Mack MP7 Diesel Engine Shop Manual
DESCRIPTION:
The information in this manual is not all inclusive and cannot take into account all unique situations. Note that some illustrations are typical and may not reflect the exact arrangement of every component installed on a specific chassis. The information, specifications, and illustrations in this publication are based on information that was current at the time of publication. Note that illustrations and instructions are based on information that is subject to change as new engine/chassis development continues. No part of this publication may be reproduced, stored in a retrieval system, or be transmitted in any form by any means including electronic, mechanical, photocopying, recording, or otherwise without prior written permission of Mack Trucks, Inc.
SCREENSHOT OF THE MANUAL:
TABLE OF CONTENTS:
INTRODUCTION 1
SAFETY INFORMATION 2
Advisory Labels2
Service Procedures and Tool Usage 3
EXPLANATION OF NUMERICAL CODE 5
CONVERSION CHART6
ABOUT THE MACK MP7 ENGINE9
Service Precautions Summary13
VISUAL IDENTIFICATION 15
MP7 ENGINE MODEL IDENTIFICATION16
Engine Information Plate 16
Engine Serial Number Identification 17
DESCRIPTION AND OPERATION 19
MP7 ENGINE DESIGN FEATURES 20
Engine Variants 20
Engine Components 20
Lubrication System 32
Crankcase Ventilation34
Fuel System 35
PowerLeash™ Engine Brake 40
Exhaust Gas Recirculation System 42
Exhaust Aftertreatment System 44
Variable Geometry Turbocharger49
Cooling System 50
Engine Management System 51
GLOSSARY OF TERMS 54
COMPONENT LOCATOR57
MP7 ENGINE COMPONENT LOCATION VIEWS 58
TROUBLESHOOTING 63
ENGINE SYMPTOM DIAGNOSIS64
Troubleshooting Technique 64
Noise and Vibration 65
ENGINE CHECKS AND TESTS 66
Special Tools 66
Camshaft Sensor Depth, Check 69
Camshaft Timing, Check 70
Crankcase Ventilation, Check70
Cylinder Head, Pressure Test71
Cylinder Liner and Piston Wear, Check 72
EGR Cooler, Pressure Test 74
Engine Compression, Test75
Flywheel Housing Runout, Check77
Oil Cooler, Pressure Test 78
Rocker Arm, Check 79
Thermostat, Check82
Valve Guide Wear, Check83
TABLE OF CONTENTS
Page v
MAINTENANCE 85
LUBRICATION SYSTEM MAINTENANCE 86
Special Tool 86
Oil Level Check 86
Oil and Filter Change Procedure 87
Crankcase Ventilation System88
FUEL FILTER REPLACEMENT 89
Fuel Filter Change89
COOLING SYSTEM MAINTENANCE91
Special Tool 91
Coolant Drain Outlets 91
Coolant Filter 91
EXHAUST AFTERTREATMENT SYSTEM MAINTENANCE92
Special Tools 92
Diesel Particulate Filter 93
Aftertreatment Fuel Injector (AFI) 98
DRIVE BELT REPLACEMENT AND TENSIONING101
General Information 101
Automatically Tensioned System102
REPAIR INSTRUCTIONS, PART 1 103
ENGINE REMOVAL 104
Special Tools104
General Instructions 104
Removal 105
ENGINE DISASSEMBLY108
Special Tools108
General Instructions 111
Mounting the Engine on a Repair Stand111
Cylinder Head (Valve) Cover Removal 112
Engine Wiring Harness Removal — External 112
Engine Wiring Harness Removal — Internal113
Timing Gear Cover Removal113
Camshaft Gear and Vibration Damper Removal113
Rocker Arm Shaft and Engine Brake Removal 114
Valve Yoke (Bridge) Removal 115
Camshaft Removal 116
Unit Injector Removal117
Starter Removal 122
Turbocharger Removal 123
EGR Hot Pipe (Cooler Inlet) Removal 123
EGR Valve Removal124
EGR Cooler Removal125
Exhaust Manifold Removal 126
Oil Filter Housing Removal 127
Coolant Pipe Removal 128
Cooling Duct Cover and Oil Cooler Removal129
Fan Drive, Idler and Fan Bracket Removal 131
EGR Crossover (Cooler Outlet) Pipe Removal 132
EGR Venturi Housing Removal 132
EGR Mixer Removal132
Fuel Lines and Fuel Filter Housing Removal133
Page vi
TABLE OF CONTENTS
EECU and Cooling Plate Removal 134
Inlet Manifold Removal 135
Tandem Pump (Fuel and Power Steering) Removal136
Air Compressor Removal136
Flywheel and Pilot Bearing Removal137
Power Take-Off (PTO) Assembly Removal 137
Flywheel Housing Removal 138
Crankshaft Rear Seal Removal 139
Timing Gear Train Removal 139
Timing Gear Plate Removal 141
Alternator and Refrigerant Compressor Removal 141
Thermostat and Cover Removal142
Coolant Pump Removal 142
Cylinder Head Removal 143
Crankshaft Vibration Damper and Fan Pulley Removal146
Crankshaft Front Cover Removal 146
Crankshaft Front Seal Removal 147
Oil Fill Pipe and Dipstick Retainer Removal147
Oil Pan Removal147
Front Engine Support Removal 148
Oil Pump and Valve Housing Removal 148
Block Stiffener Plate Removal 150
Piston and Connecting Rod Assembly Removal151
Main Bearing Cap Removal 152
Crankshaft Removal153
CYLINDER BLOCK RECONDITIONING154
Tools and Equipment154
Piston Cooling Spray Nozzle Removal 155
Cylinder Liner Removal 155
Cylinder Block Cleaning and Inspection156
Cylinder Liner Height Measurement157
Cylinder Liner Installation158
FLYWHEEL BENCH PROCEDURES 159
Flywheel Ring Gear Replacement 159
CONNECTING ROD AND PISTON BENCH PROCEDURES 160
Connecting Rod — Piston Disassembly160
Piston Inspection and Cleaning 162
Piston Ring Inspection and Replacement 163
Connecting Rod — Piston Assembly164
CYLINDER HEAD OVERHAUL 166
Tools and Equipment166
Inlet and Exhaust Valve Removal 169
Cylinder Head Cleaning and Inspection 170
Valve Guide Replacement 171
Valve Spring Inspection 172
Injector Sleeve Replacement173
Expansion Plug Replacement 180
Valve Inspection 181
Valve Installation181
TABLE OF CONTENTS
Page vii
ROCKER ARM SHAFT BENCH PROCEDURES 183
Description 183
Rocker Arm Shaft Disassembly 184
Inspection184
Rocker Arm Shaft Assembly184
CAMSHAFT BENCH PROCEDURES 185
Camshaft Inspection185
COOLING SYSTEM COMPONENTS BENCH PROCEDURES186
Special Tool 186
Oil Cooler Reconditioning 187
EGR Cooler Cleaning188
EGR Cooler Pressure Test 190
ENGINE REASSEMBLY192
Special Tools192
General Instructions 195
Crankshaft Installation 196
Main Bearing Cap Installation 197
Piston and Connecting Rod Assembly Installation 199
Block Stiffener Plate Installation 203
Oil Pump and Valve Housing Installation204
Front Engine Support Installation205
Crankshaft Front Cover Installation 206
Crankshaft Front Seal Installation 207
Timing Gear Mounting Plate Installation208
Cylinder Head Installation 209
Camshaft Installation212
Unit Injector Installation 214
Valve Yoke (Bridge) Installation 217
Rocker Arm Shaft and Engine Brake Installation218
Timing Gear Train Installation 221
Flywheel Housing Installation224
Oil Pan Installation 225
Oil Filler Pipe and Dipstick Pipe Installation 227
Power Take-Off Installation 227
Timing Gear Cover Installation 227
Crankshaft Rear Seal Installation229
Flywheel and Pilot Bearing Installation 229
EGR Crossover (Cooler Outlet) Pipe Installation231
Fan Bracket Installation 231
Coolant Pump Installation 232
Thermostat and Cover Installation 233
Oil Cooler and Cooling Duct Cover Installation 233
Coolant Pipe Installation237
Oil Filter Housing Installation238
Exhaust Manifold Installation238
EGR Valve Installation 239
EGR Cooler Installation 240
EGR Cooler Inlet Pipe Installation 240
Turbocharger Installation241
Starter Installation 242
Air Compressor Installation 243
Page viii
TABLE OF CONTENTS
Tandem Pump (Fuel and Power Steering) Installation 244
Inlet Manifold Installation245
EGR Mixer Installation 246
EGR Venturi Housing Installation 246
Intermediate and Mixer Inlet Piping Installation 246
EECU and Cooler Installation 246
Fuel Lines and Fuel Filter Housing Installation 248
Crankcase Ventilation Separator249
Alternator and Refrigerant Compressor Installation 250
Crankshaft Vibration Damper and Fan Pulley Installation 251
Wiring Harness Installation 251
Cylinder Head (Valve) Cover Installation252
Removing Engine from Engine Stand 253
Filters and Miscellaneous Components Installation 253
ENGINE INSTALLATION 255
Special Tools255
General Instructions 255
Installation 255
REPAIR INSTRUCTIONS, PART 2259
IN-CHASSIS PART/COMPONENT PROCEDURES260
OIL PUMP REPLACEMENT (IN CHASSIS)260
Oil Pump Removal 261
Oil Pump Installation261
CRANKCASE VENTILATION (CCV) SEPARATOR REPLACEMENT 263
CCV Separator Removal263
CCV Separator Installation 263
TURBOCHARGER SMART REMOTE ACTUATOR (SRA) REPLACEMENT 263
Preliminary Steps263
Turbocharger SRA Removal264
Turbocharger SRA Inspection and Installation 265
Final Assembly 268
UNIT INJECTOR CLEANING 268
Preliminary Steps268
Cleaning and Inspection269
Final Steps 269
INJECTOR COPPER SLEEVE REPLACEMENT 270
Tools and Equipment270
Preliminary Steps272
Copper Sleeve Removal272
Copper Sleeve Installation 276
Final Steps 279
VALVE STEM HEIGHT MEASUREMENT PROCEDURE 279
VALVE STEM SEAL REPLACEMENT 282
Special Tools282
Preliminary Steps283
Seal Removal283
Seal Installation 283
Final Steps 284
TABLE OF CONTENTS
Page ix
REPAIR INSTRUCTIONS, PART 3 285
MP7 ENGINE SETUP AND ADJUSTMENT286
Special Tools286
Valve and Unit Injector Adjustment 287
Checking and Adjusting Timing Gear Backlash 291
ENGINE FINAL PREPARATION AND OPERATIONAL CHECK 294
Filter Element Installation294
Engine Lubrication System 295
Fuel System 295
Engine Operational Check 297
REBUILT ENGINE RUN-IN PROCEDURES297
General 297
Run-In Check297
SPECIFICATIONS 299
MP7 ENGINE MECHANICAL SPECIFICATIONS 300
Material and Dimensional Data 300
Engine Component Torque Specifications (Standard Fasteners) 305
Engine Component Torque Specifications (Critical Fasteners) 306
ENGINE GASKETS, LUBRICANTS AND SEALANTS 329
Gasket and Seal Reuse 329
Lubricants and Sealants330
SPECIAL TOOLS & EQUIPMENT 331
MP7 ENGINE SERVICE TOOLS332
Special Tools for the MP7 Engine 332
INDEX 347
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