dbp loroed sleél and inducrion hardénéd. h hG s@n journals wiih repla@ablé beadhgs. Five mFized epl&ement beainq oplions are availáb é to aeommodaré cEnkshaft

F¡gol.14_cFnish:rt¡9al¡43'f

A Tellon@ seal b€arina dirécllv on lhe cBnkshall llanqe is used al the fo¡t ol thé crankshall. Thé flonl soal has an ouler lell ing which seres as a dusi c@[ at the Éár ol rh€ cfankshaf is arclhef seallhal beaF direclly on ihe ñachinád sulfa@ ot the cránkshaí geai Addnionally al the éar, there is a góoÉ in lho r6ar cEnkshail llange lór an Oiing whi.h forms a seal betweoh üe llanqe

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.

The @r maln €p (No. 7) i.cludes an áftachiñq poinl lor lhe lube pump. Thrusl washeB io coñrot ¿ri¿l mmménr srGdd e rhe 6nr€r iournar (cap No.4). The romaninq aps (N6.11,5 ¿nd 6) a€ numbefed io faclilale cofecl a$emb¡y.

DESCRIPTION AND OPEBATION PÉ.TONS AI{D COÑÑECÍING FODS

| | I

6 cü 7.

a

dne

Bo\: &ariñs cap ¡'droBcf chs RodB€'rc'

conEüis LrPPe

Rod Rod

Fod I ,Oe co1€.ú0 WÉ.P¡1

i ConóecÍng rcds a@ lo.qed sleel and a€ uséd in combinalión with on6-pi¿c6 tüóñósiéeiD steél pistóns. fhe beanng caps are attaohed wilh lour M12 capscrss spaced lo prrenl misalignménl. Th6 óds añd €ps are m¿de by á facloé" pr@* ihat requkes a cap be assembled wilh ils orlginal od. N4er anempl lo us€ mlsmaich€d The pislon is fin¿d wilh lhee nnas. ln lhe lop goow ¡s a @ñpressloñ rlng wllh a "keyslone c@ss seclion. ln lhe second grcove,lhe mmprésion ring has a réctangular cro$ secl¡on. ln ihe th¡d grco@ ¡s a sprlng loadéd oil

r P.roic@ io Noz. l3

oog4irqvar6

DESCBIPTION AND OPERATION f@

lor ihe pision

6óliño sysrém is @ntrclled ¡he openlng vd@ suppli6s oii ánd th¿ conlrol Elw balan@s the oil lt@ lo the p¡slon oolinq.hánñéL fhé pislon c@ling nozre is aligned so lhal the óil jst hls lhe und€Gide oi O¡l

by two va¡@s,

IIMINGGEABS The tlmlng géa6 are l@led al lhé r6af ol lh6 engine Backjñs up lh€ gea6 is a plale: a 6 mm (1/4 inch) rhi.k sreer sheer atrach€d ro the The advantages of lhls 6rliqudión ဠno@ prtris€ nmingl f4er @mponenis ánd lM6r

6Po€fstsúc]FuelPlmDGéf e.

fhe pwer sieerhg/luél pump gáar, rhe air mmpe$orqeerandlhe PTo oearafe no iminq

¡€Is.

The pump¿ndcompressorqeaÉlaslen tó

$en @specliE @mponéñts. rhé pump qed is d wn by lh€ áuxiliaryidlergear The mmpressor qear is driven by lhe double idler geai The dóubl6 idler dri@s the adluslabt€ idterand lhe qear us€d lo d ve lhe Dower take o¡1, if so equlpped. Th¡s ¡s parr or i¡á 'REPTo-Feadl féalu€. A PTO un¡t with drlvs g6ar is subslituled lor a cowr on lhe llwheel hous¡óq.

P.*efráéofr Ga

fhe camshaft

(opriondJ

oear faslens lo lhe hub oñ thé énd ol lhe shaf- A vlbdtion damper also athches ió thá hub oulboad ol lhe 96ár Téeth on the dañp6r acluale lhe Émshafr positión sensór The geaf ¡s drivén via rhé adjustable idter

DESCRIPTION AND OPERATION DANE BELTS Thls enqihe cañ be cohiigured to accomhodale eilhd the @nve¡lional cha$is or lhe low cab loead (LCF) desiqn, Dependinq on lheEhicle, the hn locarion may be high or low on ihé rán

Iwo poly V bells drive the fonl engioe accessores. The ourer, primary belr (10 or l2 Íbs) dives lhe coolanl pump and lan hub rom a pulley on lhé c€nkshali llange nested in the vibElion damper The inner, se@ndary bell (six riL\s), driveñ by the cEnkshatl vibralión damp6r, d¡@s the alternalor ánd r€irio6ant coñpréssr

Each beft us€s an aulomalic lénsioner rn lie hlgh position, v¡41 in Figure 13, ther6 aré ¡ro idler pulleys in the primaia loop: o¡e behreen the coolanl pump pulley and lhe tension idlerilhe olher bétween the cankshaft pul ey and thé fa¡

vis 2 in Figure 18,Ihé ¡dler bénreen the d¿ñpef a¡d lan pulléys ts omiltéd. ln lhe low posiUon,

Lubrication System A g€aFtypé pump at the rear of the enq¡ne, dr¡ren by the c6nkshaft g@r, draws lub¡icanr fom lhe oilDan a¡d suppliBs lhá s!61ém. Oil fows lfom thé ouñp thóuoh lhe dislr bdion houshg to the lilrefs, ro a gallery ar rhe fighr side otlhe enqineseryinq the cBnkshaft jounals.lo a galléry at th6 léft sid6 serying pislon lubriÉtion and eol¡nq, lothecyl¡ndef head and fockershall du6l (Elre @ker and camshatl) and back lo lhé oilpan. Thé syst6m incLud6s crankssé

TM

JulLnow fftéB and a by-pá$ lillér máinlá¡n cléáñ lubflcañl- A sén$r ln lhe oll pan mohito6 fluid le@|. There ¡s an oil c@ler imme6ed ln engine coolánl inside lhé coolanl dudcover

DESCRIPTION AND OPERATION

A slrai.era¡d pickup tube lead the lubn€ into the pump. Forlhe axle ardólpan,ihe strainer¡s mounled ón a shonlube h6ld n pac€ by a b@ckel allached to lhe distrtbution holsihg. Forrhe axle back mode , a longlúbe wilhour lhe

lo

DESCRIPTION AND OPEBATION

There are lhree lih€G, oné by-pa$ and tvo lu l-llow, atached lo a hous¡ng mounted al lh¿

lo@rrightsid¿ ollhéengine. Oilllowlhóughthe lillers ánd lhé lubri€lion syslem is @nlro led by

. . . .

OilCool€r fhemostal Valve

Owrl

N

Valre. Full-Flów Fillé¡

OpeninS Valve, PislonCoor¡ng

conlrolva@, Piston coolins

The Educing vdw maintalns @nstanl sysl€m o I pressu¡e. Thé sisly mlvá p@venls excessi@ p€ssu G d uring pef¡ods ol h io h viscosiry. The oil 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 syslem eaches the sl prssue The conlol valve @qulales Ihé oil llow lo lh€ pisron cooling

DESCRIPTION AND OPERATION Crankcase Vent¡lation 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 and rocker shalt). Ihé misi ridés the dctts ot alr and olher g4es lhal circútate in thé open spaces in lhe engine. To praent pressure buildup, th€

A iurbine ih the CCV separaior, drive¡ by a smat sl@am ot oll slr kino its lins, spins ár high speed. The mixturé óf g4es ard o¡ y mlst lbpped in thé €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.

opén spaces are ducred iho;h á pipé üal opens to thá almosphere ¡ear thé bottom ol the

c€nkc4é renlilaiio. (ccv) slslém sepafát* lhe oily m sl t@n lhe gases by cefnrifugal lorce. Thé oil €lurns to the oil pan. Thé rémainder e$apes lo the álmosphárá. ThB

Thé opéñ port conrecls to a lube leadinq lo lhe bottom ot the onqine where bad d6lt draws lhé qases inlo lhe alñosp he fé.

DESCRIPTION AND OPERATION Fuel System

FislE22_Fú.lsyd.ñDl.qÉn t,3.FadP,npHdrdF

'5 ¿ s@ndaryüain) e. r

un

Fiher

vd€ {P@uÉ

oir es cord i*ú

\ (rnrd- ér, %eD

7 Ai BÉdv¿tls(!ro*skháfré.HMo, 's ^j@rn seD(. Pod (P *uc cdussr je supprPresu€s€ner

rp

Pad6, (oprioÉ) shüon valv€ (dos úM 22. On*w4 vár@ (Hand Prminq)

20

rni.dor

r. Pmp sábry

wbré

2r.

R@utab)

fbe luel pump atlach6s ülh lh€ power sree ng pump lo lhe itwheel houshq at the Éár l6i side, It lums on rhé same shat as the power sléering pump. Ih€ @mmon d ve gear mesh6 wilh the aux¡ lary ¡dler driven b! th¿ cÉnkshaft gear Al 600 rpn, lhe pump dellw6 a miñimum 100 kPá (14.5 psi), and al 1200 rpm, 300 kPa (,13.5 psD. Al 400-550 kPa (5H0 psi), lhe gal¡ery requlalor válve op€ns to conlrcl luél gallery p@ssue.

sdi@

rl€f Gnr@d)

DESCRIPTION AND OPERATION Fuel is dEwn by lhe suclion side ol lhe tuel pump

lroú fte tu€l lank inlo lhé ECU cooling plate and enlefs lhe luei finer housl¡q. Fu€l pss¿s by the one-way .heck vdre wh¡ch

p@nts

th€ bre€dinq

oltuolbackrolhe lue lank and into the pr¡mary tuelliiier Th6 tu€lb¿comés liheed by pa$lng through lhe lilter media fom lhé oulslde lo the cenlef of lhe pfima¡y luel l¡lle¿ The lúel léáws lhe pr¡mary tiher and pases by a one-wáy úlvs locred in $e rhreaded nlpple ot rhe pdmary l¡rrer Thé luol llM lroñ lh6 liltér housing lo lhá

suclion side ol lhe tuel punp through an exlsrnal tue line, Fuelbeómes p@$urized afer leav¡¡g lhé luél pump ánd back lo lhé fh* hous¡ng lo €nter thé se6ndáry liftér Ths luel b€comes l¡[e€d by ing thbugn the ti[er med]a foñ rhá oulsidé ro rhá cánrér ol rhé sécondary flrár Th6 tuel leáv6s lhó se@ndary li lor and as by a¡ aulomatio air bleed valve which is lodled ¡n lhé lhrcad€d nipplélór1h6 sécondary lillér Fuél es by ihe lúel pr6úfe séñ$r and then exits lhe llte¡ housinq lo enler lhe rear ot lhe cyli¡der head lhrough an 6Íend lua lin6. Aft€r fu6l enleF lhe cyl nder head, il es lhbugh lhe lu€l gallory ol lh6 cylindér head lo conlinuous y delivertuelto allsix únn inleclórs. Fuelleáres rh¿ cylinder háad aler ing by lhe luel preslre égulator located at lhé léft lod comér of lhe cylinder h€d. Fuel is routed back róm lhe cylindér h6ad lo thé filter housing lhrcugh an enernalluelllne io dell@r somé rátunluelback inló lhe su.lion s¡de which qo6 io lhe irel pump. Any ex@si€ luél nol ónsumed is bled ol lh @ugh lh e de-aeEl¡on válve ánd thén, diracl¿d

lss

FUE! F¡ITRATION Primary and secoñdáry li[ e¡ements atiach lo lho unde6ideotlhe l¡lle¡ hlv6 housing. The housino, lo€léd at the font l@e¡ tsft sida ot lhe ctlinder block, h6 an inlogEl hand-pr¡ñ¡nq pump lor bleeding lhe syslem. Thé 30 nic@n préJiltér (primary liller) also sepa.abs wal6r lrcm the luel. Wat6r mlbcr8 in a cup on lhe bollom ol lhe pre-lillel There ls á sensd lo kéép lE k ol thé walff and signalthe EECU.

valw toÉted in th6 tittsr housing prMnls iuéltom daiñing back to the tue tank when the eñgin6 is shut down. A160 included in rhe tuelliler hols¡no ¡s rheruer pfessuré $nsorjusr abwe rhe secondary liller A one-way 6heck

NOIE The collgclsd wat€r can be dumped on y while lhe engiñe ls noi tuññing, lh6 kéy is in lh6 OA/posilion and lhe parkhg b¡ake is sel.

some lrucks a@ buill wllh a remole moúnted tuel wáter sepaÉror ln lhis case, the luel is

d6wn lhough lhe reñote nounled fher b6fo€ il .eches lhe ECU coold plate. On lhe liller bas€, ihé mouniinq lo€uon torthe siandard pháry liLter ¡s blocked ofi with a

DESCRIPTION AND OPEBATION UNN NJECTORS

FrquE 23

-

Unrr

ln¡.dor DrasEm

DESCBIPTION AND OPERATION This snq¡né usés dolblé solenoid unil injecloF. Un ike systens lhal rcquké sspá ior deÍrenng, pre$u z¡nq ánd lnleclins, this ún ir i¡jelor cómbines these tunclions. fhese inielo6 pr€cisély cónlról lha ruel deliwry beeuse ol the Mo solenoids. Th6 so enoids, pump and nozzle ae in a sinq e body iñ crose Th€ injéclor t. sel in a p€ssurizéd iuel gallery where the luel teñperatoe is @nsiant. Uniloh Iuel teñpehlue meáns uniform quanlily in each ¡njeclion which ñeans unibrm pMer oulpul irom

The luer pump préssu zes $e óalery do ihátruel rushes lnro each injetor when il opens. Gallery pressu@ is ¡egulaled by a válv6 rhal deliveB éxc€ss luél back lo lhe tank. Copper sleqes, actino as coolánl iackers, line lhé bolroms ot lhe injeotof bofes. Eñgine cmlánl crrcúlales aroúnd l¡es¿ aiding lhe po@s ol conlrolling ini€clion l€mpéBlue.

de*s

There 6ro rour phass ro rhe injeclor c,ycle ol ope €lion. fhese include:

.

Pfess!re dbp phásé

R@

FsuE24

uñtr

rnt¿dóI-

F¡ll phasé (A): Ouringrhel¡r¡nq phasé,lhe pump piunqer is on ils way up, lhe @mshan bbe is pa$inq its hiohesl poinl md rhe @cke¡arm is on its My loward lhe €dshaft báso circl€. fhe luel El€ is open, allowi¡g luello llow lnto the unii iñjdlor Jrom lhé lówer luel gallery Fuel ft@s ¡nto ihe cylinderhead and lhe unil inieclor pump 6flinder Filliñg conti¡ues until lh€ pump plunge¡ reach4 irs upper posrrlon.

F atds.i¡rPh¡s

Sp¡ll phase (B): The spill phase beqins when the camshall obe ior@s ihe rocker árm lo pu€ h the pump plungardown, The tuel€. n@ llow thouOh thé luel E vá, lhmugh lhe holes h lhe unil injeclo¡ and out ihóúqh lhe luel gallery. fhe spill p hass conlinues as long ás the tuelúh€ is

DESCRIPTION AND OPERATION

FiquE

25

-

unr rnl¿cbr hjer¡on and PressuE oED Pha€6

injecr on phs€ besins luel € w clos6s. The cahshaf lobe when lhe and rccker am coñt¡nue to press down on lhe puñp piuñger and injeclion occu.s as lhé palh lhouah üé fuo¡ va w closes. The injeclion phase conlinues as ¡onq as lheluel€lve isclosed,

hjécrion pñase (C): The

PE$ure drep phásé(D): The l¡Fcno¡ phase ends whe¡ the tuel valve opens and prcssuE in lhé unil injéclo¡dops bélow lhé nozzlB opening p6súre. The fuél flo$ thfoúgh ihe open val@, lhrolgh lhe uñil injeclor holes and oul lh.ough the luél galléry Noré rhal the luél €lvé pcliion (cl6ed or open) deterh nes when the injecl¡on phasebeginsand ends. Thelimedurinq whlch lh€ tuél Elre i5 closéd dalerminés lh¿ amouñt ol luel ¡njecied ai each pump sloké.

i€l

Unn inj¿cloB aré cal€goriz€d and

6ded wlh

Égafd lo lole€nces. wheneEra únit inieclof is replaced, lhe eplacement ¡njeclor [iUSl be p@q@mmedlorlhe cylinder i¡ whi6h il is insla léd. This is done by pogEmming EECU páÉñete6 using tho VCADS po or lhe Tech fool (PTl) ro ser ¡rlé.rol rr¡D parañerers wilh lhe lÍm codes marked on lhe injeclors.

NOTE Ihé diñe¡slon by wh ch the i¡leclor óozle dlends lrom lhe head is crilica . This means lhat machiñino lhe h6ád in any wáy lhat chánqes this nózzb énension ls ñot pemilled.

DESCRIPTION AND OPERATION Exhaust Pressure Governor (EPG) System

horGml svdsm

The qhausl pE$ue @gulalor (EPG) is placed h dlrect @nnecton with the tuóiho housi¡g of lhe tuóocharqer, and has lwo tasks:

. .

The

when idlinS, lhe engi¡e ls kept warm by créannq a báck péssu.6 in thé qhausl when lhe a@e eElor pedal ls eleased, lt ácts ás an dhausl bBke.

qiausl pre$u€

regulalor conslsis ol a 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.

uryhg corfól áir n¿6d3 of the áxhausl brake, lhe engine electronic conlol unil sénds a Puh6 widlh Modurated (PwM) signalo the AVU valve, wheré lhe siqnál pulsá w dth (s a p€rcénlage) deremines Ihe oulpú ai prosufo lo To meel ihe

Figuc 27 shM lhe silualion du ng normál d vi¡g. Wh€nñe AVU vdre is ¡ot receMnQ elecric curenl, ihe shdl6r (2) is complete y open and lhe qhausl is f@ to .

DESCBIPTION AND OPERATION Powef Leashrr Eng¡ne Brake Thé 6ngin€ cañ be equipped with a Po@rLéásh engine bhke syslem lo assisl in Thé systém sl@i¡g lhe vehiole when

n*sary

.

Exhausl od@r árm o¡ dháúsl and blake

.

ExháGt valE yokes (bridSes)

There arc multple delign Efialions o1 lhe Powe¿edhrM €nsin6 brake ulilizing a 3-@ker valvé lfain or a 4-fockef El@ l€in.

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 via a pinless yoke (bridse).

Fiqu6 23

-P

6l€a3h'¡ Í3.F.cbr) comDonsr3

L Adiudñañr shin

lil 6é

ahácr

va

c

Thore aé two smáll lob6s on each ol th€ orhaust cams ¡n áddition ro rhe regu lar robe. Thén ocalions are limed lo opeñ lhe exhalsl valves al thá 6nd of tr ¿ induclion slrc k¿ and m med iately béloé TDC oñ thé 6ñpr6ssion srok€ wh6n engine bfaking is act¡hted, The exhaust Mk6r áms ará slurdiér lhan sta¡dard a¡d afe eqúlpped Mth blade springs to

mainlaincleaBncebelweenlhe rol¡erandúenro small 6rÉ lobes when PowefLeash is nol acli€led. Vdw cloa@nca adjuslm¿nt is accompfsned lhbugh rhe use ot shhs atiached lo the lop ot lhe valve yoke.

DESCRIPTION AND OPERATION POWEBLEASHT (+ROCKEF)

oPEFATTON (3-FOCKEF ANb +BOCKER)

4jock€r désiqn. lhe qhaust rccl@r arms conla¡¡ a pump p¡lon h additión lo lhé pówer

Pow6rl66hrü opecllon depends oh eil of lhe lollowlng onditons which must ex¡st

Wilh the

pislón and no¡-@lurn valve. An additional "brak6" rock€r árm, wolking in combinalion walh lhe exh¿ust rockd am, dn€s lhé pump pislon io¡

. . . . . r .

AcceleElor pedál rél$sed Ensinespeed abóvé 10m lpm Clutch ped¿l r€l€6€d Boad speed ábóve 5

T€nsm¡sslon ln

kflh

(3.1 mPh)

9€r

oilrempeÉtuÉ ábo@ 60'c (1,ro'F) chafse aúpfessúe berow50 kPa (7.25 psD

On lh€ cylind€r hoad, lhe oil conllol valve connects lhe o¡l pasaqés in thé h¿ad and mckár shafi. Thé cont@l valve reduces the o¡l pre$úÉ in the bck6r shaft 10 100 kPa (14,5 psi) when PowerLeashrr is nót á.Jivá1é.1

F¡€uE

2e

Poturl.$hr¡ {}nocke4 comF¡enrs

3 Déómpresrdlóbá

I

L Serinq

I ii

E,h¿!dLobe

Atéáchcylinder, lherc isalourlhcamlo d velhe brake ¡ocker am. This cañ @nta¡ns lhe chárging and d€omo.e$lon lobés which are timed lo ópen lhe exhaul valves al the end ol lhe indlclio¡ slrcke and ¡nmed¡atéty betb€ TDC on lhe cómp€ssion 6l@ke whe¡ englne bdking is Wilh lhe 4-rocker desion, it is lh€ €ng¡n6 bráke rccker am lhal is equipped wnh á blade spriñg. He.e, the pulPosé is ro keep the oller in @ntact wiih the lourth "b€ke"can.

DESCRIPTION AND OPERATION When lhe a@eléÉtor pedár is rel6s6d (and rhá PowerLeash silch is O/9, lhe eleno¡d opens állowing sm¿ oil to éscape th.ough a smal¡ porl. Reduced sprino pr6ssuÉ mdés the oislon, opens lhe age lo lhe ócker shan ánd inceases lhe oil p€ssu¡e. The sysleñ opeñs the exhausl valve du nq induclion and again inmediabt b€roÉ rDC on the .omp¡e$ion The engine slo$ becaue lhe exlÉ wlume under compression lakes mo€ powerlo comp€ss¡ a¡d es€ping p6suÉ iñ thé combustioñ stfok6 reduces lhe po@r oulput. A silch on lhe inslrumenl all@s the driver lo enqage or diséngágé Powé[éashfr. ll the ABS syslem beomes acl¡w, il aulomalically disables Powe¡Leash . ll lhe oil lemp6nlur€ so6s bdMss'C (131'F), PorefLeash cannot be acl¡valed, A wam¡ng lámp ón lhá inslruménl pán€l llashs if lhé d rer atenpls lo acliÉte I uñder this @nditioñ.

pod n lhé cyliñdér héad állóG a-éss to lhé o¡laqeway- The plug can be reñoved a¡d á qauqe and hose 4sembly insened lor use dunng A

Air lntáke System Fresh at erfeÉ ihe intake áboB lh€ back ol lhe cab, Plaslic duol rcfk leads the a¡r to lhé fLlér *séñbly ñounr6d o¡ the bulkh@d underlhe hood. An iñp¡€gnal€d paper fher pBÉnts iorcign panicbslom pa$¡nqlhroloh. Thé aséúbly dgsign permit6 the additlon ol a s@nd tlller if ñeeded in €xlr6mé €nvironments.

a eñbinálion pÉsu@^empe€lure sensof mouñted oñ lh€ pipe bB¡deen lhe i ller hous¡ng and lhe lufb@hafgér aleds ths dri€r il rhe lilleB ñé6d lacémenl bebre the sch€dul€d s€frice. Thé brsk€ syst€m ai comp€ssor álso dáws fesh, clean ak floñ this samé pipe.

FicuE3l_c'¡inddH¿ado[Pf8J6^6$Pod

DESCRIPTION AND OPERATION Turbocharger The lurbocharQe¡ ls ol Map Widlh Enhancement d¿sign, which ñeanslhatthe alr iñ1ak6 is dividád inlo trvo áBas (an inne¡ and an ouler afeaJ connecied by a ring-shaped gap. Thls

lurtocharqer d4ion eñsur€s eficiéncv al bolh ow and hioh rolallon speeds.

A housins conta¡niño animpelür, shadseats. bsa ng ánd pulley anaches lo lhé móuntinq plale. Thé bean nq is a pe rmanently lub ¡icaled combinallon óll€rand ba lbearing. Betwe¡ lhe shafr sels and lhe bearino, lhe€ is a ventiláted spacewhich le¿ds ¡lo a ducil behind rhépulev fhis állówq inr.'n'l lé'k< r. hé dprédéd

F¡oure

33

cm¡6nt twdé4 sFbm comDoneds |

lr.ErhausrPre$úa I GMrnor(Ere)

Cooling Sysleh Tho coo ing syslem incorpohtes a beltdnvén @olantpuñp mounred on rhe iont ot ihe ehgine on the qhl. lt also uses a pislon-lypé themGtál housed in lhe lronl ol lhe cyl¡nde¡ head and a lan w¡lh visous or ai¡-op6ráréd d ve ñounied abow lhé cEnkshaflpurley. Acmlanlcondilioner (l¡ltel) attached lo th¿ pump housinq 1i lérs impuntus lom lhe coolánl and €léGes suppteme.lal ooJanl addilives ior system prctéclion.

'rhe back ot the coolanl (ware4 pump, with ils ducts lor dislribuli¡g coolanl, is a sepaElé casting attachéd lo lhe clli¡def block.

I

3. cooranr

tume Moünrino

Pbb

THEFMOSIAT This is a piston typ6, tutLfe lhe¡mosial wilh pislon, bu b, seala.d housi¡g ln a sinqLe assembly. Coo ani llows co¡tiñuously, eilher back lo the púúp, or lo rhe radialor and bad{ to thé PUmp.ll has lower pressu¡e dop.ompafed to oiher lypes. The lhemostal is mounled on the to¡l ol lho cylinder head,

DESCRIPTION AND OPEBATION Engine Manaqemenl System

ENGINE COOLING FAN The coollng ian (Fiqu€34) runs v¡a a visus or air-óperated driw rhrough whi6h tan speed is elecrrcni@lly conrrclled by rh€ EECU. Wirh p€cisá EECU control,lan sp€6d is mnlinuously adjusied lh response to seveál interelated inilúences. fhis makes tor eliclenl @olinq wilh

ENGINE ELECTRONIC CONTROL UNIT (EECU)

ds

The e¡giñe úanaqemérn syslom module, known as lhe Enqine El4tronic Control Onn (EECU). i. locared on ihe leil side oi lhe engine jusl below the inlel mánifold. Thé EECU is cooléd by tuelcirculariñg rhrouqh a pláte attached ro rhé cder ol lhe unil, Theluel@mesfom the lank on

l2

conn*br

0o EEcu)

Olher hn drive oplio¡s in.lude On/Of Fan Clurches and Elecrronically Modulared Fan Drives. B€ferto Enqin6 C@l ng S6fric6 i¡ánual, 7-002, tof a complele desÚlpllon ol all awilable

Alqorilhms, called ñaps, are programñed in the EECU so thal il sn ranslate sensor data ¡n1o acl¡on. fb6e ñáps enáblo lh€ EEcu lo fsivé status iniormalion ircm lhe senso6 and send lunclional dala lo the acluatoB so lhey can s im últáneously áss um e lhé p.op€r posruré for th e saiesl, mosl elfleie¡t opeÉtloh ol the ongine in Due to the EECU sell-learn¡ng capábiity il is ne@6sary lo resel lhe learned EEcu psamélérs aftd sgryicing 6ome engi¡ejeláed conponents. fh¡s all@sihe EECU lo learn lhe compone¡l! behavior Allof soruictng is complele. pelom lhe 4Learned Dala Besef located in lhe Funclion Grcup I menu on the Pc

n4

DESCRIPTION AND OPERATION SENSORS AND ACf(,ATORS

sénsoG on lhe engine p@¡de lor ól€clronic mnlol. Ths f gures lhal tollow show lhe l@l¡ons ol the dev¡ces on lhó létt ánd qhl sides oi lhe

e,

ware. F5n

L*r

tn tuéMtér

sFad {o¡ry r

danr Ld

qr

epádo4

pFd Rih v roú! bn)

E

s¿nsor (in s,Dansion r ceranr remp€ú'u€ (ar rrcnr sdse or cyrnder

hsd)

DESCBIPTION -AND OPEFATION GLOSSARY OF

¡d¡er Tens¡onet A belt lensio¡i¡s devi@ des¡oñed io naiñiain oplimum lension underEryi¡g englne spéeds

an odof e$, cooness qas Eulling ircm in@mplete @mbusiionot trydrcca,bonq lound in diesel lluck exhausli poisonous lo humans and

El€clron¡c Unir

hjetor

(EUl)

Conl@n€d él€ctronicany by the EECU, there is one álé.tronrc ünn ¡nieclof lor each cy inder ól án

€nqiñé. a unir i¡jecror incoQo@rés th€ pump,lhe ¡nlecror nozzle and rwo so enoids in a s¡ñqle body. Acluatéd by the camshall üa oc(er arms wilh mll€rloll@e6, el@foni6 unil injecloB of€r pfec¡se tuel mere nq using a pfo@ss called '€le

Eng¡re Elstrcnic contrer unil{EEcu) A micrrccessorbs€d @ntroller usualty mounl€d on the éngine bl@k. on rhe MPs e¡g¡ne, a @oling plale mounls on lhé su¡lacB ol lhe modul6, A tub€ on lhe plate conducls tuel dEwñ lloñ lhe lank on ils way lo lhe pump béfo.e beiño D.esunzd Th€ tuél acls as lhe mor¿ff. wiihlho MACK v MAcle rv svsrem, rhe EECU eñlóls luelliming and de i@ry hn opefa! on. engine pbréclion lunclions and 6ngin6

Chémlcal compounds mmposad only ol carbon and hydroqen. Gaso¡iñe, diesel tuel and molor o¡l a€ aLlqamples ol a@ry la$e g@up or tryrbons. Th6 largésl surc€ ol hydócaóons is peloleum.

A oear runnina b6tw6n a dnv na and a driv¿n gear lo make lhe d¡l@n gear biale ln the same d rcclion slhé d vi¡q gear

¡nrake A¡r Temperaturc and Húmidiry sénsor Mouñred in rhe áir inrake beloeen rhe air cleaner a¡d lhe lurbo @mpE$or housing, delecls odside an bmp€atu¡6 and humidily and rclays these values lo lhe EEclJ.

Oxid* ol N¡tbs€n (Nox) High lémp¿.alur6s and préssures of cómbuslion ptuducé oddes oi n¡tógen (Nox), whe¡ combuslionlempealureex@eds 1372'C (2,500'F), oxygén and nilos6n combirc in larqé quantilios to lóh Nor. By themséN€s, Nor eñisslons a¡e ¡o gfear hazafdr hower, when mied wirh lhe ghl amounl of Hc !n rh€ ajr, Nox willcombine iñ thé pfe*ne ol súnllqht to lofñ

A muhnbb€d b€lt d6iqn inmrcorát6d into th6 a@essory dlve ben ard pulley af€ngenentat rhe ircnr ot rhe enqine.

a lype ol bcker am with áñ d e ñóunled ó116r rhar fides on (or tollows) a camshatr robe. Ihe rclling mofon ollhis désign povides inc@aséd load €pacily wilh léss lriction than lhs llal-fácéd fockef afm desig¡, Foller lorlo@fs prov¡dé rhe ockér an I fi¡nq acr¡on for lhe ele6lronic unil ini6clor, inlai¿ ánd €xhausl valves and qhausl

véhiclé Elécironic Contd Unn OECU) A microprccessorbased conl¡ol er, emetines @lered ló ¿s a modul€, mounled in rhe @b. inside the pa$enQersidé dash . Wilh t¡e MACK V-MAC lV syslem,lhe VECU coñrols engine spe€d, c.uise @nlrol, ac@$ory relay coñrob, ldle shúldmn and fip €co¡der

COMPONENT TOCATOB MP8 EURO 3 ENGINE COMPONENT LOCATION VIEWS t200 EAI The localions of primary component 6señbllos or rhe MPB engine a¡e ide¡lllied in rhe illuslÉlions conia néd in lhis séclion.

h¿. R¡sh6r& v¡€* {FDnr 2.

Exhad P¡éss€ G@rDr (EPG)

t

COMPONENT LOCATOF

t-i.t-.t

n.¡

H€rdr vld

G 5.

NOTE 6nvénlion.! ch*sis, lhé áir inlol is ar rhé 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 For rh€

loht

16d).

collH

Fetlqeff' ompésor

(Pád

Mouio

TBOUBLESHOOTING ENGINE SYMPTOM DIAGNOSIS [2oo EAI The Vehic e Managene¡l and Cóñtrol (V-MAC lv) syslem moniroF eng¡ne luncr¡on ánd d¡splays á .odé whén a lault is detected. The @d6 €n b6 obs€ryed o¡ lhe inslrumenl or lhrouqh an életronic dlagnoslic toó|. An explanalion ol the lault cod6 can bs lound in vcADs, Gu ded Diagnorics or rhe Faurr code tvlanual. &218. Guid€d Diagnó51i6 also in.ludes symplom-basedlroubloshooling. fo oblain T€ch Tool, coffacl youf l@l MACK dealel

Beforé Troúb¡éshool¡ng Beglns Belore lrclblesh@tng b6gins, obsere all shop

No¡se and V¡bÉtion NOAMAL VERSUS ABNORMAL Notse is thé nañe wé oiv€ lo v bElion lhat úrllales us lhrough our eaÉ. lrbrarb, can b6 tu w¡lhoul be ng head. Enqire ope€l¡on can €use

l

vibálion á¡d

ñoi*

throughoul á véhiclá lhál we

fhé Ttrh Tool prdidBs compl€ls syst6m d¡agnosl¡cs. Fof more ¡ntormalao¡, see manual 9371 or lhe Tech Tool web site Fepair informal on is á@ilabl€ in lhe r€€pect @ enolne service manuals and floñ the tüacK Elecibnic lntoñaüon Syslem (ElS). EIS is easily acesed

Troubleshool¡ng Techn¡que Talk 10 lhe vehicle opeElor, Learn hd the énolne opealed béfofe ir lailed, Ask aboll the

mainlenance schedule and the lu6l, eolanr and lubrienl used. Begin by anemptlng lo delermhe wheiher anylhing hs happéned rccenltlhal @uld poinlloihe eleclrelsysteñ, bul which is nol rélal€d lo lhé éleclonic ónllol qstem. Depénding ón lhe @hicle coniguGtion, á probl6m may bé cau*d, orinllue¡@d, by maltu¡cl¡ons ¡¡ oiher whicl6 mmponénrs. Be suré ló inspec! lor unus ual condilións amonq lhe batleries, ri€s, dles. l@i¡er, bodyb!¡tder adaplalions and olher possib liti€s. Consu¡r sp¿cilicsérui.e nlormalion resourcesaccording lo the cóndlio¡s obséred. Fuelwaxing,lor exan ple, ca n cause syñ ptoñ s éasily mislaken lor olhsr €ngine p@blems. lf poss¡b e, recreat€ lhé pbblem in an envnonment siñilar b lhal desc bed by the

whicle operator Fun thé eñginé at lha lempé€lu€ al whichlhe symptom occuf€d. Eng¡ne problems cán be éléctriÉ1, mechanical or combinalion ol the n{o. Eleclri€l and eleclrcnic problems wi l, lor lhe m6t pail, causé laull @des lo b6 sér in rhé v-MAc system. a

abñómd noisés ánd vibÉlions suggésr lhar somelh¡ng is ¡ot working pop6rly or s nol assmbled prerly. A damaqed dr¡veshaf can

óause abnormál v b.álion. A loose laslener allo$ lwo suriaces lo fub or slap toaglher causino u¡usual noise in ¡espoñse lo lhe v¡bátlon.

ge sure lo d¡*úss noise and vibElion issles wilh the dri@i ll is imporlanl lo di$o@r uñder what mnditions th€s€ occu. l¡aybe a l6t drlve wft be necessary lo lañillari2e youfséll with thé details ol the drÑeis slory. Ewn so, it will pobablv bé necessarylo slaf lhé diagnostic prccess with á guess as 10 ihe nalure ol lhé dificu ry

TROUBLESHOOTING @ afbrds an opponun¡ly to make nole ol valous ¡ffluénc6 disturéd whiLe inwrigaüng lhe prob¡eñ and órganizé rhouqhrs. ll ls made ior you lo use d you ee lilThé tablé be

WrhapJddlJspedrudure

rÉ

of

chas*

s*Bion

rr{é

or

d'ñéi3

si

(ai'?)

{mab aid

l, lhe solulioñ do€s nol bscomé evidenl in lhe @u6e ol @mpleli¡g lhe check llsl abové, usé Tech Tool to inv6sligáre tunhe.

TROUBLESHOOTING ENGINE CHECKS AND TESTS lÍclúd¿d ¡n rhis €éclion are rhe toll@ing engine

. . . .

Cámshaft

Sé¡s¡

Depth, Check

Oil C@|e., Pre$ure

Camshait fming, Check

Cmkcae

cylnder Liñor and piston weai cheii EGR Cooter, Pcssu€ Tesl Eñginé cómpe$ion, Ter Flt{h@l Housing Funoul, Che.k

T6l

Venlllallon, Check

cylinder Head, Pressuré Tést Valve Guide Wear, Check

Special Tools

searnq Prab tu MP7

c'rhds

Héád

THOUBLESHOOTING PG*uEc oe¿dHG6s(a4rd'l

Fbvh*rrum

*@

Drd

n0

r@rlor MP7 Eneins

rú¡dóf {Esmi.l}

cy iidef N4d Liftre roor (E$6nrial)

TROUBLESHOOTING Fshá.rrúhi@ rooriof

cañ6halr

s.rsd

MP3 and MPl0

D€prh Gruq6 (Av,iab €)

@@

@a

s@

TROUBLESHOOTING Camshaft Sensor Depth, Check siqnalfoñ üle cámshaft sene¡ musl dceed 0.5 rcll in ofder to slart lhé éñgin6. slgñal is l@, chéck üe deplh sefling ol lh€ sensof lofowina lhis p¡ocedu€,

Trql_'lén lhe thumb

The

1

.

2.

$rew

innerpart ollhe gauqe. ll

to ¡scur6 the

Caelu¡ly Gm@ the galge lrom rh6 canshall señsor bor¿ and obsefve lhe localion ot sieps belwéeñ lh€ innér and outer pódions ol rhe gauge (Fisurs 40):

the

.

Réñóvé thé plug fom lhe lltryheél housins ánd instal th6 approp ale tlywheel tur¡¡ng lool, 39S6356 (MP7) ó¡ 43400014 {¡lPg and

.

Check lor proper camshán position sénsor

.

d€ance

using lhe $reor deplh gauge, 48400031- lo dálamine if shims áre fequÚed ior sensor depf..

Bolh steps be ow lhe surfacé ot ihe gaug6 = no shins Equired. Oné slsp below lhs

sulace ot the gauge = o.e sh¡m fequ¡red. Bolh geps ab@ lhe sulae ol ths qauq€ = lso shims @quircd.

@ @ @ a. b. c.

3Rótáté thé €ñginé until a looth ol lhé Émshait ioohed whéel is aligned wilh

lnsé

1he deplh gauge inloftó s€nsor boÉ unlillhé ouler pan ot lhe qauge is lully sealed aqa¡nsl thé limi¡g gear

Loosen lhe lhuñb screw ol lhé gáugá a.d plsh lhe jnnff pat ot the gauge in u¡lil il @ntacls a toolh of lh€ loolhed

hst6ll th6 emshatl posilion sen$r with thá

appfopriate shim(s) and ns ojing, seure lh€ sénsorwith a boll and plug ln lhá

TBOUBLESHOOTING CamshaftT¡mihg, check

1. Femove lhe cylinder head (vatue) cover 2. Chek the camshaf v¡bralion damper fo¡ damage io lhe pulse wheel pins.

3.

Chec* the pulse wheel mounling for seure,

4.

Turn thé enqlne crankshatl so thal lhe TDc ña¡k on lhe camshail @@ponds lo lh€ narks on lhe camshaft béárinq €p No. 7 (MP7) or @mshafi béarlng ép No. I {MPB and MP10) and the fywhee¡ TDc nalk "(f is

Crankcase Vent¡latlon,

1,

Check '

Check lhe inlet pipe io lhe CCV sepaElor tor

oillilm, oilreidúe a.d panicbs, F€more

any accuñulaied oil and did párlicles Jlom

opposile lhe poinler on ih¿ llyvhoel houshg.

5.

ehsu€ ihal lhe camshan is mrgclly insialted, compléts a ml@ l¡fl check on lhe inlake Elv6s of cylinder No. 1 .

To

.

Támpoanly adiust the No, 1 inlet@ckér árm, al lhe valre yoke, lo z¿fo l6h.

P6¡l¡on a dial indicalor ¿t lh€ inl6t Elvé yoké lor lh6 No. I cYlinder P€l@d rhá di¿l indicalor ánd fesel lhe Turn the enq ine ln rhe normal diecrion ol eng¡ne olalion on€ lull olalion 1ó'd and past to the ma¡k 6 degrees (atte¡

lrel

The dial ¡ndicaior €ading should b6 apprd márély 1 .6 a{-03 hm (0.06 r0.0r ¡rch) lof MP7 and MP3 of La a0.03 mm (0.05 a0.01 inch) ror i¡P10. This €ading indicales á erectly l¡med €mshaft.

R*dlústihe cylinder No, 1 lnlél € @s

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

Bámove lh6 CCV sepahtor

fbñ

the engine.

3. WiltL the s€paElor r6mowd, rotát€ lh6 turbine by ha¡d. li should olate eas¡ly. ll it

does nol olale €sily, repl&e lhe separaio¡

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.

FisuE

¿3

-

oir ftozre (s€p€Éror sase) Fqur€ 41

NOTE ll lhe oil nózzle be@mes clogged, lhe oil lurb ine does nol

- $'[nq

r. sed¡no Pd6

Pons)

PHB rrcbn.d frlpiér)

(celinq l3.c.ndionDis

I

lTh€mosrar Housinql

pressu€ s reduc€d and lhé

Cyl¡nder Head, Pressure Test (Cylinder Head Removed) The lollow¡¡g p@edúre applies for MACK MP7, MPa and MP10 engi¡e cylinder heáds. Whilethe proced u re is lypical, lhe sealin g lools req uúed w¡ll be diferenl ior each lüP éñqiñ€ sériás.

1.

Clean lhe @nlád surlac6s on ihe cylinder

.

séarins prares,9990105 (MP7), 93096s6 and 9998266 (MPB) or 9990164{MP10), o¡lo lh6 cvlinder h6ád .ooianl po ns usiñg cylinde I head bo[s and Ml6nuls

.

Co.n€.londi6cj 9990107,

.

Pluo, Ml2x1.5, in lhe tempeEture

in pcilion on lhe thermoslal housinq bore

Sealiño plalé, 48a00215, on lhe side ol

Conneci lhe pressur€ gáugé, 9996662, to a su lablé áir 6upply. Co¡net th€ pr$suré gauge hos lo lhe conneclion d¡sc on the cylinderhead- Adlust lhé pcssu€ lo 100 kPa (14.5 psi) usng lhé conlrol€ re. close fie sbp valve lo¡ l!!o m¡rules. The

Lowerlhe pressur€ in lh€ cy inder head by ádjusing lhe knob on lhe pr€ssu€ gáuge

TROUBLESHOOTING Aftach lhé cylinde¡ head |tfiing lool. 85109035, to lhs cylind€r h€ad. 5.

Using á hoisl owér lh€ cylind$ h€ad inio a @ntáiner suiiable lbr lhs pr€$ur6 16s1. Fill the conrainer wdh 70'c (153'F) warer

pressle ii lhe cy[;ér héá?d by adjusling lhe knob on lhe pre$oE qauOe

9. L@e. lhe

10. Using a hoisl, @m@ the cylinder head

lom

Rsmm lh€ s€aling plales and @n¡ecUon lom lhe cyl¡¡der head. us¡no compressed air, bl@ rhe warer ol rhe cylindor h¿ad and oul ol allthreaded hol4, d¡sc

Ac^urtoN úté

M

úilh lhe fúel paseg¿s lo tuké the f@l 6ramels. Dht ún @u@ the unl ¡nj@¡ots to be damged. usé that

tu diñ qte6

Cyl¡nder L¡ner and P¡ston Wear, Check Thoroughly clean lhe cylinder l¡ners and pislons before in6peling and measurinq, To lhoroughly chtrk 1br c€cks, r€mo€ ths cylindér liñer lrcm lhe cylinder block. Mark lhe position ol the cylinder liner in lhe cyinder bloc¡< beiore €mding il ¡l can bé inslalléd in lhe same p¡silion durino assembv.

$

Wilhrhe pressuregauge @ñnécled lo anaú supply and lhá @nn@lion disc on lhé cyllndef head, €€lullyopen the galge Sel thé p.ésure lo 50 kPa (7.25 psi) and hold thé pfess!é for one mlnule. Ráise lhe p¡e$u€ to 150 kPa (21 .3 psi) ánd close the slop valre, Allerlwo m¡nules, chéck for a dóp in pF$urá áñd turany air bubbles lorñiño aóuñd lh€ cylinder h€ad.

NOTE A

dop

in pressure and ihe appearance or alr

bubblés indicalés a Leak(s) in rhe ñolanl, luel ot oil aq€s. Thá surce ol lhe leak(s) musl be tound and lhe cyl¡nder head éoaired o¡ rlecéd

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.

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 ll wear is

NOfE Pislons and cyliñdér lin€B áe ava lable fom slock only as malched pans and should noi be

F¡qq€47_Mgsuinqcvl¡nderLlnelws¡

3.

Measu¡e the cyJind6r lin$ al Top Dead Cenler (TDC), at Borom Dead céñér (BDc)and ala colple ol pos¡tio.s in belween. al each poinr, méásue in lwo dtections engine crosswise and Bngine

PlSTOl,l lnspect the pislon ring qrcoves, lands, skirt and

comblslio¡ bowl lor w6ar, sufi ma*s, deep

scralch6s. c.acks and blow-by. P slons are NOT repai€ble. Discard wórn ordamaoéd p¡slons.

AcaurtoN Do not stanp ot ügÉve an the fOP of the pislan, Failue la h@d rhb caut¡on ñay esul

k

lhal pislons afé r6insialléd into the sam6 cyl ndérs, lhe pislons múst be laqg€d w lh the corespondino cvlind¿r numberwhen removed duri¡c disássemblv. To énsufe

TROUBLESHOOTING EGR Cooler, Pressure Tesl

(Not Applicable for MP8 Euro 3

Enqine) 1, check

ins¡de ihe 06 ¡ntét porl. tt build-up oi s@i is seen, perform lhe EGR eoler cleaning pDoedu€ belo€ checking lor

2,

Lubr @re rhe ojings on rhe c@la¡1 inrel ánd outlát po¡l plugs wilh a suilablé Oiing tubn€nt lnslall lhé pluqs ánd cap on lhé EGR coolei lns.1alllhé plugs oñ ihe EGR @o er.oolanl in¡el and oullel pon6.lnsiall lh€ couperonrhs pluq and co¡nécl lhe qauqe lo lhe co uplér

AcaurroN Do NOT overt¡üten ihe

hs¡qe6

on the plugs

NOTE llalaQe enoúghco ainsrcannol bé oblained, lhe EGB @oler cañ be tesled w¡lhoul belnq iñmeGed iñ wátér by using lhe 16l p ugs lncludedwiththekit, ma00216'5,losea lhe gas oullel po . The EGF @oler coe can lhen bé lllled wllh watéf and tésréd by applying al¡ pEsure lo lhe coolánl oull6l porr as shwn in Figurc 51. When using lhÉlehn¡qúé, th€ 60lér ñ! sl b6 téstéd in rh¿ up qht position. To ease thé instállalion of ü1e test plog, coat rha inside ot rhe hoséwith a suilabre oiing

|

7. eees333

3.

Flll a @ntáin€r w¡lh enough water 10 cover

4.

Lower ihe EGF @ol€r inlo the @ntainer ol waler a! room teñpedtu6 (orilllhe.ooler có.é wirh waler see NoTE).

TROUBLESHOOTING 5.

pfe$oé (240 kf¡a I35 psil) to lh6 EGB.ooLer Mainlain lhe pre$ure lor l5 minules. ll lhe EGR @oler is leaking internally, iheó wi I b€ a stéady sl€am ol bubbles comlng f¡om the 96 iñl€t or oullél openings, lf a sleady slream oi bubbles áppéáB, réplae rhó EGR cooler Appry a¡r

/AcavttoN Oñ

engin* i:ded wílh PowerLaathN, secute

@.ket

aMb¡y

is t¡had. Pistons and ackeÉ ¡o h@d this

k

tuté Mp@nt

aE

údiú

mlched toge¡het, Fe¡lute nñY rcsúft

NOfE

¡he

p¡Rtore ¡n the acket ams w¡th tubbet bands ot l¡e staps so thé pistme do rcl dbp ú¡ whú tha

danage.

lhe cooler is be¡ng leled wilhoul beinq immeBed n waler, look insidé lho gas inlél po¿ ll bubbÍas ar€ sé6n,lhs 6oler is l6s}ing ¡nleóally and musl be feplaced, ¡t

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

6.

Lilrhe EGF @oler ol¡ ol rhe @nrainer and reúoÉ the pÉssure testiñq equipmenl. Dump the waier llom lnside the EGR c6lér and lhen use @mpre$ed air lo @mow any r€maining wálár lom lhB coolé¡ co€ ánd

Eng¡ne compress¡on, Test

(on Vehicle) v6fit suspecled

eaks in rhe cy¡inder head or block by pÉssure leslinq báfo¡€ l¿cinglheee

lMPTshwn)

Donor úse Maqnatlu$ nspe.lionsalons as

2, B€forá poeedinq wilh lhe tests, ook for c@lanl slains afound rh€ s€a ing plugs on lhe cyl¡¡def head, Check lhat lhe plogs are nslalléd pbpeny

l.

Femore lhe cyllnder head (Élvé)

m€r

Femove tho PowérLeashi¡ (eng¡ne bÉre) .ontfol Elve ii so equipped.

Ac^urroN ¡s very ¡npoftant lo l@sen lhe n *et am shaft ássenbly un¡lúnly acrcs lhe úntple¡e shait. Laosúkg fhé .ocket shall a*nbly úñeÉnly 1l

TROUBLESHOOTING lnsiall thé appr ate liíing t@1, a5109050 (¡¡P7),3s1o9250 (MPB) or 85109035 (MPlo), oó the óckér arm 6sembly. Locen the rccker arm shai un¡iomiy acro$ thá mmplele shan. Femove lhe

rcmole danet switch lo ihe

AcaurtoN notot lü lúger than al a tiñe. Wa¡I 60 sécands belore

Do nol tuñ lha sla¡let

Bémm lh€ coppér

unn injecroB

a¡d clean the

dé4s I nesarv.

5.

lñsrall an adaprer, J 47363, in each ot rhe

6.

Fefi thé rcckar am dsémbly lo lhé éngine. lnsrall lhe Powe[eashn @nl@l valve and oi tub6 b¿twéóñ thé Éñe and lhé rocker

. . . . .

15

s@ds

9.

Femore the screM lor the F¡orerLedh'"

Lubf¡cale áód a$emble lhe seals on each end oi lhe oillube.

lnse.l lhe laqer end ol lhe oil lube in

11.

Posilion lhe vdre a$embly on lhe mourfing plal€ and insenlhé Íéá ¿nd

using a lolque wfeneh, fqtfeñ the atláching scrss accotding lo

I .f-

ii"

Femo€ he conlrc¡ valve and lhe oillube bétweéñ the valvé and lhé rockér ám shaft. hsiall ft€ lninq tool, 85109050 (MP7), 35109250 (MP3) of 35109035 (MP10), on lhé mkér am a$embly. Lo6en lhe rocker aim shalt unilormly @ro$ lhe @mdele shatl. Femo@ t¡e @ker áñ shal

Maké sure the oil seal is in place al rhe botom of lhe Elve a$embly,

9? *Fto

Connscl th€ @npression gauqe, J 6692 B, lo lhe adapl$ on thé list cy¡indér Crank lhé engine w¡lh lhe reñole slarter sitch u¡til lhe n&dl€ on l¡e compessio. gauge slops mov¡ng (maxlñun comp.éssion). Rdord and repe! lor all @ma¡n¡ng 6y l¡ders.

Remove lhe J 473&3 adapteÉ lfom all ol lh€

lnstálrlhé unil inje.lo6 using ánd new séáling washéB.

nd

O rlngs

Connecl the wiÍng hámésslólhe unil 16, Caretully lower thé

17.

Mkér arm shán

R€move lhe lifting tool lóm thé rockér arm

AcaurroN It ls very

inpodanl to t¡ghlen lhe rccket atñ

assñbv m¡¡otñtv

úaft

¿crass the @nD¡ete shat T¡ghtú¡nq Mevent ñn @use danage to the Í@ker am shaft

assúw

1

3. fghleñ

1

L

th6 mcker arm shatt

scrss

iñ 1bé

lnstall lhe Pow€[€ash¡H @nlol vatve and oillube belween lhe Élve and fi¿ rcckár am shafi naking slre lhe seá ing fings a6 dfeclry posilioned befofe tigifeninq the

TROUBLESHOOTING To chmk

A CAUTION

lo ihe

the o¡l tube ¡s ¡nslalled ¡mrrec y w¡th ke large érd k the @n¡bl Btue and lhé ffiaI end k ¡he rcckét am shaft, oil l@ks wi¡| Ih¡s nay ca@ oll slaMlio, in ¡he rocker arns whiú 1l

@t.

ún

20. Tlghlén ths mnlol

valve sc@s accodinq sp4il¡cal¡on and lhen connect lhe wning harness lo lhe EN€ assembly.

d¡.|

runour, aitach thé ¡tal qauge

lltfh6él using the magóetic bas€ and

posilion ils lip ag¿ ins r rhe outer f ange 0ranemission ñounl¡ño súfl¿€l .l lhe lly{heel housing. set lhe d¡al gáuq6 ro zé@. Rotale lh€ iywheel a.d note the indicáléd runoul al a miñimuú ol lour localions aóund lhe oúer llange ol the housinq. Compare the nol€d runoul wilh the spec¡fied áxial tunoul

10

21. Adjusr rhe vdre and rhe unir anjectof fockefs22. lnstallrhe cylinder head cowr 23. Bleed lhe iuelsyslem,

Flywheel Housing Runoul, Check

(Clutch Removed) CHECXING AXIAI AND RADIAL RUNOUT

1.

Cléan lhe llywheel a¡d llywheel houslng.

2. Bemrethe

plug lom lhe tlywheelhouslnq and install lh€ appopdaré llywhéel tuhing tool, 9996956 (t\¡Pl or a3a00014 (¡rP3,

!9--5' Frsues

Túd¡ns Frywh4r (üPa shom, ryprc.D

N

\

n:

TBOUBLESHOOTING 5.

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 To chéck

3. Adiusl lh6 pr6ssur6 oauq¿ reduclion valre knob únl¡l the pfessué gaúqe heedle is al

Connecl lhe pEsure gauge a$embly to lhe fin ng on lhé clamp. Leér lhé oi cooler inlo a bath ol wát6r Ths mler l6mp€Elur6 should be at app@ximarery 70"c (160'F).

| 2.

Máon¿r c Sráñd,

6,

ll lhe runoul klues a¡e out ot specflcatloñ, check lhé naling surhcé ior rhe ll¡vheel hóusi¡q againsl ihs éngin6 block and lhé mal¡ng surface lor the fyluheel on ihe cankshaft- Do lhis belorc rlacing the

7.

Bemo@ the ilylheel turninq lool a¡d @inslall rhe pllg in theiywheerhousinq.

O¡l Cooler, Pressurc Test

L 2.

Cleanlhecoolanlsideoilheoil.oolerwitha watéFsoruble de greasing llu id. F lush lhe oll side of the oo ¿r with degrcasing solvenl.

lnsiall rhe c amp lools, 9996a45, making sure thev aré pmperlv sealed,

5.

lnc€as¿ lhé pEsure to 250 kPa 135 psi) usinq ihe reduclion valve knob and check lbr airbubbles emerqrnslmmlheoilcoolei The iósl peiod should lar lor al leasl oná

NOTE Air bubblés emelging l¡om lhe oil cooler andicate a leak. The oi coolgrshould bé replaced,

TROUBLESHOOTING Rocker Arm, Check

3.

NOTE

Sél thé dial indl@1or to

slre lhere is clea€nce béh!één lhé rdké. tolléE and l¡e camshan whe. peformins th6 follMlng r@ker am bshing and rol er Make

éo.

Posllion a pry bar di@lt u.d€r lhé rmker afm inüe sháll a@a. Pry lhe fockéf áfñ úp 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, réplacé lhe @ker arm and check thé shalt

áñ

ROCKEF AFM BUSHINGS

1.

Push down on lhé rdkér ;rm so $at any o¡t iilm is iorced olt of thé upp€r side ot the

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

2.

Posilion lhe máonelic s1and, 9999696, and dial indi€lor, 9969876, $ lhal lhe 1¡p ol the ¡nd¡caior ¡s on top ol lh€ rock€r árm abwe lh6 middle oi lhe @ker am shait bushina

6.

Fepeal lho chéck on all oiher octer arñ

ROCKEN AFM ñOLLER BUSHINGS

'éa@

^tit

\:l

1.

Usinqlhellywheellurñiñqlool, 9996956 (tvlP7) or 38600014 (MPB ánd MPl0), lurn lhe englne unlillhe camshatt ¡s ¡n a position wheE lhe rocker añ oilér béing ohecked ¡s on lh6 b*é cicle ol lhe camshaft lobe.

2.

Make sure lhere ls deaÉn€ bélween the fockeram m l* and rhe.áñshafi roh€

NOTE To check tho ini6clor, the rccker

am

rotter

ñust

be on lhe base circlé ol rh€ camsháft lobe and

the injéclor adjuslinq

scr4

backed ofi (pr6load

TROUBLESHOOTING s

Forare rhe rcller a few lu¡ns rhat rhe oil l¡lm belween l¡e rcller bushing and shaft is lór€d out. ll thé rcll$ jams, s sli.ky or rcuqh, lhé roc*e¡ s¡m should b6 r€plaBd.

s.

Adiusl th¿ lip or lhe diari¡di@tof so $ral is hor¡zonlal lo the ce¡tér ol thá ollei Zerc lhe

NOTE Check lhai lhe Lp oi lhe d¡al p@-rensioned and can more

6.

Plácé a *éwd wrb€rwéénlhé rcckérarm añd lhe rol er Caelully pry the rorlér oui as fa¡s po$ible and nole lhe value on lhe d al

Ac^urroN l,se @e whén prykg or prñ¡ng on lhé allér ¡o aw¡d danage lo the suna@ ol the roler

4,

Pla@ lhe dial indicalo¡, 9989876, inio lh€ maqnolic sland, 9999696, añd p6ilion lhe magnelic sland as lsel 6 posslble on lhe

TROUBLESHOOTING 7.

pess lhe rollér in 5s lár posslblé. Nol¿ lhe eading on the diat ¡¡dicalol The máximuñ cléáBncédlMd be¡reen lhe oller bushing añd shaft is 0.1 mm (0.0039 inch),Itlhe cleaEnce rs qfeáter than this, €placá lhe oc¡<e. a.m. Using á blunl objecl,

6

9.

Fepeal lhe check on all olhér rocltár á¡m ólle¡ bushings as necessary.

Thermostat, Check Wilh lhe lher6oslal reñowd lDm lh€ énoina, ch@k ils opoÉlion as follorcl 1.

Chdk io

be sue thal the thermostal c oses Iully' This can b6 doné by holdinq il up 10 lhe lighr ro vefit rhal there ¡s no v¡s¡bre qap at lh6 opéning poinr. lf the ihámoslal does nol c ose Propely rop,ac6 il.

Add walef to a su¡iab e conia¡ner and warm rhé mlerro 75'c (167.F) With the water wárm€d, immefsé rhs lhemoslal in lhe waier use a p¡ee ol w¡re áttáched to lhe

a.

When replacing a ocker am, úbncale the rcck$ arm ollér bushing with clea. enqlne of. ose an o¡lcú and iñsert thé noz¿é inro rhe oil channel pasege. Fotale the follefwhile lub Éling and checklhaioil cóm¿s our on borh s¡dés or thé forrer

nq

3.

Ailer al least 30 s€conds. check lhal rhé lhermciar is sr¡rr crósc.r

TROUBLESHOOTING Now warm rhe wáter ro 1oo'c (212'D. aftér ar 30 se@rds ar rhe boillnq point,

l4r

4.

chéck lhái lhé lhánoslal has ópéned ápprdlnaréry 16 mm (0.63 inch). rr lh6 ihermoslal has noi opened, ¡t must be replaced. A good thermoslal slarls lo d6e al apprcximarery 92'c (198'F) and is lurry

clcéd

ár

áppdiñal¿ry 82'c {r30'D.

HeuÉ

Usins lhé dial indi€tor 9969676 añd ñolder 9S9S696, placé thó lip of the dial i¡dietor againsl lhe edge ol lhe valv6 dis. M@e the vdw back and lorlh lalefal y ¡n lhe diietión ot lhé iñlak¿/qhausl por15. Nole lhe measú¡ed va ue and @mpar6 it wiül lhe ac@piable w4r lim¡t specllied for lhé

6',¡ rhmosr (h€r

Valve Gu¡de Wear, Check

5.

l.

Freñove ihe oil seals fom lhe Elve guldes.

2.

Mounl rhe cylinder head on a suliable 3nqin6 sland using lh€ cylinderhead adaplef plale J 47364.

3.

lnslall a valre into lh6 quido so thar lh6 e.d ol lhe valve slem is ewn wilh lhe wlw

rd

Fepeal Step 4 to check att klw qu¡des. Replacé lhé vdw guides il lhe measured válues d@ed lh6 acc6prabb wear limit,

MAINTENANCE LUBRICATION SYSTEM MAINTENANCE Spiclal Tool

Oil Level Check when check¡ng o¡l lMis, lhe @h¡cle musl be parked on ls€lgrchd. Componénls musl bé DÓNOTOVERFILL Thé bésl limé to ch€ck oil ldél is whil6lhá ángtné is COLD (pdor to starii¡g at ihe beginñlng oi the wo¡k day, or atler lhe whicle hG sal apprd már€ly 2 hou6). al no.mál opáfaljns tempéfature (engr¡e o¡ tempeárute abow ao'c f175'Fl), oillMlcan bé checked l5minu1er

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

oill*l

For a.curár6 @dings, thedlpstL* mut be insened lully inlo rh6 dipslick tube. The lwel musl be close lo lhe FULL l¡ne (al léasl bélw€én

th6 LOw and FULL lnes) on lhe dipslick, but musr NOI6xێd lhe FULL line.

MAINTENANCE Oil and Filter Change Procedure

Crankcase Ventilation Sisteín

t2r9 EVI

The c6¡kc6á €nriration (ccv) sysrem sepaElor is ñol ¡€paiBbl€. ll lhe@ is apparenlly ñuhy opeEl¡o¡, perlom thésó iñsp€clións betore

This €nginé is €quipped wilh imprcved spln-on

DISPOSABLE SPIN-ON OIL FILTEñ

1.

lnsp€crlhe sepaBtor ¡ntet ho* ánd conneclo6 át thé wlvé cwer and al lhe sepaÉlor Refrow any obslrucl on. oil li m¡ @id!e and panicles,

2.

lnspdr lh€ sépaElor outlet hose and coñneclol Rsmd€ any obslruclion¡ oillilm¡ residue and paftc es.

3.

Femo@ l¡e separalor and alieúpt lo turñ lh€ tuóine manually. ll il d@s nol lum eas¡ly, replace the s6paÉtór.

4.

Ílh6lurbinslurns €asily inspedand clean

5, 6,

Fea$emble lhe sepa€lo¡ áñd lhe hoses.

BEPI¡CEMENÍ chanqe otland replace ollflte6 usina lhé

1.

2.

3.

B ún lhe eng¡ne u fni I ¡ornal opeÉl¡ng lempeBlu€ is reach€d. Then, shut ofl rhe enqin€ and drain lhe oi b€fors lh€ 6noin€

Thoóughly cléan lhe afea afound lhe llllefs Using lilter w€nch 9998487 or equiválenl, remm lho spin-on flters and wipo the flter mounring ba@ cl4n,

4.

F¡lleach lilterwith 1.9lite6 (2 qlans) otlhe spelliod engi¡€ oil. DO NOT all@ ány conlaminanls lo e¡ler lhe iilte6 while lilling.

5,

Appty a

6.

lnslall lhé ffieF and righrén 3/4 lo 1 lum afef the gaskel co¡lacts the b6é. Fil the cEnkc6e wllh the recoñneñded

7.

liln of clean eng¡ne o¡r lo lhe sealho gaskál on éach nw lilléi

énginé oi . ll lhe engjne is equipped wilh a BEPTO u¡lt, add on6 additionál quafi.

g.

Starl the éng ñe ánd ch€c* fo. leaks. Run lhe enqine for approximaiery fve m¡núes, thén shul it of and ccheok the oill@1. Add

NOTE Usé of ánylhing other than genu¡ne MACK titl€6 ñáy €us6 damage and vo d rhe engine MranlyChange liliers amording lo lhe rccomñended

lau[y operalion @nlinues, codhue lau]l lracing wilh Guidéd Diagnosli.s. ¡t

MAINTENANCE FUEL FILTER REPLACEMENT

FUEL FILTER REPLACEñIENT

NOfE

FuelF¡lter Change

ie buildup or tuel Mxing shich €n luelfilt€6, il may bé necessary during 4iremely @ld wealher to rcduce thé limé or mileage inleNal belween luelflter chañaos. Becaus€ of

[231 BA]

cloO

FILTER DESCBIPTION Two

lilleB ensurelhal cean, waleness tuel

rcaches lhe €lecl@nic unil inioclors. Oná is a lu |-llow fitér, thé olhér is a wáler sepahtlno 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 war€r s6pará11ñg preiiltef is in the'sucllon side' ol the luel circuil, ll is a spln-on lype wllh one end ol ils @sing lhréáded lo !éceiB lhé cup.

Thetullll@ main tiller

is on lhe hEssure side" ot lhé circuil. ll is álso an éasily r6pláced spiñ-o¡

Be carelul lo pre@nl lore¡gn matter ol any kind ircm énlá nq lh€ lillác du rg5eruice,

lnsralLn tu€llillers dry w'térSépár.i¡ng PéF¡herReplaceme.l To replace the waler separa¡ing pre-lilter:

1. 2.

Iilter fhe €sing complelely enclGeslhe lller elémenl. This li rer is Bred ár 3-s micons.

Disconnecl the eleci¡¡€l

€ble.

Make sure lhe lllter casing is thoroughly 6leaned. ll nor a¡@ady done, wash rhe afea abund thófit6rñóunting adaplé! wilh a su¡lable elÉ¡n and blów dry with

3.

Wüh a suilable @nlainer ln place lo collect spillage, opén lhe lifling and dEin the liltei

4. 5.

UnscÉw and €mo@ lhe Mler 6up.

6.

Usinq afller wBnch, em@lhe fne¡'lon thé nounliñg bá.két and dis@rd il salely. Apply a thin film ol clean engine oi¡ to the sealing gaskei ol lhe ñew lilt6r

7. Scr4

lhe nN dry lilt€¡ in da@ and lighlen an addllionaL 3/4 lo 1 lurn by hand aller lh€ g6k€t conlacrG the ba*.

NOTE Alt€r lill€r inslallalion, operate the háñd p¡iñ6r to 1¡ll lhe tuel tllteG b6loré anámpli¡g to starl the

a. 4 Dr.in Assmbt

Sc€w ihe water cup inlo th6 t [6r c4ing,

MAINTENANCE Fu¡l-Fl@ Ma¡n Filler

NOTE fhere is a new styte prej¡ner with a repped4@n diamerer ar rhe botom

To

lirte. The ¿adi¿FsMe lille¡ has st€ight sides with a la€er bottoñ diám6t6r which rcqun6s an adaple¡ to atiach lhé luelÁ@tér sspaÉtor b@l lo lhé li[er W¡en reptac¡nq ihe pB¡ous stÉ]ghtstded tiller with lhe cwe¡t slepped-down @rsion, the 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. It

nse$ary

of rhe

épla€

th6 tull-llow main li¡ter:

L

Maks su@ lhe liller esing ¡s thoóughty cleaned. ll nol ak6ády done, wash lhe a€a arcundlhe liller ñounting adaplér wlh a suilable elrenl a¡d bld dry wlth

2.

Put a suilable conlainer in p áce to coltect Using a lille¡ wrench, remde lh€ ñltsr cdinq rom lhe mounlinq brackel and

replaco ¡he lul -flow main lihe¿

follNing instruclions. Connécr lhs €l€ct cál cáb 6. Slal lh€ €naine and run al idls lor fiw m¡nutes to fll lhe l¡llef wi¡h tuel.

Apply a ihin lilm ol cl€an 6nQin€ o¡l lo lhé sealing qasker ol the new lirrer

See lh€

11,

Báphc;eñ¡ :

5.

Scrw lhe n4 dry llller ln place añd tighlen an addilional 14 lo 1 lum by hand aner $e 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 cmrad Firk' wrcn.n (a€ihnE

Coolant Drain Outlets Exlra oull€ls provids comni€nl dráin silés lor use düing mainlenan.e and olhef pfocedures

Coolant Filter The 6ólaft lilter áttachés to lhé back of rhá c@lanr pump housiñg. lr fesembles a spin-on oir lill€r The lill¿r elenenland c6inq a@ rla@d

NOTE For Auslralia, engines are c@lanl lillei VCS.oolanl

REMOVEAND REPIACE

1,

c¡ose the shut-oll Etve on the cootant puñp

NOIE positon.lhe pin on lhe shul-olf Place a suitable @nla¡ner 3.

bdM

th€ fltér lo

li[er wench J 4€061 or equivalént, unscrew the I ll€r and dlscafd ¡t salely. Usinq

Apply a lighl l¡lm ol coolañl on lhe lace ol lhé

5

Scr4 the

néw liller on lhe threaded n¡ppte slendinq lbm lhe mouñtingfange. 6. Usins lhe lillérwGnch, tiohren üe iilter one lu I lun afer lhe qasket 6ñtácls rhé bsé. 7. Opén lhe shul-olf val@ on ths coolanl pump

Ch6ck tor any coo an! leaks.

MAINTENANCE DRIVE BELT REPLACEMENT AND TENSIONING [216 AA] Genehl lntohation The seryice lilé ol lha múlli-qod€ b6lls is 6nsid6fably impfo@d def otbd systems and arlM ihe lse ot hlgher hoFepowe¡ cooling lans, All MPB enqines a@ equipped wilh mu[i-gmoB

ln thá dúal nulti-gtuo@ drl@ bell afE¡gemenl, thé lan drire and coolanl punp a@ d.i€n dicclly foñ the c@nkshali pulléy by á 10- or 12j b

mulu-qfoove bell- The aliefnator and lhe alr conditioning @mp€ssor (il equipp€d) ar6d €n ol lhé cankshalt pull6v bv a six rib multi oroo@ belt (F¡qlre 72). Tao automalic lensio¡e6 are used. one lor lhe lan dr¡vá a¡d ona for lho

The lowe¡ tensioner tor lhe fan ánd @oianl pump is mounled on lhe c@ ant pump housing. lh¡s lénsioner appli€s its load mrrrercl@{a/be, The upper lens¡oner tor the állornator (and El g€Enl @mpE$or it $ equipped) is mounled on rhe áLl€mátor b€ckéI. Thá lensioner applies ils load iñ a @!ñleeticl lse dnéc'/.ion.

Aulomatically Tens¡oned System INSTALLATION Swing lhé l€mion$ to lhé tuLly sprung posilion and wlihoul hrce, us¡ng ben lemloner iool, J 41392, pla@ lhe bell overlhe pulleys, Oo nol álLow lhé lénsion$ lo snáp agáinsl ils slops. Do hot pry the belt @r a p¡lley.

TENSIONING No lensioning adjushenl is ¡equired. On@ lhe rénsionér b feléséd ága nsr rhé be l, lhé bélr is llghiened to optlmuñ tens¡on áuloñatiÉl¡y at all

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

I 2. LcF (¡¡rA AGr¿iB)

REPAIR INSTRUCTIONS, PART ENGINE REMOVAL

sÉdd

Tools

f

REPAIR INSTRUCTIONS, PART General lnstruclions

NOTE B€lor6 reñwing lh€ 6ngin€, máké equ¡pmeff a€ ¡nspecled lor salely

1

3.

Using

4.

Using a suilab e li ler wrench,

5.

t sing the molantlillé¡wench, J 48061 or equiwlenl, €move lhe oolant fhér.

úe oil i lrer wrcnch, 99934d7 or equi€l¿nl, €nové lhe oillillers.

€mde lhe

6. Oiscoñnecl the intet áir heater il pr6sent. It

NOTE

Using NC rel geranl e@ery and recyc i¡g eqúipde recóvér bé

It ls qood práclice lo sleam clean lhe engine

lo remove foad g me, ge6e and oil belofo sla.1ino Mlk. stéáñ cleánhq lhe eñq¡ne and engine área allos more delailed insDetion and inprcved wo*manshio

oiscoñnel lhe ¡/C compreser diMhálge hGé al lhé ónné.ion¡éar

Prevenl moislu@ l@m enlé nq lhá ai inlaké syslém. It mo slu.é enl6fs rh€ systeñ, make súre rr rs fem@ed (dr¡ed) bebfe rhe engine

Discóñnéct th6 A/C lin6 at lhé Locale and d¡senqaqe lhe elecla€l connéclü l@m lhe binary pe$ure sitch on lh€ rec€¡v€r/dry€L

Prryern lhe sleam cléáning nozlé lrcm sp6y¡ng dlreclly oó any eleclon¡c @mponenls and @nn*tio¡s. Avoid the use oi any causlic or

.

l*l

2.

3.

Disconnecl lhe bafiery neqalive (gound)

Posillon lhe vehlcle on a llai,

Loóalé an d disongágé lh 6 €lé.t cál con¡eclof lom the lorpésufe cutoul swirch in rhe ¡Jc fetiqe¡anr rine.

@r@iv€

suface wilh ámple mlk spa6 abund lhevehicla. Aop y lhe pa*ino b@ke and bl@k lhe wheels io preveót lhé veh¡cle lloñ noving. Obserue all slely p€.aullons.

1

lhe veh¡cle ¡s eqúipped wlth air

S.

Di6connecr and €mo@ lhe upper Edialor lube lrom lh€ enginé.

L

Dlsconñecl thá cab héalé¡ and luel héaler coolanl relurn linés lrcñ lhe rad ator ls€r

Dis.onnécl and emore lhe lorer €d¡ator 11. Réñov6 lhé

in el lube añd

F¡emow lhe charqé an coolér óullel lube

Removal

l.

RémoElhe hood On cab oler enghe

2.

Place suilable conláináre beneaih lhe e ngine and dfain the oil and coolanl. open lhe coolanl dEin Élws ¡n lhe block and the

NOfE ll aÉilable, use the coola¡t extractor, DBT2V700, €mM @olanl lrcm lhe engine

lo

.hálgé ai c@le¡

13, Dis@nnet the Ediator

tan if et€clmnicatty

NOTE The adialor and inler@oler assemb y is heavy and dificu l to handle. Próvide a suilable lilllng device a¡d a heLper to supporl ir salély dur¡ng

REPAIR INSTRUCTIONS, PART 14. Fem@ lhe

radiator ánd charq€ án

mobt

16,

It equipped, rem@ ihé éxháu$ bÉdiet f.om lhe fwh@l housiro.

NOTE

NOTE

assembt ls h4W áñd dificull ro handl¿. obtai. ssistance to ¡t salely dúdnq

The fan

15

1

P@vide a conlainer to collecl powér

17.

Bemove rhe la¡ .5sembly.

Bémov6 thá powé¡6léé ng

stéé ¡g

hces.

Disco¡ntrl lh€ dhálsl syslem lrom the

NOTE

D¡sco¡nect electrl€l @blgs or wir6s

fo preEnl lluid leaking t¡om lhe assmbly, slore il ho¡izonlally la.é ddn (hub 'an llang¿ up) or

Di€connecl or rem@e a I olher ¡lems attáched to ihe l@e or @b lhal rculd plMnt eng¡ne émML such ás:

l) tkih"

W

q.

a : .-__-_J_

_]_

l \_!\\_J

Hydaulic hoss or lubing

Ac^u¡toN

('

BqJ673_vl'cou.F¡nonrcft3¿mblysbhge

Cow the @|ve su¡table .lolh ot and debis f@n

ñé.Í¡aniú

and gear ta¡n w¡¡h a

stnlat @wríng

qlehg

ta

p@ent .litt

the enake.

NOIE ProvidÓ a tansmissjon ja6k lo supporl trté lEnsmiss¡on when disonnécted lom the englñ6.

REPAIB.INSTRUCTIONS, PABT 22. wilh lEnsmisslon

Femo@ i¡s scrM that s;cuie lrie rear engire bdcké1s ló rhe fame

jad< ¡¡ place, r6mwé lhé srews afla.hing ihe lEnsmission to the

a.

ll a manual lEmmis6ion. make @rtaiñ the clutch linkaq€ and bBckets have

25. Remove lhe bolts thal $cu€ t¡é lont enqine lo lhe fame cGsm€mbér

AcaurroN

ll a¡ aulomalic tránsmission, make certa¡n ihe torqúe coMrter áftóss parel and rhe rofque conwrter ha@

AcaurroN Oblain a helpet and prcvjde a gina l¡hinq t@L J 47o3a, eng¡ne aleu dvinq túoval,

as

1

While remv¡ry the eng¡re, Mlch lot obs¡tucl¡ús lhal ñay ints¡ére, sudl as engine and clÉs6¡e @np@enlq bÉ.kels, .larrps and olhet parE sü anaúeó lo the eng¡ne. Fa¡turc tó heed lhis autiú nay rcsúll in .évarc danagÉ to

lha éryke and other

26.

@npúúts

Ushg the lifting ddicé ánd lhe aid oflhe helpe¡, emde th6 gnqino lrom lhávéhicle.

23. Atach lhe engine lifing

lool, J 47034, lo lhe énglne. secuélhe éñgine lifting toóllolhé ro¡r ol lhe cylinder head and to the rcar at lh6 llwhe€l housino.

ftú

had

aI bofts ú.1 p¡ñs in lIÉ hlting lool * @teuy 'lE@ posft¡one.I pt¡ú to Movitg thé engin.l¡ú tlE dta$É. Ft¡tute to ptope y lÉlal a bo¡.s an.l p¡ñs ol lhé úEítu Lifting l@l

@ ¡*ulf

1n

peBond lnluty ot tlealh.

túove cylkdet héad ^cautroN ü.Lte that srcws holdkg tha

Belúe a¡temptkg to lha bla¿k,

¡he ¡he

agalnst lhe liniDg geat Nunl¡.g p¡aÍe ha@ b@n En@ed. Failwe la h@d lh¡s may esul¡ k sewrc danage lo lhe engine and o¡het

úúiú

REPAIB INSTBUCTIONS, PART ENGINE DISASSEMBLY MACK MP8 Euro 3 Engine [200 EAI Spec¡al Tools

dd

o{'6f vadoug ussg (aÉiauo)

ui.r HokrDdñ

foors

(E€$ ia)

ud hj*,ü PRMim srews (Eser d)

unir

Inieb tu,e

seannq pruq {Essnrian

0 Dorers

{Lufnq

roors br b¿

rdnq G*f

)

1

--

REPAIR INSTRUCTIONS, PABT

cffihar ufrre

Baf

{E$adial}

FoddshaftAssmblvLihingT@l

camcapuamoElTool'8.{!h3|d6

EnsiE Bdhq r.or

(k.diaL)

1

REPAIB INSTRUCTIONS, PART

1

oy iñdef Head úlrinq ro{t tEssedtar)

nr

@1

ú ii'

H€lr.Dúry uni hiádof

Eisine

sbd

Pur

ar

adapror P are tava rab é)

cÉnksrrafi Liftins r@r

(EsdiaD

REPAIR INSTRUCTIONS, PART General lnstruct¡ons

[2r0 EN] This $clion includés s¡ep-try-slep procedu¡e tor dls6embly or tho €ngine. AÍ4 clean¡nq compo¡enls, slore them wh€r€ lhév w ll cmain clean unlilneeded lor reasseñbry.

1

Mounling lhe Engine on a R¿pair Sland I2OO

EBI

ll the onqiné is 10 be mounled oñ a r6pai sland by means ol a mounling plaie atached to lls tefr side, l¡e mounl¡ñg sudaes mlsl be clear ol

Thá s€quéncé n wh ich conponents are removed Ílom the enqine may ErV d€p€ndino on lhe lvpe ot engine repair stand used. Ihe épan dañd ldenlifed ior lhis pr@edu@ uses a mounllng plalé attachád lo lh¿ l6f side of ihé éngine which équnes lhe feñ@l oi @rlain lelt side compone¡rs ro pfovlde space bf anachment ol lhá molrtng plale, This musl b€ don¿ p.ior lo mouñtiño the éñoine on the épai siand.

Fa¡lure to ñollow the sequer@ of opMrbns may rcsull ¡n danágé to @mponénts or

tlprár

REPAIR INSTRUCTIONS, PART lñ ordár to atlach lh6 mounlinq plale, J 48662, the ¡ell s¡de ol lhe engine, thé iollowiñg componenrs musr be femoved il presenr.

lo

Locen lhe luél liné banjo liíings. Femore the banjo tlnlngs, clamps ánd the ro¡l@ ng tue line fom lhe side ol the eñginé.

de

l. 2. 3. 4-

.

Femde lhe dipsuck a¡d o¡llll plp€. Feñde thé cankcásé wnlilalion (CCV) sepafalor and tub¡ng.

.

el€c1ri€l cón¡scroE on lhe lsft sidé ol lhe enq¡¡e lo lac¡lllale fecoóneci¡on upon

.

Tag thé

Unlock and femore lhe hafness end @nne.lo6 arlached lo lhe EEcu. FemoE the scr€ws fom the harn€ss €láin€r clamps. The¡, push lhe conneclor locks i¡ward and olale oulward lo diwnnel bolh wnino ham@s€s fDm lh€ EECU.

1

. 9, 10.

FuelElurnline EEcucoolins plár€loji ler valve hous¡ng

FuélErurn line heád (ar -cylinder valv€ housirg )-lojill¿r Fuélsupplyliné lifter Blve housl¡g-lo-cylinderh€ad (ál r¿ar)

ló

-

lin6

Fuelsupplyand relurn pumpro-Íiher Elve housing

fúel

Femrye lhe iiler housing a$embly,

F€mde

the @oling plate and the 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

Cylinder Head (valve) Cover Removal [211 JBI 1

^c^uÍtoN

use @e to a|oid dañaging lhe letñkal pks. Unlock ánd sépaEte lhe exlernal wiring hamess @ñneclo6 al thé ous junclions

ú

Rém@ lhe clamps hotd¡ng the hamé$ tó nemow lhé laslene6 securing the w¡r¡nq har¡ess block ló lh€ cylind$ block Posillon lhe harness block and l€ads oú-of-way,

NOTE ¡ags ánd conlainére lor collecling ddináqo al €ach ol th6 fol¡owinq

.

RémoE lhe lasle¡ers and remove lhe cánkcase vénli alion pipé.

BEPAIR INSTRUCTIONS, PART 2.

R€mm and sl aside lhé sp ng-loaded scr4s atiachhq the cyllnder hoád (@lvél c@r lo lhe cylinder head.

5,

A1

1

lhe top ol thé cylinde. head, disnnet at €mh unir.injector

úe wning hames

F4!É D

-

Disconnecrins

H¿ms

rn'€dor

ar

"nn

6.

lr so equipped, disonned lne harnes tom lhe enghe b6ko conlol ElB,

7,

Cullhe cable li6holdngthe harn¿ssro lhe cylind€r h€ad and lhe e¡g¡ne b€ke control

3.

Caretully pull lh€ hamé$ though the hoté ál rhe lon¡ ol lhe crlihder héad and emove tho hamess lrom lhe engine.

Flqorc77_cyn¡ddH¿ad6v¿r

3.

Femow lhe

der

lom lhe cylinde¡ h@d.

Engine Wiring Harness Removal 1723 KN 1 , fo iacll¡lale @n¡eci¡oñ at reassembly, laq all ham€ss mnne.!o6lo the €rious enqine

ensó6

b

ánd compon€ds pnor d¡sconneci¡ng theñ, Alsq note thé routing ot lh€ ha.nés and leads tor proper installatloñ

2,

lf not alredy dohe, unlocl and rcm@lhe haness end connecloB atlached to rhe EECU.

3.

Unlock ánd sépaBle lhe connectoB at ihe Érious sénso6, enoi¡6 componenls and

4,

Femove lhe clamps holding lh€ harnéss to lhé cylinder¡ead and bl@k.

REPAIB INSTRUCTIONS, PART

1

Timing Gear Cover Removal 1211 AAI 1 . Femde lhe mounl¡no last6ñ6r and cmove lhecamshatlpcilionsensrlbmtheliminq

2.

Remove al¡ slÉps, P+lañps and oiher @laine6 used io rerEin harnesses, oil lines ánd coolanl lub6 lo lhe rear of lhe englne. Thls wll¡ allow lhe bÉckol al lhe rcar ol lhe enqine lo be Émded.

5. 6.

3.

Femow the suppon backet tasteneG añd reñóÉ lh6 réar supporl bGcket Remd€ thé lcrws aftaching the tim¡ng gear cder to lhe timiñg gear mounling plale ánd cyrinde¡ head (Fioúfe31).

Beñow lhe 6Ér from lhé engine. Feñow and disard lhe élslomér s¿als

BEPAIR INSTRUCTIONS, PAFT Camshatt Gear and Vibratioñ Damper Removal t213 DEI

NOTE li lhe eno¡ñe is not betño mmplél€ly disa$embled lor deñaúl ahd only lhe cánshall is to be rcmryed, cEnk lhe enqine manually (usins r¡¿ énginálumingrool 60800014) soihat the camshaft is positioned ai top d6ad cenler fiDc) by al¡qninq rhe TDc mark onlhe €ñshaft wilh lheliming ma*s on lhe No 1 camshal

1

Bocker Arm Shaft Removal

'

[213 LPi

AcaurtoN On ehgines l¡t¡ed wi¡h the eng¡ne bake, úse ntubet bands to tutak the p¡stús wnhk he rcckeF rhe ña¡d1 betueú lhee pistons and theh tackas must be nain¡aked. ff lhe t@ket shafl ¡s Io b€

d¡sasmbld.

the

añet al rccket atn assmfly mst bé nakra¡red. Make @ña¡n lhe @ls aE keü tóge¡het. MarE cdlain the rccket arns are identi ed so they en be Elútred lo hen oiginal Fajlure to heed th¡s @ut¡on ñay esúft

k

sevete

1. Remdelhe ongine brake oil.ontrclvdw oll tlow adapler (ir so equipped) riom tie

1

.

or

FemoE thé lasl€nére securing lhe llb€1io¡ damper and

ۖshati

gear to lhé camshait

2.

Remove lhe vibrá¡on dámp$ l¡om lhe

3.

Remow lhé gear lom lhe cámshaft.

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 2.

Rom@ thó scr€m ánd six eng¡né brake plale spnnos (if $ equipp6d) ánachéd 10 thé camshatr beafins caps,

1

NOTE Pislons and @ker arms aré and should nol bé mixed

4-

Beginning al lhe ce¡ler camshalt beadng cap, begin l@se¡ing lhe Jasrene6 al eaoh cap iñ siagós, tollNing lhé sequene shún in Figufe a7 u¡f¡l all lasteneb aré cómpl€l6ly loósé, Oncé loosen¿d¡ @move

*nly

^caurtoN

The laslereB tusI be loo@red eveñly, ln stages and in @qu,@ to ptevat búd¡.g ü danagiñg

(1Fe0 3.

(4tuD

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

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

fie

REPAIR INSTRUCTIONS, PART

1

Camshatt Removal [213 CH]

-*fur-M Nj

S* S+ | 2 Fodc' a'n shar'

tr€E9EFae6FE h¿ r;-

tv !

S¿ Valve Yoke (Brldqe) Removal [213 NVI

¿

-

R.mvins lbrveYorc lB dsé)

Tag lhé yokes lo lac¡litale

reassembt in thé locaiions frcm which they wee Émoved. Bemow thé yoké6 ard sel lhem aside.

lrl

camhafi Lo*er

¡--r

h'¡nq

rr-

J-

-IL-

ri-

| 3 chshd upPf I cáF

Bea¡in,

The cañshafl ¡5 h4vy. Do NOT attempt lo femow the camshall w¡thout thé hélp of an .ssislant or the üse ot a suilabló l¡ftinq devicé. Fa¡lu€ ro hed thls warning may resulr in pefsofal injufy and componé¡r

1. 1.

|

M f--ñB-.-""üf h:-*:q

2.

F¡sorá Se

eó

Máft lhe camshatl beariñg €ps (ir nor laclóry márk€d or idenllied), so that they can be Éinsialled in the o¡ig¡nal bearlnO Rémove lhe remainino lasle¡eF {oulb@ld sel) hold nglhe upper beari¡q caDs in pla@.

REPAIR INSTRUCTIONS, PART 3.

Usélh6 cam ca! cmMl lool, 85109980. in comb¡nallon wÍh slldé hanñ6r¡ 9990013, lo femove lhe upper beanng caps. fhé uppér bearing caps and l@er suppo¡ls (saddres) m6t bé k€pr in séls and i.lheir respaí@ localions at reas6mbLy.

4.

Al€ch lhé riiling bar, S5109034, ro rhe €mshalt bá¡réén lhé lobés and €¡étully Éno€ lhé Énshalt fbm lhe cylinder head.

6.

1

túi

Remove the bearinq ins¿ns {shérls) üe camshafi lorer bearinq suppórG {saddles) andlhe upperbea ng eps. hspet ihé bea ng i¡séns¡ béa ng supporls and 6aps lor wear or danagé. R6plaÉ ú16 parrs ir excssive wear or damaqe exlsls.

NOTE

5.

Ca€lully lift lho c¿mshaft and €€l il aside in a secue local¡on bl laler inspe{flon.

LcaurtoN ll the @ñshah

mshaft

¡s

hol belnq reda@d, stand the

t

on and and stute ¡l ia pla@ t sL.Ege. Use carc to aeoid .latugé Lt tE guida

This prccedure preslnes thát lh€ camsháf lower bearing suppo s (saddle) aE in pla@ on the crlinder head, h6ld ¡n posilton by guide sleeves. li removed, lhe supporls ñust b6 mafk€d añd @luned lo lheironginal local¡o¡s alonq wlh lhé 6spectiw béa ñg .aps. ll ¡eqlired, fem@ thó beariñg súppons usins a pry bai Rem@ the No 7 reamosl usino a sólt-fac€d mallel

REPAIR INSTBUCTIONS, PART 3.

Unit ln¡ector Removal

1

Renove lhe lasteneE scurino nie iniecto.

1221 GP1

/AcaurtoN us a sleel tuapér or a sreel w¡té btush lo clean ¡nje.:lot l¡ps. u@ deaning kiI J 42aa5. Do NOT

F¿ilúa to hée¿ thk @u¡ion nay

Bult

in

evéE

^caurtoN

Use hand toals to túove the klectatt Do NoT use ait trds the ¡rja.tot pu et shak. uskg an laols nay rcsúl ¡n damoe to canpmnE.

d

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

1.

I

hjedo' Hord Dokñ Yob | 2 unl ñJeróf

fho¡oughly cean aroundihe unir ini€clors and chéck lo ensufe thal lhe engine ls coñPletelY dráined ol lué|. Tag lhe injectoG wilh lh6 cllinder number belb¡e lheir removd lrom the cy inder h6ad. ll new injecrorc are nor belng insralled, ir is esseñtial lhal rh6 onginal injecloB be €inslalled ir ihe cy lnde6 lDm which lhév

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.

5.

thé inFcror cannol be remded us¡no ihe pry bar, ¡nsialllh€ heavy.duly u¡it injecto¡ pullér, J 43922, oñlo á unl ini€clol Posilion lhe pulJet lolks i. the grc@s on the únn lf

inteclor Secu16ltu pullé.by slidinq the lock collar down over the lorks holding lhe unil injeclor Rémove lhe inlector lrom th6 eyllnde¡ head bore usifg hand t@ts. The iniectors musl be lifted our w¡th thet

REPAIR INSTRUCTIONS, PART

1

NOTE

FieuEe5-unn hj..¡or Pun.4J 13s2

AcaurtoN lÍ d6ss¡B @nbusrian ledkáge has Ésulled ¡n the @ppet sl@ve bekg sluck-last ¡o the un¡I

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

7, lnse

lhe ¡njeclor inlo a poleclion slerye, 9904249.

jnjector ¡ry a¡bü, thé mit kjBctú tust bé replaced. The ú¡d¡lión ¡s louñd when the un¡¡ ¡n¡ec¡q ¡s Mowd and the @wq sbeve @n6

6.

Remore and d¡sfd allinjeclof nozle gaskers (Jlár washére) flom injedor nps or bonoms ol copp€r slewes. Also, rem@ and dis€rd arlOjings and yoke screws, Ns iniéc1or nozl€ g6k6rs (flal wsh€c), ñgs añd yoke afe fequifed tor

o

*f4s

FrquE s6

-

hiedor Pf.@ióñ srééE, 9.@4e

A. Í ñ6

inj¿cror is nor beinq installed ¡mmediately, ¡nsla I lhe proieti@ plug do lhe unil i¡jeclor bore oa the .ylinder head to pol€.t it lrcm debr s.

NOTE nozlé gskér oal washe4 had been used lor lhe seal l betw6en th€ inj€clof mppér slese and rhe injector, discafd rhe used gasket iññediátely after lha inj4lor s rém@d A used lf án inj¿ctor

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

FEUE

e7

rcraline h¡dor BoE Pbtéoitrc

Ptuq

REPAIR INSTRUCTIONS, PART 9.

Rep$r lhe prccess lo reño@

rh€ r€m¿ining

Starler Removal 1272

1

Exhaust Pressure Gove¡nor'(EPG) Bemovál 1. Disconnecllheánsupplylinetotheéxhausl govBmor end 6over

DHI

ffina.

The $aner is held in place by nuts es¿mbléd over 6rud6 installed ar rhe fonr rlghr sidé ol lhe

fhé éiártéf

¡5 héávy. Do NoT

áttempt lo

rcnove lhe sl¡rter rithout thg help ol .n a$¡stant or the use ol a sultable llll¡ng ds¡cé. Fáilurc ro h€éd this wah¡ng may rosult in p.Éoñ.I injury .nd ohponénr

L 2.

ll not ákéady done, disconneot lhe wú¡¡g ha¡ness ffoñ lhe starter ñólór

Lo6en lhe nuis iasieñiñg lh6 slanér b lhe

2.

l2

a''.hiñq Nub

lhe slarler

fóh

lh¿ énglne

Femove the exhaust clámp iróm the Erha$l Pr€sure GoÉmor (EPG) housing

REPAIR INSTFUCTIONS, PART 3.

Loosen thé clámp and r€mm lh6 pipe iom lhe EPG hoúsinq

4.

Rámow lh€ q6ke1b6¡réén lhé EPG hoGlng and éxhausi pipe.

dhá@l

5,

1

Separate lhe EPG hoúsins rron thé eihausr pipé and ubochaEer; lifi a¡d remólr th€ EPG unil from lhé engine,

REPAIR INSTRUCTIONS, PART 2. B€mm

Turbocharger Removal

lhe

1

lurbehúge'

orl supply

1214 SCI

The lúrb@hárEér ¡s hdvy. Do NOT attempr ro rcnde the turbochárgér wirhout the help ol an ass¡stanl or the úse ol á súiláblé lift¡ng dd¡e- Fá¡lurc to hed th¡s warn¡¡g ñay Esult in péraonal ¡niury ¡nd @nponenl

/AcaurroN fhotough cleañl¡ness ¡s rcgu¡rc.¡ snall patliclés

@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 @n

handlkg ¡he t¿ó@haryef, A¡@, ap the aqeninss to prcvent @ntankation.

1.

FemoÉ lhe clamp t¡om lhe EPG the lurbocharq6r, f nol p@viouslv

*:.--=

o¡l

lke

FsuE ro5

3.

-

Túrbo oir

supet lins

Femovelheo rerurnlne(l@et.

the

REPAIR INSTHUCTIONS, PART 4.

Bemow lhe lorer oharge an pipe lom lhe turbocharg€r and midpipé suppon hslener

5.

RémoB lhe luóocharqer llange moun¡nq

1

Exhausl Mañifold Removál

dhaust man¡lold consisls of thr* cást¡ngs th.t ar€ nor cbmped logetñer Thee could séPa6lé únéxPetéd,yvhén lhé anachlng screws arc rem@ed lóñ ths cylinder h€.d. To p¡event peFonar lnjury and damagé lo thé parls, iáké cáE to @ntrcl all pl*es unüllhey can be sepaÉted safély. Thé

l t + t t ! 6.

Lowd ñe turboc¡¿rg¿r áway from lhé má¡ilóld and lilr ó!t.

dhácr

2.

Sél lhe 6pace6 and erews áside for

3.

BéñoB lh€ dhaLar nanilold fom the

4

Bemow and

5,

lnspecllhe qhausl ñanilold. llrhe@ are signs oi efiausl leakage belw€€n lhe @sl segmsnls ollhe manitold, €place lhe seals.

disad

lhe qhausl ma¡iiold

REPAIR INSTFUCTIONS, PART Oil Filler Valve Housing Removal t2f

I

[215 SW]

Póvid6 suiláb e €$ and coniaiñers lor collect¡ng o¡l dÉhaqe al éách stéD.

.

Rémo@ lhé scrss and €mow lhé oil lube lrom lhe fonl ol lhé oil iillor housing and rh€ c@llno ducl covei oisÉrd the oaskets.

ñsuE11o orfrb¿(arHochsFfo

2.

1r 1

-

of

ftb

(ar Houane

NOIE Pbv¡de s¡itáb é cóntái¡á6 to @llecl coolant thal mY es€Pe dulng removál pm€du@s.

1. B€nNé thé la6tene6

and €m@ lhe coolánt pips (byp6s) hoGing rrom lhe .ylinder head, D¡scafd the fanqe seál dno.

)

Rsmov€ lh€ scr€re and emore lhe o¡l lube belween lhe valve hoúsinq át lhé Bár and lh6 ducl cder Dis€rd the gaskéls.

FisuE

3.

Coolant and Pump lnÉt Houi¡ngs

EPI

NOTE

1

1

ñaD

Fem@ lhe last6n€6 and .emore the oil t ller valve housino lrom the cylind€r block.

FIsof.11

2.

2-upFc@r¿

Prp€(Bypá33)H.chq

Remove lhe kf6ws and emove the puñp i¡larhousing at the reár ot lhs @otañl pump, Diserd the llanqe seaL inq.

REPAIR INSTRUCTIONS; PART Cooling Duct Cover and Oil Cooler

1

2.

Cárérully emow rhe

3,

Femo@ and dis€rd lhe

Removal

edlom

qó@ i¡ thé.ov¿i D¡ead

me pérr'ma* the seal h

[215 DW 2r9 EP] 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 To

COOIING DUCT COVEE REúOVAL

1. Fem@

the c@ting duct cover t¿s1eneB and em@a lhe ducl (;ftr ánd óil cool6r as6émblv from lh€ cy¡indor b¡ock.

NOTE Nólé lhé loÉtióñ óf all fásteñeb for @ssemblyj diftéreñl lenglhs are used.

c@rlo

pump

REPAIR INSTRUCTIONS, PART

1

OIL COOIEB AEMOVAL

L

Place the c@ling ducr cove¡ asembly on a .¡ean @lk sudace. Remde th6 hsl¿ñ¿rs and emm lhe tlow plale @ef¡ñq lhe oil

Drive Belis and Fan Hub Femoval [232 HB] R€mow lhe drivé belts, idle6 and hub bracket froñ the lbrt ol lhe ongine asto lw6;

2.

3.

BémoB lhá oil óoler lasleneE and €mow

1.

Renove lh6 tasrénéB md @mo@ lhe ian dri@ and coolant puhp beÍ tenslonerlmm lhé coolanl pump housing.

2.

Remove lhe hsieneG añd reñovs lh€ ác6s$ry drÚé bell lensioner lfom thé

3.

Femove ánd s6l as dé üé dr

théóoerlroñthéljML

E

bélts.

Remowlhe oil.ooe¡sea inq oiing gaskels bet¡rc6n lhé oil cooler and cover

| 1 ¡{esofy o' É Bdr

I

PunD Be[ fens]onér

4. RenM

thé f¿st6ne6 and l¿n húb b€cl@l

lnlet Air Preheater/Spacer Removal t291 DRI

NOfE Mai( lhe @ble l@lions [email protected] ensure @recl inslallaton ar ¡é*sémby

3.

1. Femm

the rásténé6 @cunng fie inlel spacer or prehealer, f e equipped, adapl6r, r. ih. iñler má¡iióld.

R€mov€ ánd dlscad lhe gaskét bghv€6n lhe spacef brock or prehearef ba* and rhe inler

Crankcase Venlilation (CCV) separator Removal

1.

ll ñol al€ady done, loosen lhe clamps and disconnecl lhó i.lel and outlót hosés at the ccv s€pa@tor Ron@ ihe feiaineF and

F'uE121_[&río|dl¡ldAd'Pbl

2.

fon ihe lnlel air equ¡pped, €m@ ail manilold. pMf and gound €bl€s lfom th6 ¡nlétá¡r p.eheabr and r6m@e the p€healer trcm Femow lh€ spácér block

o( il $

2. ñem@ lhe hsleneF

and €moE ihe separalor sséñbly lom lh€ cylinder bldk.

REPAIR INSTRUCTIONS, PART Fue¡ L¡nes and Filter Valve Housing ll nol d@dy remo@d, remore the luel li¡es and ilter valve housing usinq lhe lollowinc procedurc.

1. L@en lhe luel llne banjo finings. Fem@ rhe b¿nio liriings, (lamps ¿ndlh€ foltowing rhé léfi sde olrheenqrne.

luellnes fom

NOTE Bé

sue lo capture the banjo séalinq washeb ánd

hollow

. . . . 2.

s€ws

while rcmoving lh6m.

line

Fuelráum EECU coolng plale lojillor valve hous¡ng Fuel ¡elurn line

-

cyl¡rder head (at

fonl)-to lill€r valve housing Fuelsuppy line lillervalve housinoro cvrnd6¡ héad (al rear)

-

Fuel supply and Elum lines tuel pump-loJille¡ válve horsing

Femovelhe lillerEtuá housinq

1

REPAIR INSTRUCTIONS, PART

1

EECu and Cooling Plate Removal

L:-

ll noi akeady done for mounling lhé énginá in lhe epan dard, or it lhe e¡g¡ne is nol beiñq complél€ly disssembled lo. o@rhaul and only lhe EECU ¡s lo be rem@d, t€me üé EECU lollowing lhé p@du€ bel@. 1

.

Unlock añd remwe lhe end @óneclors aftached to thó EECU. Fémove the l@m lhe harn6s éláin6r clamps. Then, push lhe @nneclof l@ks ¡nward and tuiát€ ouload lo dikonrecr borh wilng hafneses

,AcauttoN Ue cae

2.

to a@id

Posilion lhe

danaeino lhe

tenkal

p¡re,

harne$ connectoF back out ol

s¡e$

NOfE Póvid€ suil¿blé Egsand conl¿'n€u forcollecliñq

REPAIR INSTRUCTIONS, PART 3.

Femove lhe luól I n€s lmm lhe cooling plate

1

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.

5.

R€mov€ lh€

sl€m

and the cooling plale

Fem@lhe

$¡4s

and the EECUirom lhg

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,

3.

Using a shalp pick, fem@ the tubber seal (molded gask6l) lom lhe qrode ¡n lhe intet manifold. Di$ard lhe manifold seá|.

BEPAIR INSTRUCTIONS, PABT Tandem Pump (Fuel and Power Steering) Removal

1

Ah Comprcssor Removal 1261

CKI

,\

&

NOTE Pr@ide suiiable ráqs ánd conta¡neB lor collecli¡g oiland tue¡ d@inage al each slep.

caplu€ lhe bánlosallngmhéBánd hollow srews while .emwins theú. Be suré lo

1.

It nol already done, remo@ lhe po@r sree ng oir supp y and rclum inesfom lhe landeñ púñp á¡d sól asidé.

R€move ths fusl supply ánd r€lurn lin€s ile pump and sel as¡de.

fom lhe 3

Bemove lhe fasleners securing the puñp lo thé f ywh€€l housing and remo@ lhe la¡deñ puñp ás*ñbly lóñ lhe 6ngin6.

jl

l

I 3. Moudinq sbd and Nd

| 1 Anc.ñpÉsr 1.

Dtscoñnscl and r€md6 lhe @mp@s$r c@lanl l¡nes lbm lhe eng¡ne.

D¡$onnecl and remo@ lh€ @mpressor oi 3. While supporling lhe aircompresso(

f€mov€ lhe fange nuls securing lhe @mp€ssor lo thé llywhéél housing and remde lhe @mp¡e$or lhs €notne. 'fom

REPAIR INSTHUCTIONS, PART Flywheel and Pilot Bearing Removal

1

FLYWHEEL REIIIOVAL PFOCEDUFÉ

TIMING GEAP ALIGNMENT ll th6 6nginé is nol b€ing omp elély disassembled lor d€rhaul and only the liming qeafs a@ io be remded lor €placement, ñáke su@ thar rhe camshali is ar Top Dead ceñréf tor lhe No, 1 cylirder, belore @mding lhe fiDC) nrvhéé|. ll not, pmcá6d as lollNs:

*t

1.

Usngtheengine badnq lool,9996956, bar dd ñanúallv e that the €mshaft TDC mark ls belweeó lhe lwo llnes onrhe rcar @mshatl bea nq cap, The fll vh6él w ll bó al 0' sith thé dañshán at lhé éñoiné

llywhel ¡5 héávy. Do NOI ateñpt to remde lhe lywhel w¡rhout the hetp oi an assisla¡t or lñe us ol a súit5blé l¡fting

Thé

d4¡é.

1

.

2,

2.

The l¡m¡¡g geaB can nów ba rcmMd. Use cáB ló nor @lale lhe geafs as th€y afe being f€nN€d so lhat lhe @mshalt a¡d cBnkshaf fema¡n ¡n lhé Toc posilion.

Fá¡lure ro heed thls

Mrning may

Ésult in p€fsonal ¡niury a¡d comporenr

Femwe lhe elainer screw and remde lhe enqhe sPeéd sensorlom fié llwh€él

It p¡esent, émo@ lhe tEnsmission pilol beaing using beari¡q enrador l@1,

REPAIR INSTBUCTIONS, PART 3,

lóstall1rc l\¡10 x 100 screws in holes

1

1,

ll equipped wilh lhe oplional PTO 6sembly,

3.

loosn and Gmdé lhé lasle¡eE se.u ng thá dsembly to lhe llywhe€lhousing. Rénów thé PTO ass€ñbly lom thé Ilvwh eel ho usi¡ s and ser eide. Bemove and d¡sÉfd the PTo houslno seal.

opFosité éach oihér al thé outé¡ périmél€r of .thé llywh€61- Thsss sc¡6m will b€ usd ás handles to a¡d €mMl ol lhe fy{heel.

N Frs!re

136 usdhsFV-h4l

Flywheel Housing Removal

Reñore lhe llywheel mounling fasléné¡6. whlle suppo.ling the llywheel, ca@lully lap lhe illvheé|, all¿maling from side to side, lo work it oí thé aligning dowel pin and €mo@ it lom lhe cBnkshaÍ llange.

Power Take-Off (PTO) Assembly

I

}F}!hs N

sins

1

.

Feñove lhe tDvheel hous nq rasieneF (iiem 2 i¡ FiquÉ 139) locared ar the lrcnl or lhe tinina qeáf plaie.

REPAIR INSTRUCTIONS, PABT 2.

Supporl lhé i yvrheel housing ánd rémm lhe lasleneÉ al lhe @. ol lhe ly{heel housiñg sdunnq lhé housing to thecylinde¡

1

Timing Gear Tra¡n Removal

'

l6 iúd6ñ Purp D¡i6 3 ¡ijúhbe bb' G¿r l7 arcóñpÉsrDfÉ FrqrE 1r0

3.

-

*mrc Íshom w¡h *qU¿E)

Fhvh¿¿r Houinq F TOqU¿

Remóve lhe fwhed housi¡g. l! may be ne@*ary to táp l¡ohlly on lh€ housing wilh a solt mallel lo spa€le the housing ibm lh€ liminq aáar plalé.

Crankshaft Rear Seal Removal

NOTE fo s¡mplit lhe re6smbly prcc6ss, awid roraling lhe engine orliñi¡g ge6 whlle perfohiñg ilñino oear 6ñ@ añd rcin6lallalion. CFANKSHAFT GE:AF AND IDLEF GFARSET

I2't2 JHI

1. Réñow lh¿ ¡ro

With lhe llywheel housing r6mmd, use a d¡¡fl and hammef lo femde lhe old seal ffom thé cánkshafl bóré in thá housing,

2_ Uslng

scur6 th€

Allen-head scÉws thál üe cÉnkshatl llanqe.

aear to

a suitablé puller,

¡em@ lhe

3.

Remove and $t ásidé lhe lower (auxil¡áry) idl$ geai Bemo@ ft6 soal rins lrom lhe

4.

Remóv6 lhé 6ú Al en-head srsws (inner 6ifcle) secufing lhe intermed¡ate ¡dtef geaFel hub to lhe cy i¡dar block a¡d bmdé lhe g46el lrom lh€ €no ne.

REPAIR INSTRUCTIONS, PART

1

Alternator and Retr¡gerarit Compressor Removal 127'l cB, 264 DPI

1 arcomprsorMouñrins | 2. alisñmenr oowers,

1, Femore the ómpressor studs lrom the

liñiñg goar plal6. neno€ and discad lhá ealing ring fomlhesluds. ¡nsial¡ the allgnment dowels, 9994267, and light€n lhém lo spe ncatun. Thi6 sláp is

nemaryloensuE pbperalignmentof lhé plale w¡en ea66emblinq the enoine.

3.

While supponing lhe plale lo tálling, ém@ the fasl6ná8.

pr*d n fon | |

NOTE

I

when thé riming gear plare is beinq Éñded, il músl be dawn slraishr oul to arcid m@inq or damaqinq the at¡qnment dowets.

4.

Fémove lhe plate

foñ

|ne enqhe.

comp'sr

5. FsrnF6d 6. Frenr Ens¡re

supFn

Mou inq BEcker

NOfE For lhis p@cedue, lhe eng¡¡e ls o1ll-ól'chssis, the lan d wandame*oryd vebetsáré fémoved, Ihe altefnalor ha.né6s wúing ls disconn@red, and rhe ¡LlC compGsot

felf¡Qeánt lin6 áré 1,

€m@d

Whi e súpporing úlá ahe¡nator, rem@6 th€ tusléneB and €ú@ lhs allenalor iEm the

Whi é suppo¡ling lhe refiq€Ent comp¡es$r, Énovs lh€ lasleneF and €mde the compres$r ffon ils mounúng pads on the fonl éngine supporl ñountinq bEckel.

REPAIR INSTRUCTIONS, PART Cylinder Head Removal t213 EVI

Acau¡toN aghe

is rct beirg cñple¡ely diessénbléd lar ovúhaul and anlv lhe cylkder hed is lo be etuved, fhe six A and B wh¡d1 @cure ¡he t¡ñkg geat phte ¡o the cy¡¡ndet h@d and the idrr uppet C stuing the ¡dlet geat hub to tl1é cyl¡rdú had MU9T BE BEMoVED (Fbúe 147). Fa¡lute ¡o do & ñay rcsult ¡n seveE damge ta the cyl¡ndq had and athet úgine canpúants as lhe cylkdet héad is ,REMOVING fHE Í]MING GEAR rcNOVEd. SEé PLATE TOCYLINDER HEAD 6CFEWS" an

lf the

1

GEÁF

,

FEIIIOVING THETIM¡NG PLATE-IO-CYLINDEB HEAD SCFEWS ll nol al¡eady done, r6mové üre 10 scr4s (A, B and C in Figure 147) secuÍng the cylinder head to th6 liminq géar plate as lollows:

1.

Rémove lhe fve sc@s ih@ugh ihe lñing qear práte oñ €ilh$ sidé of rhe adjusrable

tuB

stús

o

2.

()

o

o

Bar lhe eng¡ne over to aliqn a holé in r,\é

adjusiabié idler gearwith the hidden sc€w lhrough lhe plale iñtolhe.ylinder head.

Flqul€117_cylhdslH€de.rinh

FiquEr4e

Hrdd¿¡

s.@

{B.hind

Gsd

REPAIR INSTRUCTIONS, PART 3,

Fem@ lhe lour upper $r4s in lhe ádjustáblé idlér géar hub.

1

BEIMOVING THE CYLINDEF

HEA;

Wñh rh6 tming qear mount ng plate to cit¡¡dér ¡ead émowd (a, B and c in Figufe 147),

*ras

p@ceed

6

bll@s lo émds fto cyrinder head,

o

FrsúE

4.

rs

-

uDp€r Forr

ad¡u*bre

rdr¿r G¿ar Hub

F¡suB rsr

B€moE ány €siduál énqiné oil from lh6 'holldg beneath lhe camshafr lo pBent oil lom running lnlo lhe @¡anl channels. 1.

-

cfinds

Heád

u¿md,r

Femow lhe cyl¡nder h6ád bollsUsinq the cyt¡nder head titiiñg tet, 83800188, caelully remow and et asidé

REPAIR I}.TSTRUCTIONS, PART 3.

Remow and di@rd lhé cylinder head

4,

Attach cyl¡nder llnor hold-down l@lsj 9996966, lo lhe clli¡der block to kéép lh€ I n€6 tn place lempoEilv,

1

9996966

| 3 c6d3h'n

1,

fD

lf nol d@dy done, e ease ths l6nsion6rs and rcmrye the dri@ belts-

RénM F¡euér52cy||¡dqUndR.rai¡.i

Crankshaft Vibration Damper and Fan Pulley Removal t212 RB, RPI

^cÁurroN

When hand¡¡ng a úbh¿on dañper. be @ratul nat .knage ¡he h@siag. Oqts k the odet

to

t

housing ñav detthadañper¡neÍlec @, auskg an hnbala@ ahd v¡btat¡m ¡n the eng¡ne. The vjbhlbn danpq amo¡ be rahe.¡ The lan pulley nesls wilbin the damper using rhe

lhe tonl englne power iake-ofi (FEPTO) unit, ir so equipped,

Rem@ ft6 f¿sléné6 and eñore lhe cEnkshaft v bátloh dañper and lan pulley

REPAIR INSTBUCTIONS, PART Crankshaft Front Cover Removal [211 JBI

1

NOTE Apply gfease to the dlll bit to collecl meial .hips whén drilling holes in lhe seal. Usinq twó séLr-lappinq M5

$lM

ol suilable lóñqlh, ¿tlach lh€ l.onl cEnkshaf seal fenowr¡nslaller, 4a300021, to thé sel. Uslng lwo M10 s@s of su lábl6 l€nglh lh@aded inlo lhe lapped hd6 in lhe có*ñémbér ol lhé Bmow¡nsiallér, Émde lhe @al and d¡sad lt

cteanihe seateat¡¡g suda@ ¡n lhe cEnk6hat l@nr corer and l¡e sealing

+N>9,

d{5:

Oil Fill P¡pe and Dipsrick Rerainer

ÑOTE P@vide suilable Eqs and coniaine6 ior @llecl¡ng oildEináo€ al 6ách slep.

1. 1.

Whilé suppórling lh€ fónl cow¡, cmm thé éighl lásteneG alacning lh€ cover lo th6

Femore lhé cEnkshaí t@nl cover trcm ihe €nqins bv slid na il offlh€ crankshaí llanqe.

Crankshaft Front Seal Removal [21r JBI wilh lhe cEnkshan nont corer Bmov€d, use a d ft and hammerlo remove lhe old edfomlhe ll rhe engine is nol belng @mpletely disássemdédlor ove¡haul and onlythe cáñkshaft fonl séal is lo be Eplaced, emove lhe sealus¡ng the foll@ing póc€duB.

1.

Drirllwo3.smm (0.138inch) holes inihe meial r¡m oi the fonl danksháll s6ál using lhe holes ¡n lhe riñ ol lhe sear

li not already do¡€, r€mov6 and sel aside

REPAIR INSTRUCTIONS, PART Fem@ lhe relainer sd* noñ lhé dipslick pipe flange and Em@ lhe pipe lrcm thé 3.

1

fE whicle is equippéd iith an óflionál 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

1. lr

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 thé óil Pán lo lhe c6nkase.

scuÍng

NOfE Thé oil

3.

lel

ssns¡ néed nol

b6 rcm@ed unl6ss

FemM and sel aside lhe oil pan, F€mM ánd diEcád arry O-nng6 lou.d on Reñovó thó élastóñér sd lrcm tha ojl páñ and inspecl it. lf lhe *aL is danaged, lt ñust

Oil Pan Removal 1211 NBT

NOTE li the eng¡ne is in lhe vehlcle, pdide a lilllng device lo Gsume lhe weighl ot lhe oil pan duÍ¡g

REPAIB INSTRUCTIONS, PART

1

Front Engine Removal t299 GVI

1\(]

C)

rl

o

6AC) O U

Frqub

re

-

h!d, o'nh,nd [email protected] sump shMñ)

Ptpés

(F6d

2 PlnpoursrPÉ

Béñów thá fasr6né6 lom lhe pump oullel (p¡esúre side) pip€ llans€ and r€mo@ lhe pipe from lhe engine. Femore and disard

Fremove the fareneF ar rhe left a¡d nghr sides ol lhé énginá suppon and @m@ lhe suppon foñ lhe mounl¡ng báckeis al each slde ol lhe cylindor

Remov€ lh€ lasleneB tom lhe cGsder p¡pe llange and émóvé lhé pipé.

4. Block St¡ffener Plate Removal

Remde lh6 rgmaining fasleneF secufing lhe

tife¡er

plate to the cyt ndé¡ btock.

Thé inlél pipé wirh alonlsumpollpañ is toñOer lhan théon€ with a Barsump oilpan,8o1h the shoner a.d longer p¡pes atiach lo á bmck€r mounl€d on lhé srifener fañe and ctlinder 1

.

Bemow lhé supporr rcia¡n ng laslenefs and @move the punp inlal pipe. Femo@ and discad lhe sear ¡ing.

13

5.

o o o it o

Wlh lhe help ol an assislant, romo@ lhe

BEPAIR INSTRUCTIONS, PART Oil Pump Bemoval

[2r9 MU,219 NT] lf thé engine is nol be¡ng @mp elety

disassembl€d lor ovéñáuland only the oilpump is 10 be repla@d, instruclions are póvided in a sepa€le seclion enüiled "oll PUIüP REPLACEMENT (lN CHASSIS)" lor Bhovihs and rcinralling rhe oi pump wirh the enqine in

1

Piston and Connecling Bod' Assembly Removal 1212

1.

N\

212 LPI

Rolate the cránkshaft e ihat the connedinq rod bearing cap lor ihe désned cylinder is posiiionéd ior easy remdal ol th¿ od cap

NOTE

1.

lr necessary lor a.cess to lhe oil púmp

mounling lasle¡ers, rol¿le lhe cránkshalt usi¡g engi¡e bari.g r@l 43400014,

2.

T¡re rod beadng Éps can be €moved in lhé mmpanion cylindersets:Nos. 1 and 6,2 ánd 5,

Femovelhe iásleneBsecur¡¡g lhe oilpump lo lhe No.7 main bea ng cap.

FquEre or Puñp ( cb||.d on No.7 seaine ca!) 3. Ca@lully remove ihé oil pump lrom lhe

2.

Femove the piston moling rozzle to prdeñt il fom beinq dañaqéd.

3.

Femove the lour boLls and rcnove the

4.

D

5.

scadlhelowerbearino inse (shell)i¡the

Usinq a suiláble lool, púsh up on lhé bonom oi thé plston u¡lillhe rings are lree ol lhe .ylinderliner. lhe upper inner su¡face of the linér may hale io be scaped and cteaned il thefe is excéssive ca fbon build- up lo máke I eas¡er lo remow lhé pislon.

REPAIR INSTRUCTIONS, PART

Z 0.

1

Femo@ and dis€rd lhe upper beari¡g ins¿rl in ltl¿ conneci ng @d, Répeal stéps 1 lhóuqh 7 lo ¡emove

üe

F¡gUElegdonFemMl

Main Bearing Cap Removal

^caurroN

t212 HHI

@rectkg bd añd l¡ret dü¡ng etutaL Coñta.t nay @ue danage to the tkq,

6.

NOfE ma*ed, 8e sure to éllrn each

Frcm lh6 crt4indér déck, pull up lo rémové lhe p¡sion and @nneclho bd lom lhe

éngine. Ma* lhe pislon assembly lo show ils lo€tioñ in lh6 €ngin€ and sr it áside for disassembly and lnspecl¡on (see ihé CONNECTING ROD ANO PISTON BENCH PBOCEDURES s€clion)-

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

original lo@üon al

1.

ssembt.

\Mlh thé énqine invenéd (crankcase side up) on lhe €pair sland, loose ñ and Émore lh6 bolls sécu ¡ing the m ain bearlng caps.

REPAIB INSTRUCTIONS, PABT 2.

Usingpuller9990114,adapier9990262ánd sLid€ hammér 99S6400.

rémM

ánd

s1

6ide lhe beárinq caps.

1

Crankshafl Removal I2't2 HPI

Th. cránkshafr ¡s éxrrémely heavy. Do NOI attempl to rémdé thé cránksháft without thé help ol an ass¡stanl or lhe úse ol a suirab¡é l¡fting dév¡e. Fá¡lure ro heed üis w.¡n¡ng ñay rcsultir sdere peÉonal ¡njury and

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

3.

1.

Fem@ and make nole ol lhe parl on lhé inséns (sh€ls). DisÉrd rh6

Wih añ assistant and using lho cránkshaft linjnglool, J 49002, lifi rhecEnkshafilo r€m@6 il lmm lhe cylinder block,

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

ffi 2.

| 2. N0 4

4.

eh Edrio

Rém@ áñd d scard lh6lhrusl washér

cae

F¡énóveanddisÉ¡d theuppermain béa ng insens fron thá cylindef bl@k.

REPAIR INSTRUCTIONS, PART CYLINDE R BLOCK RECONDITIONING [21r DBI Tools and Equipment

Handl€ *irh

vai.w

rjrcf rn* rd

Lim,

us

6 Pr*

(rib 25 mm hob)

(a€irabr€)

HddDfrn fod tEsed d)

cyj¡úr

Lrmf Pürhr (aEirabr6)

1

BEPAIR INSTRUCTIONS, PART P¡ston Cooling Spray Nozzle

Cylinder Llner

1

Removál '

[212 NC] t2r 9 RVI

1.

lnsialllhecylinderlinerpuller,1ootPT6435 or equiváleñt, in posilion

mr

lhe cylinder

^caurroN

fo añ¡d dúág¡ng lhé suay nozlét reño@ beloe tñoving the l¡reb.

lhú

SERVICE HINT l2 mm, 6-poinl sockel on a 300 mm (12 inch) €ir€ñsion to remow lhe nozzle a ¡s besl 10 use a

1. Reñove rhe pisron cooling spEy nozlé by @movino lhe relainino Epscr6w

3.

ca€tully pull oulwárd on thé spray nozzle lo émde il lros thecyllnder block. Fepe! sieps 1 and 2 lo femow lhe rémaining spEy nozl6s-

FiEuE171_ca¡indÍliñ.iF.ú@l

Ae

^caurroN

te f,\e @gs oh ¡he pullét Leos dó nol

qtend

bét@d ¡he outs¡de d¡añetet ol the tker Fa¡|ue to héad thís aúti@ nay resull ¡n @vere

1 Pisoi coorrc

DEr

l3.sDavNozrs

Hooking puller leqs on lhé bóttom of rhé cllindér liner, lighlen lhe cenler scrs on thg plller unlil lhe iner @mes a.ee ot lhe 3. Femove lhe lin€r and puller

ssembly fom

the cylinderblock. Then, rcñóve lhé pullé¡ R€péar lhé prccedure to remore ihe

cma¡¡inq cvliñder lin€rc

REPAIR INSTBUCTIONS, PAFT NOfE al!€mauw.lool Nos. 9992955, 9996394, 9996395 ánd 9996&5 in 6nbinalióñ, €n bB used tor oflinder liner renoval.

SOLVEiIT TÁNX CLEÁNING

NOfE

As án

Block Clean¡ng and lnspectio¡ The enginé should haw b¿6n lhoóughly stéán cl€aned prior lo @mponeñt removal. li healt accumurar¡ons oi dirr and g@ase afe srill preenr, sl4m clean lhe block as thoroughly ás po$ibló belore atiemplina lo cl€an with elvents.

Use a cleañiñq tánk larq6 énough lo a.commodale lhe larlesl componóñt lo b€ cléanéd. Fillrhé rank with a suitable sol@nt. Párts may b€ dri€d wilh compressed aii

Always use caudon whlle cleanlng pans wnh solvenls. F.¡lure io héed th¡3 warn¡ng Dáy esult ¡n pé@nal lnlury.

1. cleáñiñq solvéñl is llañú.blé a.d ioxlc to üe ey€, s*ln and rsp¡Flory iract Skiñ and éyé p¡ot*tion il €qui€d. Arc¡d rep@téd or trelongéd , u* only ln a well-ve.riláréd áre¡. FailuE to hed rhis wár¡¡ñq ñ¿y rcsúll ¡n sévéé péÉonal in¡úry.

1

ScEpe áóy remainino gáskél malé

álroñ

Usinq a wire brush or roiary wheel, remove ány rusl, corGion o¡ olh$ déb s lrcm lhe

Clean all oiher crlindér block suláces wilh mineGl spnits orolhersuitable solvenl. U8ing due care and eul¡on, deñ and dry lhé cylindérblo.*wilh compressed ai[

Compe$ed air u*d lor clean¡ng can creále áirborñé párl¡clés thát ñay éñtér tho ay€s or ¡rdrate the sk¡n, Prcssure mu$ nor exceed 207 kPá (¡0 ps¡). Eyé prcreci¡on ¡s requ¡re¡|. u$ only w¡th étlectivé chip gúardirg áñd

pérsonal prctecdve equ¡pñent (gosslelsh¡eld, sldes, ércJ. Fa¡lue to hed thls wañ¡ng may résú¡l ¡n sevérc pérsoñál

NO'E A complele d¡scuss¡on ol thé proper mélhods

lor

p.€cisión mésuri¡g and inspection is oulsid€ lh€ scops ol lhis proc¿dure. H@we[ 4ery shop s hould be eq u¡pped wilh sláñda rd qauqes, s uch as bore gauges, dial indicators, oulsid¿ and i¡sidé micmmeleB, lhicknes gauqes and

NOTE Cleaning the cyl¡nder b ock is iñporlanl. whilé cléáni¡g lhe cyinder blo6k, caretully hspéct lh6 a€as around lhe cup p ugs and lhe @olant ducl cover ll cup pluqs or pips plugs shów 5¡g¡s of ¡eaking,lhey sho! d be replac€d.

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

Check thé crlind$ block lor indi€tions ol c@cking or coolañt eakas€. ll any damage is suspecledj use a slandard dt€ péñélÉnr lo delémiñé il cadc exisl A cGcked eylind6r b ock musl be fepla.6d ¿nd n@r reused,

REPAIR INSTRUCTIONS, PART Counterbore lnspect¡on and Clean¡ng

3.

1

Feset th6 tp or rh¿ diar n¡icator ágainst rhé hiqh poinl on the @nvd sufacé ot the cylinderliñer Measureánd record th6h€ight of lhé ledqe above lhe cy úderbtoch

lin

12111 lhe cylinder line¡ counle¡bóre surla6 shds or eGaon, fe6ut the counleóore 4 Bquired, Shims are ava¡lable ¡i thé ouñiérbo€ d€plh musl bé changed. Do nol rásuria.6 lh. blo.k d..k It

exe$ive piting

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¡ner He¡ght Measuremenl [212 NCI To dererniñe llner he¡ghr abore lhe cyrinder brock

déck, p¡oÉed 1

.

2.

o

lollows:

rns€n a rlácemenl llner (w¡tt'o!l sealing dnqs) ¡nto tho cyllnde r bldk bore. s¿cu ré lhe liner in pla@, using two hold-d@n lools,

¡rounr nré dia indicalor, tool 99a$76, in lhe holder, tooL 99S2479. Plae thé holder and d ia! ndiqlor in posilio n across the top ol lhe cy indef lin6l s€r lh€ üp of lhe dlal indi@lor aga nst lhe cyl¡ndef block deck and 260 thé di6l indicálór gáuge.

4. Mesué

añd record lhé height oi thé llner l€dge above lhe otlinder block ddk al Jour poinrs, 90 d€grees aparl.

5.

Calculate án déEqé heiqhl, using lhe h¡ghesr eco]1led measureménl and the measuemenl taken d¡aQonally acós lh€ cylindér bofe. checklhe calcualed height againsl speclicalions- Then¡ cal.ulate the rhi.kness ol rhe sh¡ñ(s) requirád, ir any. use thé tuwásl pcsible number ol shims.

6.

Using a marki¡q pen, markthe posi¡ón ot lhe lherlñ lhé cylinder bore ior ¡nal insrallaüon. Then, rem@ lhe lirerand ádlustmenl spacer (f requrréd) from lhe cyl¡nder block ánd p ace on a cléan work

7,

Fepeal lhé p¡o6du€ lor lhe rema nlng

REPAIR INSTRUCTIONS, PART

1

Cylinder L¡ner lnstallation t212 NCI

3,

l.EPDM(Back) 1.

Usinq liner irslallalion plate, 9S96599, and handle, 9S92000. práss lhé I nér (wllh spacer r, appoprraie) rnro rhe bo¡e uhrir

l3.YblPuDré)

Applylub canl (included in llner ki!) lo new

s€ls

ánd inslall rh6m in tha louf ánnular one under rhe fange ot the ryrlndef lin¿r a¡d lhEé néa¡ lhé borom. The puQle gasket ls insla léd in lhe l@est groove-

g@s,

ll thé cyllndd llner is bélnq iñslall6d wlh a spacer (shim), appt a 0.3 mm (0.03 i¡ch) béád ol 342SX33 MACK-app@d sealant io ihe coúntebore ledle in lho cylindar block. Do NOT apply the selanl betwen lh6 spa€r ánd lhé cylinder liner llange,

t1 cyr¡&¡ LiEr

4

ihe ine¡ in placá using nro Iner hold-down t@ts, 9996966. Seou¡e

/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 Flywheel R¡ng Gear Replacement

--[

[21687-51 1

.

Heal lhe ring géar a6und tr1é out6r 6dgé

5.

Usé a punch lo rcmove lhe ring gear

ton

Use a steel btush to cléan lhe enq¡ne

AcauÍtoN Use @¡lian mI to hat the hg geat de6¡@ly ot danage wll o6ut to the new r¡ng gear

4.

üe nM riñg géar with á torch or tn a fufnae io 180-200oc (356-392'F). Héal Heal

lhe oear w€nlv around lhe enlire surface. A good lnd¡calioñ lhal lhe corcct tempeáture ha6 been reached ls when brighr merál iurre

lnslall lh e heaied ngOearonlháangine llyuheel. Lel lhe ring Oear ai cool naluÉ lv.

REPAIR INSTRUCTIONS, PART CONNECTING ROD AND PISTON BENCH PROCEDURES Connect¡ng Rod D¡sassembly

*

Piston

1

ll is essenlial thal a @p and rod be ked b¿dhd when reñoved lmm lhé anqine and when installed. Each ¡od and mp is ma(ed with malching numbefslo idenlily lh€m ás a sér. al assémbly ü€ numbeE musl appear side by sid6 and lhe nolches musl be aligned. Rele¡ lo Figure 1a0. Tag ihe sets on r€mowl so éach sel @n be relumed lo lhe cylinderirom which I

@

l2't2 LPI

Ns rods tor sruie adv¿ wilh caps altached. Thé cap must bé sepáÉled by holdlno lhe ñd in a soft jawed vise ánd slr¡k¡rg lhe cap w¡lh a rubbeFhced hammei Caré musl bé rakén lo pGvenl damaq€ to rh6 fod, cap ánd béánno

AcauTtoN nol¡nsb

a danaged únnecüng rcd Fa¡lúe ¡o h@d th¡s ú¡i¡on nay ¡n se@te Mparent dañage. Do

a*ñw

te ll

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 daÚage.

únpüút

| 2 fré

I

dumb36 musr aq¡ee

añd b€ aricned on rhe

1.

Using snap ring pl¡e6, removelhe snap ring al é@h end oi lhe w¡isl pin.

2.

RemoE lhe w sl pin fom lhe pistóh and

REPAIR INSTRUCTIONS, PABT INSPECTION

CONI,¡ECTING ROD

1

ALIGNMENf

'

visúally inspéct lhé conneoling rod lor l\{ist ánd bend. Replace lh€ co nnectin g rcd iln*ssáry

Plston lnspect¡on and Cleaning [2f 2 NPI 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 and prcwnts praper

Ed@s tkg .leañtue

l3

w¡dPin

lnspect each @nnecliñO rod ánd cap for the following mndilions. It any fault appea6, éplace

1.

lnspect the co¡nocling rods lor nicks, cGcks, signs ot owrheat¡ng and unacceptáble bending and twisli¡g.

2.

lnsped$e boll holés lorélonqato¡ and

Be su@ that thé dean¡ng so¡veñ¡ ¡s apptóved tot sl@l and aluninun. lncmpal¡b|e saÚenE ñay Fa¡|urc lo heed th¡s cau¡ion may result

3.

k sevee

Using a brass b¡ush and an approved cleanlnq solution, cléan lhe Dislons.

NOTE Arcid damaQi.q rh6 prsroñs wh le (rean ng.

3, lnspecl lhe ñaling surlac€s b6¡réén lhe connecling @d and cap ior coreci lit.

lnsp6cllhé bolt holes torelonqauo¡ ot 5. 6. lnspectlhe wisl pjn bea ngsudaceinlhe

7.

lnspecl lhe cɡkshafi: joumal bearing sula@s oi lhe connectinq md and cap,

SERVICE HINT lt ¡l is delemined thal any componénl is in questio¡abe condll¡on, feplace it.

INSPECT¡ON

lnspecllhe pislon rinq groovos, tands, skid and combuslioñ bowl lor wear, scuf ñafks, cacks and bl@-by. Plsto¡s a€ NOT repaiabe. Discard wo¡n or damaged pislóñs.

AcauTtoN Do rcI sbnp ar engtave on he mP ol the p¡slú. Fa¡tue ro heed Lk¡s eul¡an nay rcsuft in

REPAIB INSTRUCTIONS, PART P¡slon Ring lnspection and Replacemeñt

RING END GAP ¡NSPECTION

1

Usingan inverled piston, pusha inlo a cylinder lrner máking sure

2.

Usne ü chne s6 gaugés. measu re th€ gáp béhdeen lhe rinq endr. Fétd to F¡n ard ¿imtrs in lhe SPEC|F|CA'¡ONS sec¡ion tor

3.

Fepoal sleps

[212 NVI OII AING GROOVE SIDE CLEARANCE INSPECTION

1.

Usi¡g alhicknessg¿uge measur€oi dnO oroové

Éide(lea6¡€

1

1

and 2 tor éach nng.

.hbñe-otatéd D¡stú mú. ^cau¡toN

Do nol l¡E ot a¡nd

n.y

cause ke ch@e b tl¿t¡e ¡ésuhkó in ho fa¡luÉ. Fa¡lurc ro heéd th¡E ca ¡n @we ehgine ¡lamge. Th¡s

BING INSIALLAÍION

NOTE ldenrlñ@lion ma¡k'nqson thé ringsshoutd hce lhe pislon lop Thé lteysion€ rinq qoes ú lh6 toD

Foll@ the d¡rections on each pislon r¡nq packéI.

lnsé.ra new oitcontrot¡¡ng in lhe

l¡s6rl a lhickness gauge betwáé. the nnq añd upper lánd of rhe groow. meauement and compare lhe roadi¡g with thé intormal¡oñ in F¡lt Record lhe

añd ¿ii¡i¡s in the SPEC|F|CAT|ONS

{rcydone.sh,Fd)

REPAIR INSTRUCTIONS, PART 1.

ge

prMnl disbnion, use the proper p¡ston dhq dpander, lo insén ng6in

Connectlng Rod Assembly

Slagger the ¡ihq qaps so thát they a€ nót aligned and none ls direclly @rth6

[212 LP & NPI

To

fté

-

1

Pisto¡i

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.

1.

lnsena snap ng

2.

¡nsert lhe co¡nécting .od ¡n lhé

in one ol lhe

w¡st pin pislo¡

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 Usinga g€néousámounlolclean e¡gineoi oñ ihe wrisl pih and rod beárlno, préss lhé

1

a scfs wrh rour punch malks (A) mui b¿ epla@d wilh a ns sc@.

lnsert a snap .ing ¡h the other wlist pin Sél lhe

a*ñbled

piston

6ide

in a clean

loÉlion u¡lil il is needed. Repeai sleps 1 throuqh 5 lor eách piston.

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 used, Fa¡tute b heed thís aur¡on nay t6ulf in

tins

ñvére cmporent danaae.

Punch H6rks

(Fepr#)

Uséd connécrinq rcd $rds musr be lighrv olred o. th6 lhr6áds ánd undér lhe head. N4 erews are coated dilh phosphate and oiland musl be

,AcauÍtoN Épsctws 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. lf the

REPAIB INSTRUCTIONS, PABT CYLINDER HEAD OVERHAUL [213 EVI Tools and Equiprnént

9

nn

T¿p,

e mm Bir.

uF silh 999329 (A!¿láb é)

us

w rh

sss32s (a€

resphscoñp'Nd

labr€)

(Eseúd)

1

REPAIB INSTRUCTIONS, PABT

1

= lel€s9dnqco@ÉslAd¡ol¿f ¿

il úñ' r'ldd P6i*úñ

uri¡

rñi.tu 806

ui

r'tedo¡

erc

she (ked

Garr6ry sgaring

d)

Rirss

searnq Pruq (EssiraD

0) unr rnidof

sr*

Tao

GsnriaD

))l

ll)

REPAIR INSTRUCTIONS, PABT unr rnlsrór

sr.s

1

F6ñ@r (Essnriar)

v¿iÉ ouida Fmúar

rúr

(a!:irábre)

ñ

Fleneer

rlnie

fod tEsniiaD

REPAIR INSTRUCTIONS, PART swaoins rool ror hdallins unir rnieror

saens

unir

Bir rof

hitu

c.rp€r

Bo,¿

sre*

(ani abra

creniñs K lÉsenÍaD

1

BEPAIR INSTRUCTIONS, PART lnlet ahd Exhaust Valve Bemoval [213 NB] GENEFAL INFOBMATION The MP8 has a s¡ngle cynnder head, hllrs in thé head and a sanqle oveñead camshan. The slngle óc.ke¡ árm shan resis on lhe inboard end ol sMn @ñshán béa nq caps. fhe sryénlh beíng ep also prdides a @nñectio¡ lor ubrl@nl, The opllonal engine bÉke eleclonlc oll conrol É w mnnecls lhe o¡l aqes ir the h65d and rocker arm shaf.

1

FEMOVAL PROCEDURE

1,

Using lhe splng compBsor, 9990210, compEss a va¡!€ spring s€l 10 aeéss lhe

2.

Using a magnel, emo@ lhe keepeG lrom

3. 4.

Rem@ lho @ w sp¡ing set. UsinQ á suiláblé lool, @move lhe va¡@

slem

A copper sleeve and washer lines lhe boltom of each injeclo. pon. An O{ing seals oach d6M. an ope¡lng ln the dghl lfoñl cofner @elv€ the lhermoslal, There are lhree special sc¡w6 and w6h€re usod lo align lh€ cylindér hoad, lwo in ihe block a¡d one in the cyllnder head. Vat@ seat counle,bor6s are cur in lhe block 6id¿, Valve quid€ pessed iñto p áce p¡ojet nom lhe upper A gallery de

ive6 iuel lo the inieclors and iuél régularor Thé inlel manilold ana6h6 lo the left (drl@/s) sldo ol lh€ head: lhe éxhaust manilold lo the riqhl side.

p6su€

1

v¿rEsp,inqc.mpres,

t,

v'r€ sp'rry

ut on, rhe ql@ guide and séal afe used al lhe inlel locations well as lhe qhaust Fof standafd

s

REPAIR INSTRUCTIONS, PART Cyl¡nder Head Cleaning and lnspection Cleaning lhe cflinder head is imporanl. While cleaning lhe cyllnder head, ca@tully inspecl lhe á€s áround thá Bxpánsion plugs and lhé molina ducl @€r ll lh€ cup o¡ pip€ pluos shd slgns ot leak¡nq, they should be feplaced. The cfinder héad should also be inspeled tor oracks or olher poss ble delecls lhal may be reason for Eplacenenl. ll damagé is not louñd uñUl álter lhe engine is ssnbl€d, th6 cylinder head musl be éñ@d, disa$embled and €bu l!aqain,

LJsing care and

cadion al

1

elllim¿s: l

1. 2.

Fill a tank wfh á suilablé

3.

Sc6pe reñaiñinq gask€l malérial tDn lhe

4.

Usi¡g a wire brush or olary wheel, r€md€ rusl and olherdebtis ircmthe cylinderhead.

5.

Finsé lhe cylinder héad ñaking 6urelhatall surlaBs a¡6 cl65n añd fr€e of d6bns-

6.

Usiño coñpréssed

sólwnt.

lmm€Bs lh€ pans in lhe solvent to to6en

ai(

ble

dry thó cyliñdef

SOLVEÑÍ TANK CLEANING INSPECTION

Clsning slrent is lláññáblé árd loric lo lhe ¿y€5, sk¡n añd espiÉrory tfacr. sk¡n and eye prctecrlo¡ arc rcquiFd, Arcid repeáred o¡ pElonqgd @rtaéI. U* orly ¡n a Mll Compressed alr used lor cl6n¡ng can creale áiborné parr¡cl* lh.t may ánt6r thé €yé5 ór kritaté thé skin. Prcssuré músl nol exceed 207 kFa (30 psl). Eye prctéctlon ¡s rcqlted, Use only with éféérivé ch¡p guárd¡ng áñd péMnd pbrecr¡ve equ¡pmenr (soqslas/shiéld, qlove, érc.).

Check lhe cylinder head deck surlace lor mlping, plninq ánd olher impédoclions.

AcaurtoN Do NOI nach¡re lhe cylindd haad. fh¡s w¡ll úange Íhe qtereio¡ al ¡he ¡n¡ectot and úpset

REPAIR INSTRUCTIONS, PART

1

Velve Guide Replacement

[213 EPI Fefer lo thé'ENGINE ¡¡ECHANICAL SPECIFICATIONS' se.lio¡ n)r d¡máñsi.ns appli€ble to thó úLvá guides.

NOfE Wor¡ Etu€ guides may result in poor valve lo seal conlacl, válv6 dámage or excessive

L

lnspécl lhe

E

ve glides lor wear, damaoe,

Usinq a suiiable 9aug6, measure the iñs tde Usinq a suitable qauge, meásu€ rhé valve

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

SEFVICE HINT Clean lhe exhausr válve guide

b6lore emoval, wilh th6 guidé rctary brúsh lo p@enl sco¡lng dhausl val@ guide boG.

1

Assémble lhe hyd rautic €m, 9a09729, p€s6 loo l, 99901 76j pu mp, 9996222, and vatve guide remder, 9996263, on lop ot lhe

Pessoll the old va ve guides irom lhe lop orthá rylinder head usinq the press. Cl€an all surfaces thomuqhty.

BEPAIR INSTBUCTIONS, PART

Valve Spring lnspection

VALVE GUIDE INSTALLATION 1.

Heal lhe cylinder hed wirh hor warer and ar lhe samé timá coól Elvé guidé lo m nus 60 200'C C/6 323'D usiñg dry ic6 or equ¡valent. Lubf¡€le cyllndef head ulve guide bore belbre i.sralla1ion.

oil lhé outslde ol the guide beloe us¡ng lhe pfess Iool selup, press lhe Elw guide inró irs borc lrcm thé lop ol the

e*nlhl

^cauftoN

lhal ¡he @rect valve g!¡de

irstalaüú lúl @aa00a62 bt klel and dhaus¡) be u@dto kslal the cu ent wlve gu¡de. tfthe

[email protected]

tod ¡s used, the vatve guide and @al

iretalledhéighlwillbe¡tu ecl a¡ú ñay t4ull peñatwe la¡turc ol the @ñponent' 6. Tho@ughly clea¡ a I dáb¡is fóm lhá w guid€s and surounding area.

NOTE grc@d,

Assemble ihe hydEul¡c Em, 9409729, press 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

É

l2f3 MBl ll lhe inside sulace o,a splng coilis ouoh or il nusi be replaced,

us¡ñq poie
¡t

1

k

w

lnstáll thé valves in ihe cyllnder head and

chek io¡ binding, l@seness and olher @ndilions lhal may esuft in p@malu@ vd@

ll spring siEnqrh is norwithin spe.ilicarions, ir

Fo¡ indicalions ol oroovino or rouohness:

1

lnspé.tlhé insid6 suláces ol éách spring

2.

Fbél

3. 4.

Replace lauhy spf¡ngs wilh new ones.

üé inside sdfaces

of éach sprinq

Using a spfing resrer as show¡ iñ Figorc 190, measure lhe efon requned

6f b

REPAIR INSTRUCTIONS, PART

1

lnjector Sleeve Replacement t213 GBI CYLINDER HEAD REMOVED

The injeclor sleqe ls saqed ln plac6 in ils bore. 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.

5.

Lubficare lhé rip ol the

I

mñ lap with

6. fh@d

the lap in smáll increments. Rehove lhe lap and w¡pé off the grcas and @pper dewe shavirgs. Apply lresh q¡6asé, ¡ei¡siall the lapping tool and thread ñoe ol

lhe.opper slee€. Conlinuélhis po@ss10 thr6ád lhelap alllhewaylhroughlhe.opper dewe unli no @sislance is lell ad lhé lap

lurnsfreely.Tappina insmall incrementsand Gmov ng the shavi.qs minimizeslhe cháncé ol lhe sleeve luhinq in lhe cv inder head, Ensure lhal the lap ls comptet6ty lhrouqh the @pper slédé.

NOTE Two

4.

saling

ngs ae requlred io

cmr

lhé luel

Adjust lhé g mm iap so Ihat it extends a min¡muñ ol25 mm or I inch ldimersion A) fom lhe end of lhé taopina lool.

BEPAIR INSTRUCTIONS, PABT

1

Tigh¡én rhé sel scrw ot the eriraclor l¡ol b sécufe lhe bolr. Maké sure lhal lhe sel screw is sealed againsl lhe flat pán ol $e éxl@lor 11. Pla@ the exlfaclof iool with the bo l in10 lh6 injeclor bore. Make surc lhe oul on the spind ¿ is báckéd of so lhar lhé rhreaded

end can bé mñpleiely iñslalled thmuqh the @ppef sle4erip. Hand righreñ unrirrhe bon boloms oll n lhe slésé.

Frqu€1e3

rapp¡ns

ld4b slsvs

I 2 C'IiMÜHéú R€mové the tap and iapp¡ng lool. Using lhe chlp kcuuñ, remove anY ¡emainlng shavinqs fom lhé óppé¡ sléevé.

lnstalllhe extracror boh inlo lhé ánd oi rh6 dlEclor lool. Adiust ihe bolt unlil it exlehds app.d¡marely 22 mm (0.9 ¡¡6h) beyond the end or lhé rod {dimé.sion a).

AcaurroN wke

sute lhe enñdot balt ¡s th@ded @nptete¡y ¡rna he cappet sl@@ beloE anmpfina ro maw n at hé tip at the sleeve ñay tuak ofi as it ¡s EnMd.

12.

Screw the lnjeclor slerye reñovál tool, 9998253, complele y inlo lhe injeclor sleeve and lh€n báck il oul l/2lum. Fem@elhe by 1uñiñg the nLn while holding rhe lhreáded sháñ ol lhe remóvál L'ól

de*

Fqu€

1e4

-

ad¡usri4 copFr

sr4€ frrdor

Bolr

REPAIR INSTRUCTIONS, PART

1

13. Feñove

lhe lM sellng ri;gs lDni lh€ tuel agé. using the chip vacuuñ, rem@ any rcñarning déb s iróm rhe injector bofe.

14. lnslalltho FDue rs6

1 rnjedü s 6se

-

frsruinc rnido'

ini¿clor bo€sealinq tool lo protecl lh€ luél áoé area and pfsent debf¡s tom enie ñ9. use the unit iniéclor hold d@n boll lo secure lhe lool in lhe cllinder h6ád. (J 42a35 25)

slesv€

Fenm' jr.riieddses 15,

NOTE Whenlhe copper de* is ¡em@d make súÉ lhal lh€ éxlaclor boll is extended al leasl one lhread beyond lhe copper sledé. ll ñol, ñákB .urc lhal no pa ot lhe @pper de* has broken

/AcaurroN NI u* at loo¡s ¡o eñM @Wet sleMg at dana@ to lhe iniedot bare @n t$ull. Do

Us¡ng lh e injecto¡ bore cleanin g kil, cláán lhé 6pper 6lede seal of ihe cvlindef héád.

NOTE The inielor bore *aling lool must be used to pre@nt dirt from 6nl€rinq the luel pas*oe.

BEPAIR INSTRUCTIONS; PART 17.

1

Usiñg tha blush¡ .lean opeñino in lhe cYlind6r

it!2,-r

fr' 16. Usi¡g lhe bru6h. .lean lhe cylinder head inieclor boré walls for lh€ copp€r

F¡qum

d€M.

d -

\/

chn¡nq rñlebr np BoE

NOTE The injector bore sealino tool ñust be used to pr4¡t débris lrom enle ñq lhe luel aqe.

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

18.

Using $echip vacuum, rem@é alldebris lh6 coppér slee@ bofe.

lóñ

SEFVICE HINT Do nol ¿tl€mpl lo bl@ away debris usanQ compressed air Dóing só €n rasull in eye iniufy.

19. Fem@the

NOfE Thé inieclor b.re sealing ioo mur be used lo pfMnt debfis lrom ente ¡g lhe luel pa$aqe.

niéclor bo¡é sealing lool lrom lhe cylinder head. Usingrhschip vacuum, €move a.ry rcmaining deb¡is.

REPAIB INSTRUCTIONS, PART

1

6. sc@

lhe sMsanq iip lhroush ihe cddpér dd complelely inlo lhe swag¡ng tool holder, 333001 96, untill slops (fingertight). Ensure lhal lhe lool is tully s€aléd in lhá

d€wé

NOfE Swaging bil @n bé ordé€d s

a

spáF p.rt

if

thé

7.

Loosen th6 swaging blt iFralling rhe roolln rhe

/AcaurtoN Fa¡ture to bi¡

l@en

the

eagkg

bako twisled ot baken.

b¡t

cú

É

]t iñ the

Lubdcats ths swaoinq bil and lhe lhreads on

9

5.

Thead lhe swaging bir @mp¡erely inro lhe lla ng lool unlil il 6lops (iinqe¡ liqh0.

Caretult place the sr€we insallarion lool

lwirh new @pper deM aflached) iñto th6 unl ¡niedor borá ol the ctlinder head. Ca€lully mow ths copper slerye downwad inlo lhe injeclor bore so that lhé $áging bil is quid€d inlo ihe injecfor tlp boÉ in tho cyl¡nderbaád. Push downward on the inslallalion lool usiñO hand lo¡cá io m@e the copPér de4 dowñwád úntll it bonoms oul on ihé injeclor deeE seal in lhe boilom oi lhe injector boé. Use lh€ unil injéclor hold down and boll 10 hold the lool ln position. fo ensu@ thal lhe @pper s ¡s boltoñed in lh6 cylindér héad, tghlen lhe unil injeclor hold down bolt io speilication.

e4

HEPAIR INSTBUCTIONS, PART

1

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.

1 1

FicuE 205

-

rni€dor Y.ke ¿nd

sred

10. Fla€ ihe copper dewe

by turning thá nul

(1) .lockuise while holdinq lhe spindle unlil lh€ swaqing bil hás béén pu lled @mplelely Ihrough lhe copper sleeve.

AcaurroN Fá¡lurc ta hold ¡he sp¡nde

an

rcsutt in a rw¡s¡éd

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.

,

12.

Femore lhe

slse

insiallárion rool flom thé

Usinq brush, J 42aa5-9, a.d enénsion, J 42435 1, ensu€ lhal the@ppers¡eqe bore É clean. lñse¡l á néw wásh€r and the injeclor or a @alinq pluq,999a251.

NOTE ll th€ injeclor is nol be ng instal ed imñediat6ly, inslall the seal¡no plug inlo the i¡jecior bore to

REPAIR INSTRUCTIONS, PART

FslEm

unr ¡n¡dor BoE

ssn4

1

Ptu!

Expansion Plug Replgcement [213 FPI The cyl¡ndef head

he thÉe dpansion

p uqs

ol

29 mm (1-9/64 or 1,142 inch)

-

40mm(1-37164orl.575inch)

50mm(l-31/32or1.96Sinch)

Allare iGialled using lhe tollowlng procedure:

1,

Clean lhe plug bo€ thorough y.

2.

Apply loclil@ 277 saler, or eqútuálsnl, 1o lh6 6xpansion plug and plug bore,

3.

Ustñg a

4,

Fepeal sleps

sdkét, éxrénsio¡ and a hammer, pess lhe dpañsion plug inlo rhe plug boe

1l

lor éách

ne

plug.

NOTE Thé p ug shoúld be iGlalled llush to 0.503 mm (0,020 iñch) bdethe sul¿ce.

Valve lnspection L lrocl lhe vdv€

lor cEcks, pils and olher @ndlfio¡s that ñáy causé impmpe¡

2,

lnspecl lhe slem ends ol lhe hh€s lór nicks and bu¡6 rhar may damage the seáls at

3. 4. 5.

tüeasúe lhe válvó séál a¡gie. ¡¡€asuB EbE slem length and diameter Discárd and rBpla@ damaged or

won

REPAIR INSTRUCTIONS, PART

1

ffi

rb

€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 lt in eng¡ne Íailurc

e

.

Using engine oil, lubrical6 lh6 Elve slems.

2.

Slide lhesleñ back and forlh in ilsguide to

3.

Using lhe appDpriale %l@ seal inslaller, 45112460. assembl¿lhé seals on |hé válv6

4.

Drop a bottom washér, a spring sel and a top Msher @er 6ach sl€m.

5.

Usinq thespnno compessór. 9990210, to compress the spr ngs, ass€mblérhe keepeE on lhe slems.

1

d

REPAIB INSTRUCTIONS, PART ROCKER AFM SHAFT BENCH PROCEDURES (rriAcK MP8 EURO 3 ENGTNE) [213 LP] Descr¡ption The MPB ocker arm shatl assembly i6 held in 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.

1

Rocker Arm Shaft Disassembly wlTH OF WÍTT¡OUT ENGINE BBAKE Dis4semble lhe shaft and @mponenls as

1.

Mad<üo rock€rarns and b dg4 so lhey can bé pút back h th6n o oiñal locations.

2

Slid6lhá ro.k€r

"ms

off

rh. shelr

REPAIR INSTRUCTIONS, PART lnspeclion 1. lnspel

all cómpó¡énls of rhe @cker afñ assembly lor damaO€ and éxcéssiw weai ll lhe rcller does nol m@or binds, répláce

2.

vdre and pislon aclion on lllé dháust ró.ker am6 ior any signs oi blnding. Check the

R€placs as n6c6ssary

3.

lñspet $é rcckér shal lor ga ling, s.oring or ex@*ive wear R6p ac€ ás n€cossary

Rocker Arm Shaft Assemb¡y wlTH OR WTHOUT ENGINE BRAKE The asembly pócedur6 lór lhé ro.kar am shall 1

,

A@ñge lhe rocker arms an sels aeordlng tó ihe ñalklngs ñád€ al disa$émbly.

2.

1

ft; rcilkei arm borcs. Then. slide lhé rockér am séis oñro lhé sh¿ftaNodlne to the ñar[iñqs máde at Lubri€te the shalt and

BEPAIR INSTRUCTIONS, PAHT CAMSHAFT BENCH PROCEDUFES Camshaft lnspection

1

NOTE The v¡bfáion dampéf ánd camsha¡ lini¡g gear a@ *paEle componefts atiached 1o th€ shafi by

[213 CH] libalion dmper can be rémN€d whilo lhe emshal¡ remains o¡ lhe

The liminq gear and

CAMSHAFT GEAR REMOVAL

AcaurroN

1. Pov¡de

and

Handle lhe @nshal¡ @teluly to awid béndkg ¡¡. go mno¡¡ced. Sl¡ght but hanlul bends Fáilue lo heed ds ñut¡ú coúd t$ull ¡n

m

mۖs

g€r

ol @nto linq lhe damp€r when lhe atehinq $r4s a€

scws. S6t ás dé lhé damp$ trd 96ár

2. R€move lh€ atl¡chinq

üetutúE qsine h¡lúe.

3.

L(Mr Esains cap (suDod)

in a safá

REPAIR INSTRUCTIONS, PART t¡lsPEcTloN l. ClÉn lhe camshalt lhobuoh¡y.

NOTE lf arry 6mpon6nr displá's scoÍng or eke*iw úear, 2.

lnspocl the amshall, lobes and louma s.

s, lnsp@r lh€ Bmsháll oear lnspect lhe vibralioh dahper

CA

1

SHAFT GEAB INSTALLAION

T

€mshafi can be inslalléd o¡ a irope y inslalled cylinder hád bélor6 atlaching rh€ riming ger and v¡bElion dampei The

1

,

2, 3.

Us¡ng two or lh¡ee ariachinq sclM, loosét ssmds rh€ damper, gar and shalt,

¡.slall lh¿ @maindér ol rhe sc@ws l@sely. Tighleñ lhe s@s a@od¡ng 10 lhe sequehce specilied h the ENGINE ÍOROUE SPECIFICAf IONS seclion.

REPAIR INSTBUCTIONS, PART

1

EXHAUST PRESSURE GOVERNOR, OVERHAUL Sp;c¡al Tools

vdE sprno hrard {ah rdr.)

il

REPAIR INSTRUCTIONS, PART

1

REPAIR INSTRUCTIONS, PART

1

Disassembly 1. Rémow the end

@Er lrcm abde lhe

2. RémM th€ bofts and lake oul lhe plu¡gei 3. Fem@ lhe seals (4, 20 and I9). Feier lo

4. 5.

Fem@ lhe sel scrs on lhe plunqer rod. Placé lhe qhausl pfe$u€ gdefnor inlo a pfess. comp@$ rhe 6p¡ing enouqh ro €mow lhe @lw ké¿p€fs.

NOTE Do nol pr€ss mo€ lhan néés*ry to remdé the k€6p6rs- Coñpr€ssing thé spnng lully en

L

CIéán all parts áñd repláce any tlát áÉ

Assembly 1. l¡6rá I rhe plunqer

rod into c6nlér lhe ¡¡slalla seal wlth thé tacinq in6ide ihe housing. and a n.w spnnq holder

b€hind so

a

¡s

RémM

rhe plunger rcd,

splng and shutter

Femore lhe bolls hold¡¡g the shiéld and ecu ¡g llanqe.

L

10

erer, h€at

careiully rap our the spr¡¡q horder that

s€cu¡eslhésp nsandseal(9)(Foufe216).

FiluE2r9Hous¡nqAsmblv

REPAIR INSTHUCTIONS, PABT 2.

1

Pll the plunoe¡ fod orfo dfifl999261o in a 11 999a225, pre$ on lhe

p@ss. Using d¡

spring holdé. unlil it bolioms in lhe houslngBemové lha plung6r md. Ch4k to make sufe lhai lhe spr hg holder is coreclly

I 6.

lnstalllhe secúr¡ñg fance, heat shietd and cwef. Tighlen rhe bolts to speciiioation. lnslalllhé shunér, sprlng and piunger

od

5. Compess the spriñg by hánd, making sure thalihe shufiershaft and pluhger rod togeihe¡ a¡d lhai lhe p u¡ger rcd l¡ls corcclly nto thé seal- slop applying p€ssu.é il undue stance is len.lnstáll

ft

6

sprho

lnslaLl the sel screw into the ptunger rod. Apply seaLanl lo lhé scr4 beiore inslalllng. Tiqhlen lhá sér sc@w to

sl

lñslalla

3.

2.

ns

seal lnto lhe plunger rod and inslall lh6 p unger Apply sealani to the bolls and ughieh them lo speciñ.alion,

lnslalllhe eñd ev6r using new *als, lvake sure lhal lhe seal boioms ¡n lhá housing. lnslall lhe seal with the t át s de lácing lh6 houslno. Tigtf€n lhé end .over botis 10

HEPAIR INSTRUCTIONS, PABT COOLING SYSTEM COMPONENTS BENCH PNOCEDUBES Oil Cooler Recondit¡oning [21s DWI The or cooler cannol be

ds$embled, Should il

FicuE2_oilcool€rAgblv t3

Frd PhE

1

@ -

REPAIR INSTRUCTIONS, PART

ENGINE REASSEMBLY MACK MPB Euro 3 Engine [200 EAI Special Tools

Hadr¿

L

€

Fnd

'rh

wrú3 lss (b2s nñ

HddDen

ce,

rds

s@€r

(E$enriaD

Frnq

(EsnrÉ[

hor4,

1

REPAIR INSTRUCTIONS, PART

unl rñ]dor Pddion s ee€s {Essriat

PMn Rnq ftmpf6s, (bsnnd)

swsp

Dar rndi¡aro, (Esedi¿l)

1

REPAIR INSTRUCTIONS, PART cffiMi úhq

B*dns

c4

&r lEs*d

¿

)

PGs rmr (EEgrE )

F sh¿d ru'nrno roor(EssrÉl)

1

REPAIH INSTRUCTIONS, PART

c¿msh¿Ii

se$r

Depm

Ges (Esda

rd

crindd Hdd

Lih nq

rnjedton EoF

creaijE Ki (Esdü

3d

rensione'

Re

€*

leediar)

rml (Esnr

)

a )

)

1

REPAIR II,ISTRUCTIONS, PART hk$d

rhns

root

{EssÍd)

1

REPAIB INSTRUCTIONS, PABT

1

General lnslruct¡ons

Crankshaft lnstallatlon

t210 ENI

f212 HP1

This sclion includes slePby-slep pDcedues lor complélé 6a*éñblv ol th6 óraln6. Maior componeñis thar @e lñspected and @erháuled or repraced under the fespecrire bench procedue seclions oi lhis manual are Einslalled he re as 4se m blies. Screw lighl€ning séqu 6nc6s, rorsué sp€cifi€lióñs ard séalárt appllÉtbñ pan€fns lbf majof component parls appeaf in lhis s@r¡on and arso iñ rhe ENGINEToRoUE SPECIFICAÍ IONS smiton.

Ths cEnkshalr ¡s hé.vy. Do NOT aliempl to lnstall lhe c€nkshalt wilhoul lhé h6lp óf áñ Gslsiani or the use ot a s(hable lifting ddice. Fá¡lüE io héed thie warn¡nq mav Ésuftin sere péend ¡njury and

Failue to follow the aequén6 ol operations náy Ésult ¡n damage to compo¡ents or

1,

Perlo ¡m a visu a insp€clion ol lhé cÉnksh aft iournáls, block and bgaring eps lor siqns ol wea¡ and/or damage- Che.k lhe back ol lhe beanng br beadng si@. Bedngs.an be slamped as "STD" lor gandard, or wilh a ¡umber¡nd¡caftglhe dersl2e of lhe

Cleanlhemainbea ng seals in lhe cylinder block and inslállnw béaing insons (shens). Lubd€ie ihe beadnq hsert

NOTE Aner cleanlng the componenls, slore them whe@ lhéy will @main clean unlil néédéd lor

wh6n requiréd lor inslálling componenLs, be sure to u* crean engi¡e o I ot rhe apprcved Do nol reus6 Ma bo[s. Lubncab

whefs

NOfE The bean ng shells should ¡ol be

lu b

ri@led on

lh€ads,

and undef screw heads wllh clean éngi¡é oil dcépt a6 nored. Do

¡ol lub cálé .mred bohs.

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.

Frsué223

Ma¡n

|

A..finq lupFd 2. Eeaíns

REPAIR INSTRUCTIONS, PART

1

Lubrcaté thá th@ads ol thé rásr6ie6 with d@n eng¡ne oiland jnsen in lhe caps. Position the No. 1 bea ng€p@¡théNo c€nkshatljourñalandsla lhecap*res th€ lht€aded ho es ¡n the cylnder bt@k.

NOTE tüake suro lh€ beannq €ps (se malklnss oñ lh6 €p).

aé @rdlv fined

Using á pl6l¡c mallet,lap lh€ b€a no caD down unlil il conlacls Ihe mach¡¡ed

=::::--

F¡ ] J

6. Tighlen

lhe.apscrem f ng€rlighl,

''':

Ma¡n Bearing Cap lnstallation

f212 HHI 1. C¡ean the bo@ lnlhé ol rhé

2.

l@r

beárinq cap ánd b.ck

bea¡¡nq,

lnslall lhé bea.lnq in the b@Ínq .ap. The bearinq ñGt b€ ircralléd dry

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 and 7. fhs c€nlér bearind cap, No. 4, is insratted tate[

Nc. 2.3,5,6

L

':- -"'/4 | t

\\--) FsuÉ

225

-

Mah

B4

Using a torq@ w@nch, tighten lhé bea nq c.p.cras according lospec¡t¡€ttoñ.

NOTE Thrust washefs á16 sléél wilh a bfonze facing. Thé hclng has oil q@oves cut ¡n1o Use slandád rhick¡ess lhrustwasheG

ñs

CdptBb d'on(Lmet

REPAIR INSTRUGTIONS, PART

1

Pla.é thé uppér thtust washe. sections in pos¡tion ¡n the cylind6r bl@k ar lhe cenler bering lo@1lon. fhe steet stdé ot lhe thrust washs ra@s ihe block. The bbnze side la€s üs cEnkshaft. This app i6 lo bolh upper and l@er thrusl Msh¿r s€clions.

lj"ffir

rñ

FiguE¿3_M3¡nBEin!c¡P,ftrudwÁhg

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 lJs¡¡g the pfy bar,

m@ lhé cdnkshafr

in

the

NOfE R¿lár lo allo@ble c@nkshaft end ptay totehñcos

under F¡¡s a¡d ¿iñ¡ts in lh€

10.

Posilion lhe lower f)tusl ú6hér s€crions ón lh€ cé¡lá¡ béa ng.apwllhlhe bónzesid€ heing the c¡ankshaít and a$emble the €p and capscrews ¡n lhe enoiñé block.

NOTE Lub¡icate lhrusl Mshor seclions wfih engine oil

sPEclFlcalloNs

BEPAIR INSTRUCTIONS, PART 14

1

Usiñq á ñagn€t c bas indicalor lool wilh ils lip agáinst a cÉnkshall euñtémeighl, check cÉnkhatl end play as iollM.

Piston and Connect¡nd Rod¡ Assembly lnstallation

a, b.

ser the dial indi@rof ro @ro.

[212 NB 212 LP]

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,

@m@ rhe rhrur washeE and insrall w4he6 ot suilable lhickne$ lo meel

1.

Rótáté lhé cÉnkshaft so lhat the ¡ournals 10¡ Ihe No. 1 ánd No 6 cylindéB ae al Botlom

Dead Ce¡ler (BDC),

AcaurtoN búkg

fhe thi¿kné* oftha rtuus¡ washets k lhe 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

us¡nq á loqoe wfen.h w¡th thé @@t lhru6l @sher 6eclions in place, lighlen all b6ánng cap capsrws a€ording lo Reched( the eñd play to be súre thal the thrusr MsheF hare been insralled corccrly ánd lhal end play is within sp¿ciliEtion. Rotal€ th€ crankshaft by hand sMEl olalio¡s lo rer¡t lhal lhe bear¡ngs ha@ be€npopé y insloll€d and rhar lhé

Fsuré 22e

-

N..

l cyrñd.' {cBnklh¡n d

BDc)

Apply a ligh¡c@lofclean engin€ oilto üe pislon ánd rjnqs. Check lhal lhe paston dno gaps are equally displacéd around lhe circumlerence ol lhe pislon át a 12o-deg@e r€lalionship lo one anolher Apply a lighl c@l oi clean engina oil to the lnside suffá6 ol the pigon rinq @mpressor Carelu ly cleañ lh6 béaring o¡ the connecli¡g fods and bea ñg caps. alsq Position a nN upper bear¡nq insert hlo lhe connecl¡nq rod. alignrhé rab in the bearing

REPAIR INSTRUCTIONS, PART s.

NOTE fhé bearing sizs

is

lound on lhé báck ol lhe

1

Uslns lhe rns coñpréssor, s!¿e úe pjston and rcd a$embly ¡nlo lhe cyliñd€r unlil lhe comp€ssor @nlacts the top ol lhe llñér

AcauttoN ñtd

fhe arcw an top ol the p¡slan 4d lhe FRONT oD tha Mnacting @d ñust be le¡ng the ltút ol the eng¡ne. IhJs ensútés thdt tha ntch ¡n ¡he ¡awet iñolt,\e ski d@Bthep¡ston@tihs

6.

Apply a llghi @al ol.¡ean eng¡ne oll lo lhe

\L"

Apply a liqh¡ @al ot clean engine oillorhe i.slde suda@ ol thó cylindóf lin6r T€mpor¿rily r€mm lh6 pr€s lool, 9996966, when lhe pisto¡ ¡s lo be anslalled. Be¡nsiall thé prcss lools whén lhé pislon ¡s in pcilion.

?,ffi W | 2. Fisron Fins comprcs$¡

I

rot

10- Máke suBthé coñneclinq lhe c€nkshafjournal-

1.

Fblon Riñq

como€sel I

2.

Pfs

Tor,

sM6

fod isat¡qnedw¡lh

REPAIR INSTRUCTIONS, PABT 11. Whils Gina a hammer

handle lo push lhe

1

13.

Ensúr€ thal rhé .orcct €p É litrdd lo lhé @rect coñn€cliry rcd (reter rothe mafks).

r4.

lnsrall lhe lasreners and nghre¡

p¡slon lhrouqh the iool, ápply pEs6uré lo lhe ¡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

lo

r1 /A r. Pcron F¡nq

Gnpres' t2 Phbn ls.cyridérBd

AcaurtoN e@¡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 úmp6sü túl rcñaire in @ntacl v¡lh lhe Do ñot lse

cyhhdet sleM until ¡he pbton c¡eaB the toat. Failue lo heed lh¡s eu ón nay bsuft ¡n eree

12.

Lubf¡cale the cáñkshall b€a ngansensañd cEnkshailioumals wilh €nqiné oil.

|

2.

Atehiio cs.rews

15.

Bepeat the above sleps to lnstalt the No 6

16.

Folate lhe cránkshaft so that the journats tor lh6 No 2 and No. 5 cyllnders ac ar bonom dead cént€r and installthe No.2 and No. 5 pislons foll@ing lhe abo@ steps.

REPAIR INSTRUCTIONS, PART

1

i7.

Forare rhe cEñkshaar so rbar rhe journals bf lhé No, 3 and No 4 cfiindéB arc al bonom . d€ad cenbr and nslall th6 No. 3 ánd No. 4 p¡stons, aga¡n tollo{,lng ihe abde sleps.

13. lnslall

all pistóñ c@ling

nozlés using lasteners, T¡chte¡ the fasteneG io

Fhrr¿

á6

Prsron coolrns

lr

tw

llozlé lnd¡lrdion

2\X 2.

lofque tlghien prmp fasteneG to

PÉbn coorinq Noz é

Oil Pump and Block Stiffener Plate

lnslallalion [211 DD]

NOTE

i\3

o C oI O

Clean lhe oilpump mounl¡nq surla@ ol lhe @ar nain beáring cap béforo installino the ñéw oil

oilpumplo lhe rcarmaln and install the punp lasteneE.

NOTE The cEnkshan may need lo be @lated io allow a@6$ lor lhe oil punp la6leñeG.

Thé eng¡n€ sr¡íening |rame has sharp édgés that car c¿us€ ¡njury. To p¡event ¡njury, wÉr protect¡ve gtoves whén handt¡nq.