Mack Truck MP8-(EURO 4) Diesel Engine Service Manual(5-117) – PDF DOWNLOAD
FILE DETAILS:
Mack Truck MP8-(EURO 4) Diesel Engine Service Manual(5-117) – PDF DOWNLOAD
Language : English
Pages : 368
Downloadable : Yes
File Type : PDF
Size: 4.10 MB
DESCRIPTION:
Mack Truck MP8-(EURO 4) Diesel Engine Service Manual(5-117) – 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 MP8-(EURO 4) Diesel Engine Service Manual(5-117) – 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 MP8 EURO 4 ENGINE 9
Service Precautions Summary 11
VISUAL IDENTIFICATION 13
MP8 EURO 4 ENGINE MODEL IDENTIFICATION 14
Engine Information Plate 14
Engine Serial Number Identification 14
DESCRIPTION AND OPERATION 15
MACK MP8 EURO 4 ENGINE DESIGN FEATURES 16
Engine Components 16
Lubrication System 24
Crankcase Ventilation 27
Fuel System 28
PowerLeash™ Engine Brake 33
Exhaust Gas Recirculation System 35
Air Intake System 37
Variable Geometry Turbocharger (VGT) 37
Cooling System 37
Engine Management System 38
GLOSSARY OF TERMS 40
COMPONENT LOCATOR 43
MP8 EURO 4 ENGINE COMPONENT LOCATION VIEWS 44
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 60
Flywheel Housing Runout, Check 62
Oil Cooler, Pressure Test 63
Rocker Arm, Check 64
Thermostat, Check 67
Valve Guide Wear, Check 68
TABLE OF CONTENTS
Page v
MAINTENANCE 69
LUBRICATION SYSTEM MAINTENANCE 70
Special Tool 70
Oil Level Check 70
Oil and Filter Change Procedure 71
Crankcase Ventilation System 71
FUEL FILTER REPLACEMENT 72
Fuel Filter Change 72
COOLING SYSTEM MAINTENANCE 74
Special Tool 74
Coolant Drain Outlets 74
Coolant Filter 74
DRIVE BELT REPLACEMENT AND TENSIONING 75
General Information 75
Automatically Tensioned System 75
REPAIR INSTRUCTIONS, PART 1 77
ENGINE REMOVAL 78
Special Tools 78
General Instructions 79
Removal 79
ENGINE DISASSEMBLY 82
Special Tools 82
General Instructions 86
Mounting the Engine on a Repair Stand 86
EGR Crossover Piping Removal 87
EGR Venturi Tube Removal 88
Cylinder Head (Valve) Cover Removal 89
Engine Wiring Harness Removal 89
Timing Gear Cover Removal 90
Camshaft Gear and Vibration Damper Removal 91
Rocker Arm Shaft Removal 92
Valve Yoke (Bridge) Removal 94
Camshaft Removal 94
Unit Injector Removal 95
Starter Removal 100
Turbocharger Removal 101
EGR Hot Pipe (Cooler Inlet) Removal 102
EGR Valve Removal 103
EGR Cooler Removal 104
Exhaust Manifold Removal 106
Oil Filter Housing Removal 107
Coolant and Pump Inlet Housings Removal 107
Cooling Duct Cover and Oil Cooler Removal 108
Drive Belts and Fan Hub Removal 109
EGR Mixer Removal 110
Crankcase Ventilation (CCV) Separator Removal 111
Fuel Lines and Filter Housing Removal 112
EECU and Cooling Plate Removal 113
Inlet Manifold Removal 114
Tandem Pump (Fuel and Power Steering) Removal 114
Air Compressor Removal 115
Page vi
TABLE OF CONTENTS
Flywheel and Pilot Bearing Removal 115
Power Take-Off (PTO) Assembly Removal 116
Flywheel Housing Removal 117
Crankshaft Rear Seal Removal 118
Timing Gear Train Removal 118
Timing Gear Plate Removal 119
Alternator and Refrigerant Compressor Removal 120
Thermostat and Cover Removal 120
Coolant Pump Removal 121
Cylinder Head Removal 121
Crankshaft Vibration Damper and Fan Pulley Removal 123
Crankshaft Front Cover Removal 123
Crankshaft Front Seal Removal 124
Oil Fill Pipe and Dipstick Retainer Removal 124
Oil Pan Removal 125
Front Engine Support Removal 125
Block Stiffener Plate Removal 126
Oil Pump Removal 126
Piston and Connecting Rod Assembly Removal 127
Main Bearing Cap Removal 128
Crankshaft Removal 129
CYLINDER BLOCK RECONDITIONING 130
Tools and Equipment 130
Piston Cooling Spray Nozzle Removal 131
Cylinder Liner Removal 131
Block Cleaning and Inspection 132
Liner Height Measurement 133
Cylinder Liner Installation 134
FLYWHEEL BENCH PROCEDURES 135
Flywheel Ring Gear Replacement 135
CONNECTING ROD AND PISTON BENCH PROCEDURES 136
Connecting Rod — Piston Disassembly 136
Piston Inspection and Cleaning 137
Piston Ring Inspection and Replacement 138
Connecting Rod — Piston Assembly 139
CYLINDER HEAD OVERHAUL 141
Tools and Equipment 141
Inlet and Exhaust Valve Removal 145
Cylinder Head Cleaning and Inspection 146
Valve Guide Replacement 146
Valve Spring Inspection 148
Injector Sleeve Replacement 148
Expansion Plug Replacement 155
Valve Inspection 156
Valve Installation 156
ROCKER ARM SHAFT BENCH PROCEDURES 157
Description 157
Rocker Arm Shaft Disassembly 158
Inspection 158
Rocker Arm Shaft Assembly 158
TABLE OF CONTENTS
Page vii
CAMSHAFT BENCH PROCEDURES 159
Camshaft Inspection 159
COOLING SYSTEM COMPONENTS BENCH PROCEDURES 161
Special Tools 161
Oil Cooler Reconditioning 162
EGR Cooler Cleaning 162
EGR Cooler Pressure Test 164
ENGINE REASSEMBLY 167
Special Tools 167
General Instructions 171
Crankshaft Installation 171
Main Bearing Cap Installation 172
Piston and Connecting Rod Assembly Installation 175
Oil Pump and Block Stiffener Plate Installation 177
Oil Pump Pipes and Strainer Installation 178
Front Engine Support Installation 179
Crankshaft Front Cover and Seal Installation 179
Timing Gear Plate Installation 181
Cylinder Head Installation 182
Camshaft Installation 185
Timing Gear Train Installation 186
Unit Injector Installation 190
Valve Yoke (Bridge) Installation 192
Rocker Arm Shaft and Engine Brake Installation 193
Flywheel Housing Installation 196
Crankshaft Rear Seal Installation 198
Flywheel and Pilot Bearing Installation 198
Oil Pan Installation 200
Oil Filler Pipe and Dipstick Pipe Installation 202
Power Take-Off Installation 203
Timing Gear Cover Installation 203
Coolant Pump Installation 206
Thermostat and Cover Installation 206
Coolant Pipe Installation 207
Oil Cooler and Cooling Duct Cover Installation 208
Oil Filter Housing Installation 209
Exhaust Manifold Installation 210
EGR Valve Installation 212
EGR Cooler Installation 214
EGR Hot Pipe (Cooler Inlet) Installation 216
Turbocharger Installation 217
Starter Installation 219
Air Compressor Installation 220
Tandem Pump (Fuel and Power Steering) Installation 221
Inlet Manifold Installation 221
EGR Mixer Installation 222
EECU and Cooler Installation 223
Fuel Lines and Filter Housing Installation 223
Crankcase Ventilation Separator 225
Crankshaft Vibration Damper and Fan Pulley Installation 225
Alternator and Refrigerant Compressor Installation 226
Page viii
TABLE OF CONTENTS
Wiring Harness Installation 227
Cylinder Head (Valve) Cover Installation 228
EGR Venturi Tube and Crossover Piping Installation 229
Fan Hub and Drive Belt Installation 232
Removing Engine from Engine Stand 233
Filters and Miscellaneous Components Installation 234
ENGINE INSTALLATION 235
Special Tools 235
General Instructions 235
Installation 236
REPAIR INSTRUCTIONS, PART 2 239
IN-CHASSIS PART/COMPONENT PROCEDURES 240
CAMSHAFT BEARING BRACKETS, REPLACEMENT 240
Preliminary Steps 240
General Information 240
Camshaft Inspection 241
Bracket Replacement Procedure 241
Final Steps 242
OIL THERMOSTAT AND PRESSURE SAFETY VALVE REPLACEMENT 243
Pressure Safety Valve Removal 243
Oil Thermostat Valve Replacement 244
CRANKSHAFT FRONT SEAL REPLACEMENT 245
Special Tools 245
Seal Removal 245
Seal Installation 246
CRANKSHAFT REAR SEAL REPLACEMENT 248
Special Tools 248
Neoprene Seal Removal 248
Neoprene Seal Installation 248
Teflon® Seal Removal 249
Teflon® Seal Installation 250
CRANKCASE VENTILATION (CCV) SEPARATOR REPLACEMENT 252
CCV Separator Removal 252
CCV Separator Installation 252
OIL PUMP REPLACEMENT (IN CHASSIS) 253
Special Tools 253
Oil Pump Removal 254
Oil Pump Installation 254
INJECTOR COPPER SLEEVE REPLACEMENT 256
Tools and Equipment 256
Preliminary Steps 258
Copper Sleeve Removal 258
Copper Sleeve Installation 262
Final Steps 265
TURBOCHARGER SMART REMOTE ACTUATOR (SRA) REPLACEMENT 266
Preliminary Steps 266
Turbocharger SRA Removal 266
Turbocharger SRA Inspection and Installation 268
Final Assembly 271
TABLE OF CONTENTS
Page ix
UNIT INJECTOR CLEANING 272
Preliminary Steps 272
Cleaning and Inspection 272
Final Steps 273
VALVE STEM HEIGHT MEASUREMENT PROCEDURE 274
VALVE STEM SEAL REPLACEMENT 277
Special Tools 277
Preliminary Steps 278
Seal Removal 278
Seal Installation 278
Final Steps 279
REPAIR INSTRUCTIONS, PART 3 281
MP8 ENGINE SETUP AND ADJUSTMENT 282
Special Tools 282
Valve and Unit Injector Adjustment 284
Checking and Adjusting Timing Gear Backlash 289
ENGINE FINAL PREPARATION AND OPERATIONAL CHECK 293
Filter Element Installation 293
Engine Lubrication System 293
Turbocharger 293
Cooling System 294
Fuel System 294
Engine Operational Check 296
REBUILT ENGINE RUN-IN PROCEDURES 297
General 297
Run-In Check 297
SPECIFICATIONS 299
MP8 ENGINE MECHANICAL SPECIFICATIONS 300
Material and Dimensional Data 300
Engine Component Torque Specifications (Critical Fasteners) 305
Standard Bolt and Nut Torque Values 332
ENGINE GASKETS, LUBRICANTS AND SEALANTS 333
Gasket and Seal Reuse 333
Lubricants and Sealants 334
SPECIAL TOOLS & EQUIPMENT 335
MP8 ENGINE SERVICE TOOLS 336
Special Tools for Engine Overhaul 336
INDEX 351
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