Mack MP8 Diesel Engine OEM Service & Repair Manual (+ Operators Handbook)
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JULY 2009
(REVISED)
5-113
MACK
®
MP8
DIESEL ENGINE
SERVICE MANUAL
(’07 EMISSIONS REGULATIONS)
MACK
®
MP8 DIESEL ENGINE
SERVICE MANUAL
('07 EMISSIONS REGULATIONS)
JULY 2009
(REVISED — SUPERSEDES ISSUE DATED JANUARY 2009)
© MACK TRUCKS, INC. 2009
ENGINE 5-113
1
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. Note that
illustrations and instructions are based on information that is subject to
change as new engine/chassis development continues.
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.
TABLE OF CONTENTS
Page iii
TABLE OF CONTENTS
Page iv
TABLE OF CONTENTS
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 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service Precautions Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
VISUAL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MP8 ENGINE MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine Information Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine Serial Number Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
MACK MP8 US07 ENGINE DESIGN FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
PowerLeash™ Engine Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Exhaust Gas Recirculation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Exhaust Aftertreatment System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Variable Geometry Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Engine Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
GLOSSARY OF TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
MP8 ENGINE COMPONENT LOCATION VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
ENGINE SYMPTOM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Troubleshooting Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Noise and Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
ENGINE CHECKS AND TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Camshaft Sensor Depth, Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Camshaft Timing, Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Crankcase Ventilation, Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Cylinder Head, Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Cylinder Liner and Piston Wear, Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
EGR Cooler, Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Engine Compression, Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Flywheel Housing Runout, Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Oil Cooler, Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Rocker Arm, Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Thermostat, Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Valve Guide Wear, Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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What's Included?
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Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$44.99
Mack MP8 Diesel Engine OEM Service & Repair Manual (+ Operators Handbook)
This Mack MP8 Diesel Engine OEM Service & Repair Manual (+ Operators Handbook) delivers complete factory-grade procedures and specifications for servicing Mack’s 13.0L inline-6 MP8 diesel engine compliant with 2007 emissions standards. Whether you're a fleet technician rebuilding an engine or an owner-operator performing routine maintenance, this manual provides the detailed documentation used by authorized Mack repair centers.
It covers everything from basic oil changes to full engine overhauls, including disassembly, diagnostics, and reassembly procedures. You'll also find critical information on the PowerLeash™ engine brake, EGR systems, and emissions aftertreatment, along with troubleshooting charts and complete torque specifications.
Content Overview:
- Safety information, advisory labels, and service procedure guidelines
- Engine model identification and serial number location
- Complete MP8 engine design overview and operational theory
- Engine systems: lubrication, cooling, fuel, air intake, turbocharger, exhaust, and EGR
- PowerLeash™ engine brake and engine management system
- Component locator diagrams with labeled system views
- Engine symptom diagnosis and troubleshooting techniques
- Detailed checks and tests: compression, camshaft, EGR cooler, sensors, valves, and timing
- Lubrication system service and oil/filter replacement
- Fuel and cooling system maintenance procedures
- Exhaust aftertreatment system diagnostics and service
- Drive belt replacement and tensioning
- Complete engine disassembly and reassembly procedures
- Removal and installation: injectors, turbocharger, cylinder head, manifolds, pumps, and more
- Cylinder block reconditioning, piston/rod assembly, and crankshaft service
- Camshaft, rocker arm, and valve system inspection and replacement
- EGR and cooling system bench procedures
- Engine setup, adjustment, and final operational checks
- Run-in procedures for rebuilt engines
- Complete torque specs, critical fasteners, gasket types, and sealants
- Special tools list for MP8 engine overhaul and servicing
Whether you’re servicing emissions components or performing a top-end rebuild, this manual equips you with precise, manufacturer-approved methods for every MP8 maintenance and repair task.
Printable: Yes
Language: English
Compatibility: Pretty much any electronic device
Requirements: Adobe Reader (free)
