MACK 12.0L E7 E-7 Diesel Engine Service & Repair Manual

E7 ENGINE OVERHAUL AUGUST 1997 ENGINE 5-101

front.fr5 Page 0 Friday, March 17, 2006 11:04 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?  Yes  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?  Yes  No If yes, please describe: _____________________________________________ _______________________________________________________________ _______________________________________________________________ Did you find any errors in the procedures or illustrations?  Yes  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 Monday, September 12, 2005 8:59 AM

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

E7 ENGINE OVERHAUL MARCH 2006 2.5M (REP.) AUGUST 1997 10M © MACK TRUCKS, INC. 1997 ENGINE 5-101

Page 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.fr5 Page ii Friday, March 17, 2006 11:04 AM

SAFETY INFORMATION Page iii SAFETY INFORMATION front.fr5 Page iii Friday, March 17, 2006 11:04 AM

Page iv SAFETY INFORMATION Advisory Labels Cautionary signal words (Danger-Warning-Caution) may appear in various locations throughout this manual. Information accented by one of these signal words must be observed to minimize the risk of personal injury to service personnel, or the possibility of improper service methods which may damage the vehicle or render it unsafe. Additional Notes and Service Hints are utilized to emphasize areas of procedural importance and provide suggestions for ease of repair. The following definitions indicate the use of these advisory labels as they appear throughout the manual: Directs attention to unsafe practices which could result in damage to equipment and possible subsequent personal injury or death if proper precautions are not taken. Directs attention to unsafe practices which could result in personal injury or death if proper precautions are not taken. Directs attention to unsafe practices and/or existing hazards which will result in personal injury or death if proper precautions are not taken. An operating procedure, practice, condition, etc., which is essential to emphasize. A helpful suggestion which will make it quicker and/or easier to perform a certain procedure, while possibly reducing overhaul cost. 000001a front.fr5 Page iv Friday, March 17, 2006 11:04 AM

SAFETY INFORMATION Page v Service Procedures and Tool Usage Anyone using a service procedure or tool not recommended in this manual must first satisfy himself thoroughly that neither his safety nor vehicle safety will be jeopardized by the service method he selects. Individuals deviating in any manner from the instructions provided assume all risks of consequential personal injury or damage to equipment involved. Also note that particular service procedures may require the use of a special tool(s) designed for a specific purpose. These special tools must be used in the manner described, whenever specified in the instructions. 1. Before starting a vehicle, always be seated in the driver’s seat, place the transmission in neutral, be sure that parking brakes are set, and disengage the clutch. 2. Before working on a vehicle, place the transmission in neutral, set the parking brakes, and block the wheels. 3. Before towing the vehicle, place the transmission in neutral and lift the rear wheels off the ground, or disconnect the driveline to avoid damage to the transmission during towing. REMEMBER, SAFETY . . . IS NO ACCIDENT! front.fr5 Page v Friday, March 17, 2006 11:04 AM

Page vi SAFETY INFORMATION 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 their 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. front.fr5 Page vi Friday, March 17, 2006 11:04 AM

MACK 12.0L E7 E-7 Diesel Engine Service & Repair Manual

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