Mack Truck MP10 Diesel Engine (’07 EMISSIONS REGULATIONS) SERVICE MANUAL(5-115) – PDF DOWNLOAD
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Mack Truck MP10 Diesel Engine (’07 EMISSIONS REGULATIONS) SERVICE MANUAL(5-115) – PDF DOWNLOAD
Language : English
Pages : 360
Downloadable : Yes
File Type : PDF
Size: 39.2 MB
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Mack Truck MP10 Diesel Engine (’07 EMISSIONS REGULATIONS) SERVICE MANUAL(5-115) – PDF DOWNLOAD
INTRODUCTION
Mack Trucks, Inc. cannot anticipate every possible occurrence that may involve a potential hazard. Accidents can be avoided by recognizing potentially hazardous situations and taking necessary precautions. Performing service procedures correctly is critical to technician safety and safe, reliable vehicle operation. The following list of general shop safety practices can help technicians avoid potentially hazardous situations and reduce the risk of personal injury. DO NOT perform any services, maintenance procedures or lubrications until this manual has been read and understood.
- Perform all service work on a flat, level surface. Block wheels to prevent vehicle from rolling.
- DO NOT wear loose-fitting or torn clothing. Remove any jewelry before servicing vehicle.
- ALWAYS wear safety glasses and protective shoes. Avoid injury by being aware of sharp corners and jagged edges.
- Use hoists or jacks to lift or move heavy objects.
- NEVER run engine indoors unless exhaust fumes are adequately vented to the outside.
- Be aware of hot surfaces. Allow engine to cool sufficiently before performing any service or tests in the vicinity of the engine.
- Keep work area clean and orderly. Clean up any spilled oil, grease, fuel, hydraulic fluid, etc.
- Only use tools that are in good condition, and always use accurately calibrated torque wrenches to tighten all fasteners to specified torques. In instances where procedures require the use of special tools which are designed for a specific purpose, use only in the manner described in the instructions.
- Do not store natural gas powered vehicles indoors for an extended period of time (overnight) without first removing the fuel.
- Never smoke around a natural gas powered vehicle.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Mack Truck MP10 Diesel Engine (’07 EMISSIONS REGULATIONS) SERVICE MANUAL(5-115) – PDF DOWNLOAD
INTRODUCTION 1
SAFETY INFORMATION 2
Advisory Labels 2
Service Procedures and Tool Usage 3
EXPLANATION OF NUMERICAL CODE 5
CONVERSION CHART 6
ABOUT THE MACK MP10 ENGINE 9
Service Precautions Summary 11
VISUAL IDENTIFICATION 13
MP10 ENGINE MODEL IDENTIFICATION 14
Engine Information Plate 14
Engine Serial Number Identification 14
DESCRIPTION AND OPERATION 15
MACK MP10 US07 ENGINE DESIGN FEATURES 16
Engine Components 16
Lubrication System 24
Crankcase Ventilation 25
Fuel System 26
PowerLeash™ Engine Brake 31
Exhaust Gas Recirculation System 32
Exhaust Aftertreatment System 34
Air Intake System 37
Variable Geometry Turbocharger 37
Cooling System 38
Engine Management System 39
GLOSSARY OF TERMS 41
COMPONENT LOCATOR 45
MP10 ENGINE COMPONENT LOCATION VIEWS 46
TROUBLESHOOTING 49
ENGINE SYMPTOM DIAGNOSIS 50
Troubleshooting Technique 50
Noise and Vibration 50
ENGINE CHECKS AND TESTS 52
Special Tools 52
Camshaft Sensor Depth, Check 55
Camshaft Timing, Check 55
Crankcase Ventilation, Check 56
Cylinder Head, Pressure Test 57
Cylinder Liner and Piston Wear, Check 58
EGR Cooler, Pressure Test 59
Engine Compression, Test 61
Flywheel Housing Runout, Check 63
Oil Cooler, Pressure Test 64
Rocker Arm, Check 64
Thermostat, Check 67
Valve Guide Wear, Check 68
TABLE OF CONTENTS
Page v
MAINTENANCE 69
COOLING SYSTEM MAINTENANCE 70
Special Tools 70
Coolant Drain Outlets 70
Coolant Filter 70
Drive Belt, Replacement 71
FUEL SYSTEM MAINTENANCE 73
Special Tool 73
Fuel Filter Replacement 73
UNIT INJECTOR CLEANING 77
Preliminary Steps 77
Cleaning and Inspection 77
Final Steps 78
LUBRICATION SYSTEM MAINTENANCE 79
Special Tool 79
Oil Level Check 79
Oil and Filter Change Procedure 80
Crankcase Ventilation System 81
Piston Cooling Valve, Replacement 81
EXHAUST AFTERTREATMENT SYSTEM (EATS) MAINTENANCE 82
Special Tools 82
Diesel Particulate Filter (Compact), Replacement 83
Diesel Particulate Filter (VBOC), Replacement 86
Aftertreatment Fuel Injector (AFI) 89
REPAIR INSTRUCTIONS 91
ENGINE REPLACEMENT 92
Special Tools 92
General Instructions 93
Engine Removal 93
Engine Installation 95
ENGINE FINAL PREPARATION AND OPERATIONAL CHECK 97
Filter Element Installation 97
Engine Lubrication System 97
Turbocharger 98
Cooling System 98
Fuel System 98
Engine Operational Check 99
CYLINDER HEAD PROCEDURES 101
Special Tools 101
Valve Cover, Replacement 108
Solenoid Valve, Compression Brake, Replacement 110
Rocker Arms, Replacement (ALL) 113
Camshaft, Replacement 121
Camshaft Bearing Brackets, Replacement 128
Unit Injector, Replacement (One) 130
Copper Sleeve, Unit Injector, Replacement 138
Cylinder Head, Replacement 147
Valves, Replacement 154
Valve Guides, Replacement 156
Valve Stem Seal, Replacement 158
Page vi
TABLE OF CONTENTS
Valve Seat, Replacement 160
Valve and Unit Injector Adjustment 164
TIMING GEAR PROCEDURES 171
Special Tools 171
Timing Gear Cover, Replacement 172
Timing Gears, Replacement (All) 175
Sealant, Timing Gear Plate, Replacement 180
CYLINDER BLOCK PROCEDURES 183
Special Tools 183
Oil Pan, Replacement 185
Engine Stiffening Frame, Replacement 187
Main Bearings, Replacement (All) 188
Crankshaft, Replacement 191
Cylinder Liners and Pistons, Replacement 195
Flywheel Housing, Replacement 205
Sealant, Crankshaft Cover, Replacement 208
Crankshaft Seal, Replacement (Rear) 212
LUBRICATION SYSTEM PROCEDURES 215
Special Tools 215
Oil Cooler, Replacement 216
Oil Pump, Replacement 218
Gasket, Oil Filter Housing, Replacement 220
Piston Cooling Nozzle, Replacement 222
Piston Cooling Valve, Replacement 223
Oil Cooler Overflow Valve, Replacement 223
Safety Valve, Oil Pressure, Replacement 224
FUEL SYSTEM PROCEDURES 226
Special Tool 226
Fuel Feed Pump, Replacement 226
Fuel Filter Housing, Replacement 228
Fuel Overflow Valve, Replacement 233
INLET AND EXHAUST SYSTEM PROCEDURES 234
Special Tools 234
Injector, Aftertreatment, Replacement 235
Shut-Off Valve, Aftertreatment, Replacement 237
Separator, Crankcase Ventilation, Replacement 239
Discharge Recirculation Valve, Replacement 240
EGR Cooler Replacement 242
EGR Cooler Cleaning 245
EGR Pipe (Cooler Inlet), Replacement 247
EGR Valve Replacement 251
EGR Venturi Tube Replacement 257
Exhaust Manifold Replacement 260
Inlet Manifold, Replacement 262
Turbocharger, Replacement 269
Turbocharger Smart Remote Actuator (SRA) Replacement 275
EXHAUST AFTERTREATMENT SYSTEM (EATS), PROCEDURES 281
NOx Sensor and Control Module, Replacement 281
COOLING SYSTEM PROCEDURES 284
Special Tools 284
Coolant Pump, Replacement 284
TABLE OF CONTENTS
Page vii
Fan Hub, Replacement 285
Thermostat, Replacement 286
CONTROL SYSTEM PROCEDURES 288
Engine Control Unit, Replacement 288
SPECIFICATIONS 291
MP10 US07 ENGINE MECHANICAL SPECIFICATIONS 292
Material and Dimensional Data 292
Engine Component Torque Specifications (Critical Fasteners) 297
Standard Bolt and Nut Torque Values 319
ENGINE GASKETS, LUBRICANTS AND SEALANTS 320
Gasket and Seal Reuse 320
Lubricants and Sealants 321
SCHEMATIC & ROUTING DIAGRAMS 323
MP10 ENGINE SYSTEM SCHEMATICS 324
Engine Fluid Flow 324
Drive Belt Routing 327
SPECIAL TOOLS & EQUIPMENT 329
ENGINE SERVICE TOOLS 330
Special Tools for Engine Overhaul 330
INDEX 347
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