Mack Truck MP7 Diesel Engine (’07 EMISSIONS REGULATIONS) SERVICE MANUAL – PDF DOWNLOAD
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Mack Truck MP7 Diesel Engine (’07 EMISSIONS REGULATIONS) SERVICE MANUAL – PDF DOWNLOAD
Language : English
Pages : 364
Downloadable : Yes
File Type : PDF
Size: 36.1 MB
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Mack Truck MP7 Diesel Engine (’07 EMISSIONS REGULATIONS) SERVICE MANUAL – 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 MP7 Diesel Engine (’07 EMISSIONS REGULATIONS) SERVICE MANUAL – 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 MP7 ENGINE 9
Service Precautions Summary 13
VISUAL IDENTIFICATION 15
MP7 ENGINE MODEL IDENTIFICATION 16
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 Ventilation 34
Fuel System 35
PowerLeash™ Engine Brake 40
Exhaust Gas Recirculation System 42
Exhaust Aftertreatment System 44
Variable Geometry Turbocharger 49
Cooling System 50
Engine Management System 51
GLOSSARY OF TERMS 54
COMPONENT LOCATOR 57
MP7 ENGINE COMPONENT LOCATION VIEWS 58
TROUBLESHOOTING 63
ENGINE SYMPTOM DIAGNOSIS 64
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, Check 70
Cylinder Head, Pressure Test 71
Cylinder Liner and Piston Wear, Check 72
EGR Cooler, Pressure Test 74
Engine Compression, Test 75
Flywheel Housing Runout, Check 77
Oil Cooler, Pressure Test 78
Rocker Arm, Check 79
Thermostat, Check 82
Valve Guide Wear, Check 83
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 System 88
FUEL FILTER REPLACEMENT 89
Fuel Filter Change 89
COOLING SYSTEM MAINTENANCE 91
Special Tool 91
Coolant Drain Outlets 91
Coolant Filter 91
EXHAUST AFTERTREATMENT SYSTEM MAINTENANCE 92
Special Tools 92
Diesel Particulate Filter 93
Aftertreatment Fuel Injector (AFI) 98
DRIVE BELT REPLACEMENT AND TENSIONING 101
General Information 101
Automatically Tensioned System 102
REPAIR INSTRUCTIONS, PART 1 103
ENGINE REMOVAL 104
Special Tools 104
General Instructions 104
Removal 105
ENGINE DISASSEMBLY 108
Special Tools 108
General Instructions 111
Mounting the Engine on a Repair Stand 111
Cylinder Head (Valve) Cover Removal 112
Engine Wiring Harness Removal — External 112
Engine Wiring Harness Removal — Internal 113
Timing Gear Cover Removal 113
Camshaft Gear and Vibration Damper Removal 113
Rocker Arm Shaft and Engine Brake Removal 114
Valve Yoke (Bridge) Removal 115
Camshaft Removal 116
Unit Injector Removal 117
Starter Removal 122
Turbocharger Removal 123
EGR Hot Pipe (Cooler Inlet) Removal 123
EGR Valve Removal 124
EGR Cooler Removal 125
Exhaust Manifold Removal 126
Oil Filter Housing Removal 127
Coolant Pipe Removal 128
Cooling Duct Cover and Oil Cooler Removal 129
Fan Drive, Idler and Fan Bracket Removal 131
EGR Crossover (Cooler Outlet) Pipe Removal 132
EGR Venturi Housing Removal 132
EGR Mixer Removal 132
Fuel Lines and Fuel Filter Housing Removal 133
Page vi
TABLE OF CONTENTS
EECU and Cooling Plate Removal 134
Inlet Manifold Removal 135
Tandem Pump (Fuel and Power Steering) Removal 136
Air Compressor Removal 136
Flywheel and Pilot Bearing Removal 137
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 Removal 142
Coolant Pump Removal 142
Cylinder Head Removal 143
Crankshaft Vibration Damper and Fan Pulley Removal 146
Crankshaft Front Cover Removal 146
Crankshaft Front Seal Removal 147
Oil Fill Pipe and Dipstick Retainer Removal 147
Oil Pan Removal 147
Front Engine Support Removal 148
Oil Pump and Valve Housing Removal 148
Block Stiffener Plate Removal 150
Piston and Connecting Rod Assembly Removal 151
Main Bearing Cap Removal 152
Crankshaft Removal 153
CYLINDER BLOCK RECONDITIONING 154
Tools and Equipment 154
Piston Cooling Spray Nozzle Removal 155
Cylinder Liner Removal 155
Cylinder Block Cleaning and Inspection 156
Cylinder Liner Height Measurement 157
Cylinder Liner Installation 158
FLYWHEEL BENCH PROCEDURES 159
Flywheel Ring Gear Replacement 159
CONNECTING ROD AND PISTON BENCH PROCEDURES 160
Connecting Rod — Piston Disassembly 160
Piston Inspection and Cleaning 162
Piston Ring Inspection and Replacement 163
Connecting Rod — Piston Assembly 164
CYLINDER HEAD OVERHAUL 166
Tools and Equipment 166
Inlet and Exhaust Valve Removal 169
Cylinder Head Cleaning and Inspection 170
Valve Guide Replacement 171
Valve Spring Inspection 172
Injector Sleeve Replacement 173
Expansion Plug Replacement 180
Valve Inspection 181
Valve Installation 181
TABLE OF CONTENTS
Page vii
ROCKER ARM SHAFT BENCH PROCEDURES 183
Description 183
Rocker Arm Shaft Disassembly 184
Inspection 184
Rocker Arm Shaft Assembly 184
CAMSHAFT BENCH PROCEDURES 185
Camshaft Inspection 185
COOLING SYSTEM COMPONENTS BENCH PROCEDURES 186
Special Tool 186
Oil Cooler Reconditioning 187
EGR Cooler Cleaning 188
EGR Cooler Pressure Test 190
ENGINE REASSEMBLY 192
Special Tools 192
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 Installation 204
Front Engine Support Installation 205
Crankshaft Front Cover Installation 206
Crankshaft Front Seal Installation 207
Timing Gear Mounting Plate Installation 208
Cylinder Head Installation 209
Camshaft Installation 212
Unit Injector Installation 214
Valve Yoke (Bridge) Installation 217
Rocker Arm Shaft and Engine Brake Installation 218
Timing Gear Train Installation 221
Flywheel Housing Installation 224
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 Installation 229
Flywheel and Pilot Bearing Installation 229
EGR Crossover (Cooler Outlet) Pipe Installation 231
Fan Bracket Installation 231
Coolant Pump Installation 232
Thermostat and Cover Installation 233
Oil Cooler and Cooling Duct Cover Installation 233
Coolant Pipe Installation 237
Oil Filter Housing Installation 238
Exhaust Manifold Installation 238
EGR Valve Installation 239
EGR Cooler Installation 240
EGR Cooler Inlet Pipe Installation 240
Turbocharger Installation 241
Starter Installation 242
Air Compressor Installation 243
Page viii
TABLE OF CONTENTS
Tandem Pump (Fuel and Power Steering) Installation 244
Inlet Manifold Installation 245
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 Separator 249
Alternator and Refrigerant Compressor Installation 250
Crankshaft Vibration Damper and Fan Pulley Installation 251
Wiring Harness Installation 251
Cylinder Head (Valve) Cover Installation 252
Removing Engine from Engine Stand 253
Filters and Miscellaneous Components Installation 253
ENGINE INSTALLATION 255
Special Tools 255
General Instructions 255
Installation 255
REPAIR INSTRUCTIONS, PART 2 259
IN-CHASSIS PART/COMPONENT PROCEDURES 260
OIL PUMP REPLACEMENT (IN CHASSIS) 260
Oil Pump Removal 261
Oil Pump Installation 261
CRANKCASE VENTILATION (CCV) SEPARATOR REPLACEMENT 263
CCV Separator Removal 263
CCV Separator Installation 263
TURBOCHARGER SMART REMOTE ACTUATOR (SRA) REPLACEMENT 263
Preliminary Steps 263
Turbocharger SRA Removal 264
Turbocharger SRA Inspection and Installation 265
Final Assembly 268
UNIT INJECTOR CLEANING 268
Preliminary Steps 268
Cleaning and Inspection 269
Final Steps 269
INJECTOR COPPER SLEEVE REPLACEMENT 270
Tools and Equipment 270
Preliminary Steps 272
Copper Sleeve Removal 272
Copper Sleeve Installation 276
Final Steps 279
VALVE STEM HEIGHT MEASUREMENT PROCEDURE 279
VALVE STEM SEAL REPLACEMENT 282
Special Tools 282
Preliminary Steps 283
Seal Removal 283
Seal Installation 283
Final Steps 284
TABLE OF CONTENTS
Page ix
REPAIR INSTRUCTIONS, PART 3 285
MP7 ENGINE SETUP AND ADJUSTMENT 286
Special Tools 286
Valve and Unit Injector Adjustment 287
Checking and Adjusting Timing Gear Backlash 291
ENGINE FINAL PREPARATION AND OPERATIONAL CHECK 294
Filter Element Installation 294
Engine Lubrication System 295
Fuel System 295
Engine Operational Check 297
REBUILT ENGINE RUN-IN PROCEDURES 297
General 297
Run-In Check 297
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 Sealants 330
SPECIAL TOOLS & EQUIPMENT 331
MP7 ENGINE SERVICE TOOLS 332
Special Tools for the MP7 Engine 332
INDEX 347
VIDEO PREVIEW OF THE MANUAL:
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