MACK Truck Engine TUNE UP E-TECH CCRS Manual

2001 MACK TRUCK ENGINE TUNE-UP SPECIFICATIONS JULY 2002 ENGINE 5-313 INCLUDES E-TECH TM CCRS ENGINES

front.fm Page -ii Friday, April 26, 2002 10:24 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

2001 MACK TRUCK ENGINE TUNE-UP JULY 2002 (NEW ISSUE) © MACK TRUCKS, INC. 2002 ENGINE 5-313 SPECIFICATIONS (INCLUDES E-TECH TM CCRS ENGINES)

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 (but not limited to) electronic, mechanical, photocopying, recording, or otherwise without prior written permission of Mack Trucks, Inc. front.fm Page ii Friday, April 26, 2002 10:24 AM

TABLE OF CONTENTS iii TABLE OF CONTENTS front.fm Page iii Friday, April 26, 2002 10:24 AM

iv TABLE OF CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Advisory Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Service Procedures and Tool Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 EXPLANATION OF THREE-DIGIT NUMERICAL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 VISUAL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ENGINE INFORMATION PLATE LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 E-Tech™ Pre-CCRS and CCRS Engine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ENGINE INFORMATION PLATE EXPLANATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 WASTEGATE TURBOCHARGER DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . 16 Diaphragm-Controlled Wastegate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Barometric and Boost Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 FUEL INJECTION NOZZLE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Testing the One-Way Check Valve (Pre-CCRS Nozzle Assemblies) . . . . . . . . . . . . . . . . . . . . 23 WASTEGATE TURBOCHARGER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Wastegate Diagnostics and Fault Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Wastegate Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 FUEL INJECTION NOZZLE INSPECTION AND CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Disassembly and Inspection of Nozzle Holder and Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Injection Nozzle Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Nozzle Cleaning (Ultrasonic Method Preferred) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Mechanical Method (Alternate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Nozzle Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 E-TECH™ (V-MAC III) SIX CYLINDER ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 38 E-Tech™ EM7-275 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 E-Tech™ Pre-CCRS EM7-275 Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 E-Tech™ CCRS EM7-275 Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 E-Tech™ EM7-300 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 E-Tech™ Pre-CCRS EM7-300 Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 E-Tech™ CCRS EM7-300 Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 E-Tech™ E7-300 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 E-Tech™ Pre-CCRS E7-300 Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 E-Tech™ CCRS E7-300 Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 E-Tech™ Pre-CCRS E7-300A Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 E-Tech™ Pre-CCRS E7-300A Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 E-Tech™ E7-310/330 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 E-Tech™ Pre-CCRS E7-310/330 Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 E-Tech™ CCRS E7-310/330 Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 E-Tech™ E7-330/350 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 E-Tech™ Pre-CCRS E7-330/350 Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 E-Tech™ CCRS E7-330/350 Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 E-Tech™ E7-355/380 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 E-Tech™ Pre-CCRS E7-355/380 Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 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TABLE OF CONTENTS v E-Tech™ CCRS E7-355/380 Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 E-Tech™ CCRS E7-380/410 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 E-Tech™ CCRS E7-380/410 Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 E-Tech™ E7-350 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 E-Tech™ Pre-CCRS E7-350 Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 E-Tech™ CCRS E7-350 Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 E-Tech™ E7-400 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 E-Tech™ Pre-CCRS E7-400 Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 E-Tech™ CCRS E7-400 Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 E-Tech™ E7-427 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 E-Tech™ Pre-CCRS E7-427 Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 E-Tech™ CCRS E7-427 Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 E-Tech™ Pre-CCRS E7-460 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 E-Tech™ Pre-CCRS E7-460 Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 E-Tech™ CCRS E7-460P Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 E-Tech™ CCRS E7-460P Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 E-Tech™ CCRS E7-460E Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 E-Tech™ CCRS E7-460E Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 SPECIAL TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 front.fm Page v Friday, April 26, 2002 10:24 AM

vi NOTES front.fm Page vi Friday, April 26, 2002 10:24 AM

MACK Truck Engine TUNE UP E-TECH CCRS Manual

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