Mack Truck Diesel Engine MP8 (EURO 3 EMISSIONS REGULATIONS) Service Manual(5-116) – PDF DOWNLOAD
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Mack Truck Diesel Engine MP8 (EURO 3 EMISSIONS REGULATIONS) Service Manual(5-116) – PDF DOWNLOAD
Language : English
Pages : 342
Downloadable : Yes
File Type : PDF
Size: 38.5 MB
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Mack Truck Diesel Engine MP8 (EURO 3 EMISSIONS REGULATIONS) Service Manual(5-116) – 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 Diesel Engine MP8 (EURO 3 EMISSIONS REGULATIONS) Service Manual(5-116) – 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 3) ENGINE 9
Service Precautions Summary 10
VISUAL IDENTIFICATION 11
MP8 EURO 3 ENGINE MODEL IDENTIFICATION 12
Engine Information Plate 12
Engine Serial Number Identification 12
DESCRIPTION AND OPERATION 13
MACK MP8 EURO 3 ENGINE DESIGN FEATURES 14
Engine Components 14
Lubrication System 22
Crankcase Ventilation 25
Fuel System 26
Exhaust Pressure Governor (EPG) System 31
PowerLeash™ Engine Brake 32
Air Intake System 34
Turbocharger 35
Cooling System 35
Engine Management System 36
GLOSSARY OF TERMS 38
COMPONENT LOCATOR 39
MP8 EURO 3 ENGINE COMPONENT LOCATION VIEWS 40
TROUBLESHOOTING 43
ENGINE SYMPTOM DIAGNOSIS 44
Troubleshooting Technique 44
Noise and Vibration 44
ENGINE CHECKS AND TESTS 46
Special Tools 46
Camshaft Sensor Depth, Check 49
Camshaft Timing, Check 50
Crankcase Ventilation, Check 50
Cylinder Head, Pressure Test 51
Cylinder Liner and Piston Wear, Check 52
EGR Cooler, Pressure Test 54
Engine Compression, Test 55
Flywheel Housing Runout, Check 57
Oil Cooler, Pressure Test 58
Rocker Arm, Check 59
Thermostat, Check 61
Valve Guide Wear, Check 62
TABLE OF CONTENTS
Page v
MAINTENANCE 63
LUBRICATION SYSTEM MAINTENANCE 64
Special Tool 64
Oil Level Check 64
Oil and Filter Change Procedure 65
Crankcase Ventilation System 65
FUEL FILTER REPLACEMENT 66
Fuel Filter Change 66
COOLING SYSTEM MAINTENANCE 68
Special Tool 68
Coolant Drain Outlets 68
Coolant Filter 68
DRIVE BELT REPLACEMENT AND TENSIONING 69
General Information 69
Automatically Tensioned System 69
REPAIR INSTRUCTIONS, PART 1 71
ENGINE REMOVAL 72
Special Tools 72
General Instructions 73
Removal 73
ENGINE DISASSEMBLY 76
Special Tools 76
General Instructions 79
Mounting the Engine on a Repair Stand 79
Cylinder Head (Valve) Cover Removal 80
Engine Wiring Harness Removal 81
Timing Gear Cover Removal 82
Camshaft Gear and Vibration Damper Removal 83
Rocker Arm Shaft Removal 83
Valve Yoke (Bridge) Removal 85
Camshaft Removal 85
Unit Injector Removal 87
Starter Removal 89
Exhaust Pressure Governor (EPG) Removal 89
Turbocharger Removal 91
Exhaust Manifold Removal 92
Oil Filter Valve Housing Removal 93
Coolant and Pump Inlet Housings Removal 93
Cooling Duct Cover and Oil Cooler Removal 94
Drive Belts and Fan Hub Removal 95
Inlet Air Preheater/Spacer Removal 96
Crankcase Ventilation (CCV) Separator Removal 96
Fuel Lines and Filter Valve Housing Removal 97
EECU and Cooling Plate Removal 98
Inlet Manifold Removal 99
Tandem Pump (Fuel and Power Steering) Removal 100
Air Compressor Removal 100
Flywheel and Pilot Bearing Removal 101
Power Take-Off (PTO) Assembly Removal 102
Flywheel Housing Removal 102
Crankshaft Rear Seal Removal 103
Page vi
TABLE OF CONTENTS
Timing Gear Train Removal 103
Timing Gear Plate Removal 104
Alternator and Refrigerant Compressor Removal 105
Thermostat and Cover Removal 106
Coolant Pump Removal 106
Cylinder Head Removal 107
Crankshaft Vibration Damper and Fan Pulley Removal 109
Crankshaft Front Cover Removal 110
Crankshaft Front Seal Removal 110
Oil Fill Pipe and Dipstick Retainer Removal 110
Oil Pan Removal 111
Front Engine Support Removal 112
Block Stiffener Plate Removal 112
Oil Pump Removal 113
Piston and Connecting Rod Assembly Removal 113
Main Bearing Cap Removal 114
Crankshaft Removal 115
CYLINDER BLOCK RECONDITIONING 116
Tools and Equipment 116
Piston Cooling Spray Nozzle Removal 117
Cylinder Liner Removal 117
Block Cleaning and Inspection 118
Counterbore Inspection and Cleaning 119
Liner Height Measurement 119
Cylinder Liner Installation 120
FLYWHEEL BENCH PROCEDURES 121
Flywheel Ring Gear Replacement 121
CONNECTING ROD AND PISTON BENCH PROCEDURES 122
Connecting Rod — Piston Disassembly 122
Piston Inspection and Cleaning 123
Piston Ring Inspection and Replacement 124
Connecting Rod — Piston Assembly 125
CYLINDER HEAD OVERHAUL 127
Tools and Equipment 127
Inlet and Exhaust Valve Removal 131
Cylinder Head Cleaning and Inspection 132
Valve Guide Replacement 133
Valve Spring Inspection 134
Injector Sleeve Replacement 135
Expansion Plug Replacement 142
Valve Inspection 142
Valve Installation 143
ROCKER ARM SHAFT BENCH PROCEDURES 144
Description 144
Rocker Arm Shaft Disassembly 144
Inspection 145
Rocker Arm Shaft Assembly 145
CAMSHAFT BENCH PROCEDURES 146
Camshaft Inspection 146
TABLE OF CONTENTS
Page vii
EXHAUST PRESSURE GOVERNOR, OVERHAUL 148
Special Tools 148
Disassembly 150
Assembly 150
COOLING SYSTEM COMPONENTS BENCH PROCEDURES 152
Oil Cooler Reconditioning 152
ENGINE REASSEMBLY 153
Special Tools 153
General Instructions 158
Crankshaft Installation 158
Main Bearing Cap Installation 159
Piston and Connecting Rod Assembly Installation 161
Oil Pump and Block Stiffener Plate Installation 164
Oil Pump Pipes and Strainer Installation 165
Front Engine Support Installation 166
Crankshaft Front Cover and Seal Installation 166
Timing Gear Plate Installation 168
Cylinder Head Installation 169
Camshaft Installation 172
Timing Gear Train Installation 173
Unit Injector Installation 176
Valve Yoke (Bridge) Installation 179
Rocker Arm Shaft and Engine Brake Installation 179
Flywheel Housing Installation 182
Crankshaft Rear Seal Installation 184
Flywheel and Pilot Bearing Installation 185
Oil Pan Installation 187
Oil Filler Pipe and Dipstick Pipe Installation 189
Power Take-Off Installation 189
Timing Gear Cover Installation 190
Coolant Pump Installation 192
Thermostat and Cover Installation 193
Coolant Pipe Installation 193
Oil Cooler and Cooling Duct Cover Installation 194
Oil Filter Housing Installation 196
Exhaust Manifold Installation 197
Turbocharger Installation 198
Exhaust Pressure Governor (EPG) Installation 199
Starter Installation 200
Air Compressor Installation 201
Tandem Pump (Fuel and Power Steering) Installation 202
Inlet Manifold Installation 203
Engine Preheater/Spacer Installation 204
EECU and Cooler Installation 204
Fuel Lines and Filter Housing Installation 205
Crankcase Ventilation Separator 206
Crankshaft Vibration Damper and Fan Pulley Installation 207
Alternator and Refrigerant Compressor Installation 208
Wiring Harness Installation 209
Cylinder Head (Valve) Cover Installation 210
Fan Hub and Drive Belt Installation 211
Page viii
TABLE OF CONTENTS
Removing Engine from Engine Stand 212
Filters and Miscellaneous Components Installation 213
ENGINE INSTALLATION 214
Special Tools 214
General Instructions 214
Installation 214
REPAIR INSTRUCTIONS, PART 2 217
IN-CHASSIS PART/COMPONENT PROCEDURES 218
CAMSHAFT BEARING BRACKETS, REPLACEMENT 218
Preliminary Steps 218
General Information 218
Camshaft Inspection 219
Bracket Replacement Procedure 219
Final Steps 220
OIL THERMOSTAT AND PRESSURE SAFETY VALVE REPLACEMENT 221
Pressure Safety Valve Removal 221
Oil Thermostat Valve Replacement 222
CRANKSHAFT FRONT SEAL REPLACEMENT 223
Special Tools 223
Seal Removal 223
Seal Installation 224
CRANKSHAFT REAR SEAL REPLACEMENT 226
Special Tools 226
Neoprene Seal Removal 226
Neoprene Seal Installation 227
Teflon® Seal Removal 228
Teflon® Seal Installation 228
CRANKCASE VENTILATION (CCV) SEPARATOR REPLACEMENT 231
CCV Separator Removal 231
CCV Separator Installation 231
OIL PUMP REPLACEMENT (IN CHASSIS) 231
Special Tools 231
Oil Pump Removal 232
Oil Pump Installation 232
INJECTOR COPPER SLEEVE REPLACEMENT 234
Tools and Equipment 234
Preliminary Steps 236
Copper Sleeve Removal 236
Copper Sleeve Installation 240
Final Steps 243
UNIT INJECTOR CLEANING 244
Preliminary Steps 244
Cleaning and Inspection 244
Final Steps 245
VALVE STEM HEIGHT MEASUREMENT PROCEDURE 246
VALVE STEM SEAL REPLACEMENT 249
Special Tools 249
Preliminary Steps 250
Seal Removal 250
Seal Installation 250
Final Steps 251
TABLE OF CONTENTS
Page ix
REPAIR INSTRUCTIONS, PART 3 253
MP8 EURO 3 ENGINE SETUP AND ADJUSTMENT 254
Special Tools 254
Valve and Unit Injector Adjustment 256
Checking and Adjusting Timing Gear Backlash 262
ENGINE FINAL PREPARATION AND OPERATIONAL CHECK 265
Filter Element Installation 265
Engine Lubrication System 265
Turbocharger 266
Cooling System 266
Fuel System 266
Engine Operational Check 268
REBUILT ENGINE RUN-IN PROCEDURES 268
General 268
Run-In Check 268
SPECIFICATIONS 269
MP8 EURO 3 ENGINE MECHANICAL SPECIFICATIONS 270
Material and Dimensional Data 270
Engine Component Torque Specifications (Critical Fasteners) 276
Standard Bolt and Nut Torque Values 304
ENGINE GASKETS, LUBRICANTS AND SEALANTS 305
Gasket and Seal Reuse 305
Lubricants and Sealants 306
SPECIAL TOOLS & EQUIPMENT 307
MP8 ENGINE SERVICE TOOLS 308
Special Tools for Engine Overhaul 308
INDEX 325
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