Mack E-Tech Engine Service Manual

E-TECH ™ ENGINE SERVICE MANUAL (Includes Left-Side Redesign) OCTOBER 2000 (REVISED) 5-106

front.fm Page -ii Friday, August 4, 2000 11:16 AM

DO NOT STAPLE — USE TRANSPARENT TAPE PLEASE LET US KNOW! Your comments and suggestions will help us improve this manual! Please complete and mail this form or FAX your comments to: (610) 709-3800. Manual: _______________________________ Publication Number: _______ Vehicle Model: _________________________ Model Year: ______________ Do you find procedures properly organized and easy to follow? m Yes m No If not, please explain: ______________________________________________ _______________________________________________________________ _______________________________________________________________ Manual page numbers: _____________________________________________ Are there any important procedures or other information presently not in this manual that you would like to see included? m Yes m No If yes, please describe: _____________________________________________ _______________________________________________________________ _______________________________________________________________ Did you find any errors in the procedures or illustrations? m Yes m No If yes, what pages? _______________________________________________ Please explain: ___________________________________________________ _______________________________________________________________ Please include a copy of each page in question and mark your comments and suggestions. Name: ________________________________ Phone: (_____) _____-_______ Company: _______________________________________________________ Address: ________________________________________________________ City: _________________________________ State: _______ Zip: _______ Position Title: ____________________________________________________ Thank You For Your Assistance Mack Trucks, Inc. (ATTENTION: RTS STAFF, 6S3) newknow.fm Page 1 Thursday, May 21, 1998 2:23 PM

FOLD ALONG THIS LINE • DO NOT STAPLE • USE TRANSPARENT TAPE NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO. 1602 ALLENTOWN, PA POSTAGE WILL BE PAID BY ADDRESSEE SERVICE PUBLICATIONS (RTS), 6S3 MACK TRUCKS INC WORLD HEADQUARTERS PO BOX M ALLENTOWN PA 18105-9972 FOLD ALONG THIS LINE Busreply.fm Page 1 Thursday, May 21, 1998 2:24 PM

ERRATA SHEET — ENGINE Crankshaft Center Main Bearing Specification Update Effective January 2006, Mack Powertrain Engineering has widened the crankshaft center main bearing runout specification. The maximum allowable crankshaft runout specification was changed from 0.005 in. (0.127 mm) to 0.007 in. (0.178 mm). The manuals listed below are affected by this change. Reference: Engine Manuals 5-101 E7 5-106 E-Tech™ 5-107 E7G 5-110 ASET™ AI/AMI 5-111 ASET™ AC JANUARY 2006 © MACK TRUCKS, INC. 2006 (NEW ISSUE) MACK ENGINE SERIES 10_125erb.fm Page 2 Tuesday, April 18, 2006 11:43 AM

SB-210-034 — Page 1 of 1 2 0 0 2 . C N I , S K C U R T K C A M © 5 0 1 8 1 A P , N W O T N E L L A , S N O I T A C I L B U P E C I V R E S SERVICE BULLETIN NUMBER: SB-210-034 DATE: 5/14/02 MODEL: E-Tech™ (Also applies to Mack Trucks Australia) MISCELLANEOUS FASTENER CHANGES — E-TECH™ ENGINES The following fastener changes were made on E-Tech™ engines: Injection Nozzle Hold-Down Screws — Beginning 3/00, the injection nozzle hold- down screws having the 15 mm external hex head have been changed to a new screw (part No. 421GC2116M) that has a 16 mm internal hex head. Rocker Shaft Mounting Bracket Bolts — Beginning 4/00, the bolts and washers used to secure the rocker shaft mounting brackets to the cylinder head have been changed to a flange-head bolt (part No. 65AM5010). Tightening torque value for this new fastener remains the same at 40 lb-ft (50 N•m). Air Compressor Mounting Screw — Beginning 8/00, the original hex-head screw has been changed to a flange-head screw (part No. 27AM16). This change was made so that the mounting screw clamp load is distributed over a wider area of the flat washer. Camshaft Thrust Washer — Beginning 10/00, the two screws and washers used to secure the camshaft thrust washer to the block were changed to a flange-head screw (part No. 66AM44). Tightening torque value for this fastener remains the same at 15 lb- ft (20 N•m). Cylinder Head Capscrews — Beginning 6/01, the cylinder head capscrews and the separate hardened flat washer were replaced in production with capscrews having captured washers (part number series 400GC317M). This change was implemented to prevent the possibility of omitting or installing more than one washer during assembly. Additionally, the outside diameter of the captured washer was reduced slightly (approximately 0.030″) to accommodate the redesigned cylinder head cover that was phased into production 7/01. Cylinder head capscrew torque remains the same at 205 lb-ft (278 N•m). Flywheel-to-crankshaft mounting bolts — Beginning 9/01, bolts having captured washers (part Nos. 419GC31M and 419GC31M2) were released into production to replace the previously used bolts and separate hardened flat washer used to secure the flywheel to the crankshaft. Flywheel-to-crankshaft mounting bolt torque remains the same at 185 lb-ft (250 N•m). Electronic Unit Pump (EUP) hold-down screws — Beginning 11/01, new hold-down screws (part No. 421GC2123M) were released into production for the electronic unit pumps. These screws are dimensionally the same as the previously used screws, but conform to a more stringent specification that controls minor surface forming defects to a greater degree than for common fasteners.Torque of the EUP hold-down bolts has been changed from 42 lb-ft (57 N·m) to 60 lb-ft (81 N·m). Turbocharger Mounting Nuts — Beginning 5/02, new turbocharger mounting nuts were released into production. These nuts (part No. 142GC247M) are composed of silver-plated stainless steel to provide greater resistance to heat than the previous nuts. Additionally, these nuts have the Spiralock™ self-locking thread feature to prevent loosening in service.

E-TECH ™ ENGINE SERVICE MANUAL (Includes Left-Side Redesign) MAY 2006 REPRINTED 2.5M SEPTEMBER 2004 REPRINTED 2.5M APRIL 2003 REPRINTED 2.5M JUNE 2002 REPRINTED 2.5M OCTOBER 2001 REPRINTED 2.5M OCTOBER 2000 (REVISED – SUPERSEDED ISSUE JULY 1999) © MACK TRUCKS, INC. 2000 5-106

ii ATTENTION 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. 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. front.fm Page ii Friday, August 4, 2000 11:16 AM

TABLE OF CONTENTS iii TABLE OF CONTENTS front.fm Page iii Friday, August 4, 2000 11:16 AM

iv TABLE OF CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Advisory Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Service Procedures and Tool Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 EXPLANATION OF NUMERICAL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Changes from the Existing E-Tech™ Service Procedures Manual . . . . . . . . . . . . . . . . . . . . . . . 6 ABOUT THE E-TECH™ ENGINE AND ITS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ENGINE MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine Information Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine Serial Number Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 DESCRIPTION & OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 E-TECH™ ENGINE DESIGN FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Electronic Unit Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 V-MAC III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Belt Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 J-Tech™ Engine Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Valve Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Low-Pressure Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Fuel Filtration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 High-Pressure Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 High-Pressure Fuel Injection Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Fuel Injector Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Block Heater for Front (Water Pump) Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Cylinder Head Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Vibration Damper Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Centri-Max® Oil Filter Breather Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 GLOSSARY OF TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 ENGINE SYMPTOM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 V-MAC III Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 CAMSHAFT TIMING AND LOBE LIFT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Camshaft Timing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Camshaft Lobe Lift Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 CHASSIS-MOUNTED CHARGE AIR COOLING TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Special Tool Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 CMCAC Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 CMCAC Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Restriction Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 front.fm Page iv Friday, August 4, 2000 11:16 AM

Mack E-Tech Engine Service Manual

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