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Mack E-TECH SB-210-034, Service Manual

The Mack E-TECH SB-210-034 Service Manual is essential for maintenance and repair of this vehicle. Download the manual for free from manualshive.com to access detailed instructions and diagrams for keeping your Mack E-TECH running smoothly. Ensure proper care and knowledge with this comprehensive manual.

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TABLE OF CONTENTS

vii

Valve Seat Insert Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Valve Spring Inspection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Injection Nozzle Holder Insert Replacement   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Valve Yoke Guide Pin Replacement   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Cylinder Head Cup Plug Replacement   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Cylinder Head Pipe Plug Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Valve Replacement   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

VALVE ROCKER ARM SHAFT BENCH PROCEDURES  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Rocker Arms   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Valve Rocker Arm Shaft Disassembly (without/with Engine Brake) . . . . . . . . . . . . . . . . . . . . . 206
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Valve Rocker Arm Shaft Reassembly (without Engine Brake) . . . . . . . . . . . . . . . . . . . . . . . . . 207
Valve Rocker Arm Shaft Reassembly (with J-Tech™ Engine Brake)   . . . . . . . . . . . . . . . . . . . 209

LUBRICATION SYSTEM BENCH PROCEDURES  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Oil Cooler Assembly Reconditioning  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Oil Pump Reconditioning  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

COOLING SYSTEM COMPONENTS BENCH PROCEDURES   . . . . . . . . . . . . . . . . . . . . . . . . . . 215

Oil Cooler Reconditioning   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Water Pump Reconditioning   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

FUEL SYSTEM COMPONENTS BENCH PROCEDURES  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Electronic Unit Pump (EUP) Inspection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Installation of Electronic Unit Pump Plunger Spring and Seat  . . . . . . . . . . . . . . . . . . . . . . . . . 219
Fuel Injector Nozzle Cleaning   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

ENGINE REASSEMBLY   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

General Instructions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Crankshaft Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Main Bearing Cap Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Piston and Connecting Rod Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Flywheel Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Crankshaft Rear Oil Seal Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Valve Lifter Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Camshaft Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Camshaft Core Plug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Camshaft Idler Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Auxiliary Shaft Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Oil Pump Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Front Cover Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Crankshaft Front Seal Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Crankshaft Hub Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Vibration Damper Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Oil Pan Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Cylinder Head Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Exhaust Manifold Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Nozzle Holder Assembly Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Push Rod Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Valve Yoke Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Rocker Arm and Engine Brake Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Valve Cover and Spacer Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Oil Fill Tube Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Engine ECU/Cooling Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

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

BDC for engine manuals and specs 

https://barringtondieselclub.co.za/

Summary of Contents for E-TECH SB-210-034

Page 1: ...E TECH ENGINE SERVICE MANUAL Includes Left Side Redesign OCTOBER 2000 REVISED 5 106 BDC for engine manuals and specs https barringtondieselclub co za...

Page 2: ...ii front fm Page ii Friday August 4 2000 11 16 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 3: ..._________________________________ _______________________________________________________________ _______________________________________________________________ Did you find any errors in the procedu...

Page 4: ...PLY 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...

Page 5: ...e 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...

Page 6: ...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 t...

Page 7: ...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 B...

Page 8: ...cifications 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...

Page 9: ...TABLE OF CONTENTS iii TABLE OF CONTENTS front fm Page iii Friday August 4 2000 11 16 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 10: ...l 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 Gea...

Page 11: ...Oil Filter Element Replacement 90 Fuel Filter Replacement 93 Coolant Conditioner Replacement 94 REPAIR INSTRUCTIONS 95 ENGINE REMOVAL 96 General Instructions 96 Removal from Vehicle 96 ENGINE DISASSEM...

Page 12: ...5 Auxiliary Shaft Bushing Replacement 148 Cylinder Sleeve Installation 152 Piston Cooling Spray Nozzle Installation 157 Cylinder Block Dowel Pin Replacement 159 CRANKSHAFT AND FLYWHEEL BENCH PROCEDURE...

Page 13: ...and Seat 219 Fuel Injector Nozzle Cleaning 221 ENGINE REASSEMBLY 222 General Instructions 222 Crankshaft Installation 222 Main Bearing Cap Installation 224 Piston and Connecting Rod Installation 230...

Page 14: ...t 286 Camshaft Replacement Engine in Chassis 288 Engine Brake Control Valve Replacement 293 Valve Lifter H Ring Installation Check 295 ENGINE SETUP AND ADJUSTMENTS 297 Fuel Injection Timing 297 Valve...

Page 15: ...4 Lubrication System Flow Diagram 335 Fuel System Flow Diagram 336 SPECIAL TOOLS EQUIPMENT 337 E TECH ENGINE SPECIAL TOOLS 338 Special Tools for Engine Overhaul 338 V MAC III Special Tools 341 INDEX 3...

Page 16: ...x NOTES front fm Page x Friday August 4 2000 11 16 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 17: ...INTRODUCTION Page 1 INTRODUCTION 5_106_00 bk Page 1 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 18: ...with Danger indicate that death or serious personal injury may result from failing to heed the advisory Serious personal injury may be equated to career ending injury Activities associated with Warnin...

Page 19: ...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...

Page 20: ...ve shoes Avoid injury by being aware of sharp corners and jagged edges r Use hoists or jacks to lift or move heavy objects r NEVER run engine indoors unless exhaust fumes are adequately vented to the...

Page 21: ...ROUP 400 STEERING AXLES WHEELS AND TIRES DRIVELINE GROUP 500 BRAKES AUXILIARY SYSTEMS GROUP 600 CAB TRUCK BODY GROUP 700 ELECTRICAL The second two digits of the three digit code are used to identify t...

Page 22: ...nd assembly of each component Each bench procedure helps in determining if the part is serviceable or should be replaced The engine reassembly procedure includes step by step instructions for reassemb...

Page 23: ...assembly setup and adjustment procedures etc are included in the respective sections of this publication Development of the E Tech engine has been driven by three basic requirements It was designed to...

Page 24: ...Page 8 NOTES 5_106_00 bk Page 8 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 25: ...IDENTIFICATION Page 9 IDENTIFICATION 5_106_00 bk Page 9 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 26: ...tions If an engine has an X in block one and two dashes in block two it is referred to as a 49 state engine meaning it is not certified for sale in California Block 3 ADR Regulations r An X in block t...

Page 27: ...IDENTIFICATION Page 11 1 Figure 1 Engine Information Plate Location 5_106_00 bk Page 11 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 28: ...d cover the engine is also identified by the engine serial number stamped into the cylinder block This serial number is located on the block right side just below the turbo oil drain tube flange as sh...

Page 29: ...DESCRIPTION OPERATION Page 13 DESCRIPTION OPERATION 5_106_00 bk Page 13 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 30: ...is very similar to a unit injector The primary difference is that the EUP delivers fuel through a fuel injection line to a conventional style nozzle holder assembly whereas a unit injector has a nozz...

Page 31: ...er O ring will be eliminated Present EUP service kits available through MACK service parts do not contain the center brown O ring The EUP system using proven industry technology is well adapted to tro...

Page 32: ...ELECTRONIC CONTROL UNITS The Engine Electronic Control Unit EECU is located on the right side of the engine Figure 8 in early production engines Characteristics of the engine design such as heat shie...

Page 33: ...as a package to the other control unit via a single high speed communication line Inherent to this system is a significant reduction in the length and number of wires specifically those which must pa...

Page 34: ...r depends upon chassis model but in general it is located at the front of the chassis mounted either on the front crossmember behind the bumper on a hood hinge hood hinge bracket body spring bracket o...

Page 35: ...s used with the standard dashboard and sensor part No 64MT2103 is used with the electronic dashboard 12 Figure 12 V MAC III Sensor Locations at Filter Mounting Bracket with Left Side Mounted EECU 1 Fu...

Page 36: ...ompressor and boost pressure access ports 13 Figure 13 V MAC III Sensor Locations with Front Air Inlet Manifold Left Side Mounted EECU 1 Boost Temperature Sensor 2 Fuel Filter Mounting Bracket Boss 3...

Page 37: ...MAC III oil pressure boost temperature fuel temperature and coolant temperature sensors have English pipe threads r Dash gauge sensors for coolant and oil temperatures are threaded sensors with Engli...

Page 38: ...n The illustration that follows shows a CH CL DM engine mounted fuel filter adapter The RD MR LE chassis mounted secondary fuel filter mounting adapter has a similar sensor mounting boss In either cas...

Page 39: ...r as the engine speed sensor This sensor is designed to monitor the passage of holes which are in the front face of the camshaft timing gear This sensor performs a function similar to the TEM sensor i...

Page 40: ...lics using a master slave piston arrangement similar to a hydraulic jack When the engine brake is operated a single exhaust valve opens near top dead center of the compression stroke releasing high pr...

Page 41: ...ote that the E Tech engine uses a different valve yoke from the E7 engine The E7 and E Tech yokes are not interchangeable r A hollow yoke adjusting screw with a floating pin in the screw is used in th...

Page 42: ...n opening the outboard exhaust valve via a valve actuating pin which passes through the center of the yoke adjusting screw Activation occurs near top dead center and releases compressed air into the e...

Page 43: ...hing temperature a groove has been added to the No 4 journal of current production camshafts This groove was not included on early production units Adding the groove to the camshaft journal has not re...

Page 44: ...n the E7 to accommodate the more aggressive cam profiles Push rod design also incorporates a larger diameter to handle the increased loads YOKES Pin Type Yokes During February of 1999 the welded wear...

Page 45: ...positive means of identification are by looking at the nose of the valve yoke The E Tech yoke has the nose end of the slipper pad area ground flat as shown in Figure 28 28 Figure 28 E Tech E6 E7 and...

Page 46: ...of a J Tech brake equipped E Tech engine the yoke will disengage from the valve stem tip during engine brake operation See Figure 31 31 Figure 31 Yoke Valve Combinations 1 Correct E7 Yoke Valve Combi...

Page 47: ...th the rocker arm adjusting screw For the exhaust valves it is still necessary to adjust the valve yoke first then the rocker arm lash The bottom of the valve yoke that bridges the two inlet valves ha...

Page 48: ...the supply pump the secondary filter and the unit pumps Unused fuel is collected in the fuel return gallery in the cylinder block and returned to the fuel tank by a fuel return line To decrease restr...

Page 49: ...DESCRIPTION OPERATION Page 33 34 Figure 34 Low Pressure Fuel System 5_106_00 bk Page 33 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 50: ...ry close toleranced internal components 35 Figure 35 Fuel Filters The fuel filter mounting adapter is made from a casting on which the primary and secondary mounting flanges are the same large size Fi...

Page 51: ...ch of the unit pumps by the fuel supply gallery in the cylinder block The high pressure required for fuel injection is generated by a pump plunger 10 mm diameter 18 mm stroke which is actuated by a ro...

Page 52: ...differ from those used in the E7 in that they have increased material strength a larger 22 mm diameter and a higher pressure capability These features are essentially due to the higher operating pres...

Page 53: ...s shifted up and outboard to operate the unit pumps and provide cam to crank clearance Figure 40 To accommodate this change in cam position the push rod holes are angled four degrees and the air compr...

Page 54: ...l length of the block s right side just below the unit pump mounting flange surface Current production cylinder blocks were changed to accommodate a redesigned oil cooler filter mounting arrangement E...

Page 55: ...ice engines having either the externally drained Centri Max or the internally drained Centri Max PLUS filter assemblies When a block is used for an engine equipped with the externally drained Centri M...

Page 56: ...de the lower support and are held in position with capscrews The bearing caps are not interchangeable and each has a number stamped on it which signifies its correct location and alignment in the cran...

Page 57: ...inders and has two inlet and two exhaust valves per cylinder Circular grooves correspond with the fire ring bead on the cylinder sleeves This design sets the fire ring over the liner With the cylinder...

Page 58: ...nozzle holder assembly r Water jacket casting designed to improve coolant flow r Lower exhaust stud holes intersect with push rod holes upper exhaust holes may intersect as well This requires that all...

Page 59: ...he E7 gasket is straight except for protrusions at the four right side head bolt holes The E Tech gasket has these protruded areas as well but also has six larger protrusions at the push rod hole cuto...

Page 60: ...he larger camshaft on the E Tech had to be relocated upward and outward from the original E7 location in order for the engine camshaft to drive the unit pumps This placed the camshaft further away fro...

Page 61: ...air system recovery and less operating time under load Power Steering Pump E7 and E Tech engines have the capability of driving a power steering pump from either the front or rear of the auxiliary sh...

Page 62: ...m the engine pass upward through the filter element then down and out through the center standpipe which exits from the canister lower outboard side When blow by gases pass through the filter element...

Page 63: ...evolved with changes to the oil cooler and oil filter mounting arrangement These changes are also described in this section MAIN OIL GALLERY The main oil gallery on the E Tech is the same as the E7 oi...

Page 64: ...d should not be removed OIL PASSAGES r The passage from the main oil gallery to the No 1 main bearing bore intersects the idler gear hub bore to provide lubrication to the idler gear bushing r There a...

Page 65: ...K Parts System to ensure the correct component is being used 54 Figure 54 Oil Pump Drive Gears The E Tech auxiliary shaft speed or rpm is 22 faster than that of the E7 As a result the E Tech oil pump...

Page 66: ...so with this arrangement the external oil drain is eliminated On current production engines the main member to which the oil cooler and oil filters are mounted is a new one piece aluminum casting whic...

Page 67: ...chanical oil pressure gauge or a remote mounted centrifugal oil filter 57 Figure 57 Oil Supply Ports 1 Turbocharger Oil Supply Port 2 Oil Temperature Sensor Harness Connectors 3 Oil Supply Port for RE...

Page 68: ...d Centri Max filter is mounted on early production engines 58 Figure 58 Centri Max PLUS Oil Filter Assembly OIL COOLER The removable bundle type oil cooler used on early production engines has been re...

Page 69: ...es the O ring connection was replaced by a hose connection The most commonly used tube has two smaller tubes attached to the main tube one tube for the thermostat bypass and the other for the water li...

Page 70: ...ine from the top of the water pump to the top of the thermostat housing This replaces the steel line used on CH model chassis with the removable bundle type oil cooler The de aeration line is made fro...

Page 71: ...esigned to maintain optimum tension under varying engine speeds and load The idler tensioner is optional on the E Tech engine Poly V Belt A multi ribbed belt design which is incorporated into a single...

Page 72: ...Page 56 NOTES 5_106_00 bk Page 56 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 73: ...TROUBLESHOOTING Page 57 TROUBLESHOOTING 5_106_00 bk Page 57 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 74: ...Disassemble engine and repair as required Possible Cause Correction 1 Slow cranking speed 1 Check corrections listed in preceding chart ENGINE WILL NOT CRANK 2 Code s present 2 Correct cause of code...

Page 75: ...leared after test is completed Make sure all EUP terminal wires are connected and tight With the engine operating at low idle 625 675 rpm connect a jumper wire across the EUP terminals one cylinder at...

Page 76: ...place as required 3 Plugged fuel tank vents 3 Clean the fuel tank vents 4 Restrictions in the air intake system such as clogged air filter s 4 Check for restrictions in the air intake system Check the...

Page 77: ...core fin obstructions 3 Clean intercooler fins 4 Insufficient air for combustion 4 Check air cleaner for restrictions Check inlet manifold pressure and inspect the turbocharger for proper operation Re...

Page 78: ...replace defective parts as required 3 External fuel system leakage 3 Check external piping on fuel system for signs of fuel leakage Repair as required 4 Defective injection nozzle assembly 4 Isolate d...

Page 79: ...d with shutters 12 Check shutter operation Repair as required Possible Cause Correction 1 Operating chassis in wrong gear ratio for load grade and or altitude 1 Instruct operator on correct gear selec...

Page 80: ...ult in incorrect oil pressure Make any necessary repairs or install a new relief valve 7 Oil pump gears not meshing properly 7 Check mounting arrangement If the engine has been rebuilt check that the...

Page 81: ...ated 5 Determine and correct root cause and repair engine as required 6 Camshaft or valve lifters worn 6 Replace camshaft and or valve lifters and perform any other necessary repairs as required Possi...

Page 82: ...rocker adjusting screw jam nut Ensure that the valve yoke is correctly adjusted Adjust the inlet valve to zero lash 4 Position a dial indicator magnetic base type probe on the valve spring retainer P...

Page 83: ...leshooting Symptom Probable Cause Remedy Normal Boost High Pyrometer 1 Core fin obstructions 1 Clean core fins Low Boost High Pyrometer 1 Restriction in ducting between air cleaner and turbo 1 Check f...

Page 84: ...Pressurize the system to 30 psi 207 kPa 7 Shut off the air source Pressure should not drop more than 5 psi 35 kPa within 15 seconds Repair or replace the core if pressure drop exceeds specification 8...

Page 85: ...oss the cooler r If the pressure drop is higher than 2 psi 13 79 kPa at full load condition the cooler has internal restrictions r If the pressure drop is lower than 2 psi 13 79 kPa the cooler is OK a...

Page 86: ...of flow 4 Carefully inspect cooler to ensure cleanliness Do not use caustic cleaners when flushing the cooler Be extremely careful when handling the cooler so as not to damage the core Damage Core Fai...

Page 87: ...ests watch for indications of minor leaks such as small bubbles that can develop into more severe leaks during engine operation Cylinder Head and Head Gasket Check In Chassis 1 Look for coolant stains...

Page 88: ...ead s should be replaced Cylinder Block Cylinder Head Coolant Passages Leak Check In Chassis Refer to Figure 64 1 Drain coolant from the engine 2 Remove the engine oil pan and cylinder head valve cove...

Page 89: ...sleeve indicates a leaking head gasket Water leaking from the No 2 or No 5 cam bushings or from the No 2 or No 5 main bearings can indicate a breakthrough between the rocker arm feed passage and the w...

Page 90: ...e surface Drill and tap the oil supply passage to accept an air fitting 4 Bolt the modified bracket with air fitting to the cylinder head over the oil supply passage 5 Immerse the cylinder head in wat...

Page 91: ...n drilled for bolts 3 Use suitable plate and gasket to seal the water manifold openings Install an air fitting onto the plate 4 Immerse the cylinder head in water Heat the water and head to 150 F 66 C...

Page 92: ...sealed can be used to seal off the cylinder head coolant ports Fittings can be installed on the water manifold to introduce the heated water and air pressure needed for the test 2 Remove the water pu...

Page 93: ...ge Leak Check Out of Chassis 1 Cylinder Block 2 1 4 inch Rubber Gaskets 3 3 4 inch Steel Plates 4 Rubber Gasket 5 Plate with Air Water Inlet Fittings 5_106_00 bk Page 77 Friday August 4 2000 11 17 AM...

Page 94: ...d yoke adjustment or broken or weak valve springs TEST DRIVE 1 Test drive the vehicle and measure intake manifold boost pressure while operating the engine brake Refer to the Table on page 78 for boos...

Page 95: ...the preliminary checks outlined below For more information see the V MAC III Service Manual 8 211 NO ENGINE BRAKE OPERATION 1 Check for a blown fuse or circuit breaker 2 With electrical power OFF chec...

Page 96: ...ection and do not expose your face over the engine area Keep hands away from moving parts Take precautions to prevent oil leakage down onto the engine Whenever engine is running and the cylinder head...

Page 97: ...replace with a new control valve If the bore is damaged scored use a light crocus cloth to smooth the bore Clean the bore and install a new control valve If severe damage to the bore is found replace...

Page 98: ...slowly until the retainer is depressed to about 1 32 inch 1 mm relieving pressure against the retaining ring 5 Remove the retaining ring using retaining ring pliers Back out the holder until the sprin...

Page 99: ...upply voltage is the appropriate voltage Recommended power source is from the key switch ON position Ensure that power is not taken from a source with an additional on off switch i e light switch See...

Page 100: ...of contamination r Control valves binding in housing bore Remove control valve If body is scored replace the control valve Check for contaminants in lube oil Clean housing and control valve If binding...

Page 101: ...ins down with no electric current being supplied replace the solenoid valve r Center solenoid seal ring damaged allows oil to enter brake with solenoid valve closed Remove solenoid and replace all sea...

Page 102: ...Page 86 NOTES 5_106_00 bk Page 86 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 103: ...MAINTENANCE Page 87 MAINTENANCE 5_106_00 bk Page 87 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 104: ...elt 270 lbs 10 lbs r Used belt 230 lbs 10 lbs r Minimum allowable tension before retension is required 150 lbs MAINTENANCE The belt tension and condition of the belt should be checked when performing...

Page 105: ...69 Regardless of the canister style the breather filter element can be cleaned if it has become plugged following the procedure in this section 69 Figure 69 Canister Housings 1 Fiberglass Reinforced N...

Page 106: ...nning with engine serial number series 7V With this change the oil filter mounting adapter was redesigned to accommodate the poppet style relief valve and to eliminate the section that contained the p...

Page 107: ...following procedure 1 Run the engine until normal operating temperature is reached Then shut off the engine and drain the oil before the engine cools 2 Thoroughly clean the area around the filters bef...

Page 108: ...linder block and filter housing 9 Start the engine and check for leaks CENTRI MAX PLUS FILTER REPLACEMENT Internally Drained Filter 1 To prevent contamination from entering the engine thoroughly clean...

Page 109: ...be identified by the two 1 4 inch wide bands around the circumference of the filter Figure 74 shows the fuel filters required for the E Tech engine Attempting to install E7 filters with English threa...

Page 110: ...g the Fuel System under Engine Final Preparation and Operational Check Coolant Conditioner Replacement 125 LD If the engine is equipped with the optional coolant conditioner the conditioner element is...

Page 111: ...REPAIR INSTRUCTIONS Page 95 REPAIR INSTRUCTIONS 5_106_00 bk Page 95 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 112: ...away from the work area to prevent accidents or hood damage to conventional models On cab over engine models tilt cab forward 2 Place a suitable container beneath the engine and drain the engine oil...

Page 113: ...be sure to store the assembly either horizontally with the fan face down hub flange up or vertically as shown in Figure 76 This will prevent fluid leaking from the assembly 75 Figure 75 Fan Assembly...

Page 114: ...applicable 27 Obtain the appropriate lifting equipment bar or chain and attach to the proper lift points on the engine 28 Position and attach the engine hoist to the lift bar or chain and using the ho...

Page 115: ...removed remove the filters following the procedure below Refer to Figure 77 1 Place a suitable container below the filter element area to catch any spilled fluids 2 Using a suitable filter wrench remo...

Page 116: ...remove the centrifugal oil filter housing 9 Apply the filter wrench to area labeled WRENCH HERE on the Centri Max filter housing Application outside of the labeled area will result in damage to the Ce...

Page 117: ...acket 9 2 Disconnect the turbocharger lubrication supply line 2 from the mounting bracket 3 Loosen the hose clamps at the cooler to water pipe connection and slide the hose away from the cooler and fu...

Page 118: ...n assembly The assembly can be disassembled later if necessary Refer to Oil Cooler Disassembly under Lubrication System Components Bench Procedures in the REPAIR INSTRUCTIONS section Later production...

Page 119: ...te J 38048 are recommended to safely support the engine during disassembly and assembly procedures Avoid using an engine stand that supports the engine on the oil pan rail while the oil pan is still i...

Page 120: ...38048 1 to the left side of the engine 2 Secure adapter plate 1 to engine stand J 29109 3 with six mounting capscrews 4 3 Remove lifting device from the engine 82 Figure 82 Engine Mounting in Stand 1...

Page 121: ...Mounted Assembly The following procedure applies for an EECU mounted on the left side of the engine The procedure for a right side mounted unit with cooling plate is covered later in this section 1 Th...

Page 122: ...inlet manifold 4 Carefully remove the EECU from the inlet manifold The bracket can remain attached to the inlet manifold providing the manifold is not being replaced 85 Figure 85 EECU Removal Left Si...

Page 123: ...adapter assembly 4 Remove fuel filter adapter assembly from the air inlet manifold 7 5 Remove fuel supply hose stand off bracket from head bolt water pump support bracket and remove supply hose 86 Fig...

Page 124: ...t manifold Position leads out of way 2 Disconnect fittings 3 from both ends of the coolant conditioner supply tube Remove tube 2 Remove only the supply tube Do not remove the brass elbow fittings at t...

Page 125: ...If it resists movement and does not return to its seat freely the check valve assembly must be replaced Oil Cooler to Water Pump Inlet Line Removal If the engine is equipped with the plate type oil co...

Page 126: ...emove the thermostat housing 5 and thermostat Discard gasket 8 90 Figure 90 Coolant Conditioner and Thermostat Removal 1 Capscrew 2 Coolant Conditioner Head Assembly If Equipped 3 Check Valve Assembly...

Page 127: ...uction 4 Remove manifold assembly It may be necessary to pry or tap lightly with a soft mallet on the housing sections to break the seal 5 If necessary separate the two coolant manifold sections 1 and...

Page 128: ...let manifold It may be necessary to gently pry or tap the manifold lightly with a soft mallet to break the seal 3 If the air inlet manifold is to be replaced remove sensor 7 located on the inlet manif...

Page 129: ...d 2 Loosen the tube sleeve nut 1 at the unit pump for the No 1 cylinder Be careful to avoid twisting the line while loosening the nut 3 Loosen tube sleeve nut 2 and tube clamping screw at the cylinder...

Page 130: ...ifold and remove 12 mounting nuts Figure 96 securing the manifold to cylinder heads 2 Remove the exhaust manifold 3 Discard gaskets 96 Figure 96 Exhaust Manifold Removal 5_106_00 bk Page 114 Friday Au...

Page 131: ...lean the area around the EECU harness connector to make sure the terminals remain clean for reassembly 2 Disconnect the wiring harness and coolant inlet and outlet lines to the EECU cooling plate if n...

Page 132: ...the EUP comes out against the screw head The EUP may spring out against the screw head The rapid upward movement of the EUP may result in the tappet spring retainer becoming dislodged from the plunge...

Page 133: ...nal injury Refer to Figure 101 1 Remove three mounting capscrews 5 securing air compressor 1 to auxiliary shaft housing 2 Taking care not to damage or lose the lubrication oil supply tube 2 remove the...

Page 134: ...led view 1 Remove valve covers 1 by removing six retaining capscrews 2 from each cover 2 Discard seals 3 If an engine brake is installed perform the following a Remove control wire 3 from left side of...

Page 135: ...the top end to provide a hardened wear surface for contact with the push rod Figure 103 The insert is staked in place during manufacture of the lifter later production is press fit However with very...

Page 136: ...ng Screw 6 Standard Adjusting Screw and Jam Nut Inlet Valves 7 Cylinder Head 8 Exhaust Valve Yokes 9 Actuator Pin Assembly 10 Rocker Arm Shaft Assembly 11 Engine Brake Oil Supply Screw 12 Slave Piston...

Page 137: ...9 is slightly compressed 3 With tool in position turn nut 12 clockwise to draw nozzle holder from cylinder head nozzle mounting hole 8 4 Continue turning nut until nozzle holder is free of insert Remo...

Page 138: ...or location of bolts if necessary Cylinder head assemblies are heavy Lifting a cylinder head requires the help of an assistant or suitable lifting device Attempting to lift a cylinder head without ass...

Page 139: ...ing engine on the stand Failure to do so may result in damage to components or severe personal injury Refer to Figure 109 1 Remove the nuts from the two studs early production or shouldered bolts curr...

Page 140: ...ce or integral hex head shoulder studs one piece along the pan rails Some early engine versions used an additional washer between the nut and the isolator 109 Figure 109 Isolating Oil Pan Hex Head Sho...

Page 141: ...cured in position Do so before loosening the three retaining capscrews The E Tech screen for the oil inlet tube is held in place by a steel retainer ring Remove the oil pump as a unit by removing thre...

Page 142: ...efer to Figure 111 1 Remove front engine mount pedestal 2 by removing six retaining capscrews 3 and 4 2 Remove remaining mounting capscrews from front cover 1 3 Remove front cover It will be necessary...

Page 143: ...l to avoid damaging the auxiliary shaft bushings or journals while removing the shaft 4 Remove the auxiliary shaft 3 by pulling it rearward out of the air compressor mounting flange opening With engin...

Page 144: ...shaft removal 2 Remove the two 12 point capscrews 3 that retain camshaft thrust washer 1 Camshaft may have to be rotated slightly to make the capscrews accessible through openings 2 in the camshaft dr...

Page 145: ...emoving pistons connecting rods and rod caps ensure they are marked so they can be reinstalled in the same cylinders from which they were removed Remove connecting rod and piston assemblies in compani...

Page 146: ...Piston and Connecting Rod Assembly Removal 5 Using a hammer handle push piston 1 from the cylinder bore Remove piston 6 in the same manner 6 After removing pistons 1 and 6 rotate crankshaft so that ne...

Page 147: ...w flywheel to be safely removed from the crankshaft 3 Remove remaining capscrews 4 Carefully tap flywheel by alternating from side to side to work it off the aligning dowel pins The flywheel is heavy...

Page 148: ...2 Remove flywheel housing It may be necessary to tap lightly on the housing with a soft mallet to separate housing from engine block 121 Figure 121 Flywheel Housing Removal 1 Capscrew Locations 2 Flyw...

Page 149: ...bearing caps 4 and 5 The center main bearing cap 5 houses the thrust washers 3 Position a lady foot pry bar under the tabs provided on bearing caps and pry bearing caps upward To work them loose it m...

Page 150: ...g Remover Installer J 21428 01 r Counterbore Tool PT2210 r Counterbore Cutter Plate PT2210 3A r Hex Key Wrench PT2210 14 r Universal Dial Depth Gauge PT5025 r 3 Inch Stylus Extension PT5025 11 Piston...

Page 151: ...Figure 126 1 Rotate the engine in the stand so that it is upright deck surface upward 2 Use puller PT6435 or equivalent to remove the cylinder sleeve 1 from the cylinder block 4 3 Position the puller...

Page 152: ...gs or pipe plugs show signs of leaking they should be replaced Cleaning the cylinder block is a good time to inspect it for cracks or other possible defects that may be reason for rejection Refer to t...

Page 153: ...If the cylinder block deck is resurfaced the cylinder sleeve counterbore depth must be recut to specification If the cylinder block deck was not resurfaced but cylinder sleeve counterbore surface show...

Page 154: ...by backing off the depth set collars 5 and 16 and lowering the cutter plate 13 into the counterbore to center the tool 4 Secure the cutter plate to the cylinder block with four M16 x 2 x 90 hex head...

Page 155: ...e cutter to rest on the counterbore ledge b Rotate both depth set collars 5 and 16 down until the bottom collar contacts the main housing 8 Do not force the collar beyond this point as it will lift th...

Page 156: ...h Set Collar 6 Lower Thumbscrew 7 Oil Fill Tube 8 Main Housing 9 Hold Down Capscrews 10 Cutter Bit Adjuster 11 Cutter Bit 12 Hold Down Cap 13 Cutter Plate 14 Cylinder Block 15 Main Shaft 16 Lower Dept...

Page 157: ...osen the two cutter bit hold down capscrews 9 and rotate the cutter bit adjusting screw 10 counterclockwise until the cutter bit is retracted into the cutter plate 13 b Remove the four machine hold do...

Page 158: ...inserted under the head of the screw and pry the plug out 2 Clean the plug hole s with a wire brush or wire wheel After cleaning visually check the surface for cracks 130 Figure 130 Cylinder Block Pl...

Page 159: ...ug to specification Refer to the torque chart in the SPECIFICATIONS section of this manual New plugs may already have a sealer applied to the threads Applying a Teflon sealer to the threads will not a...

Page 160: ...of the H ring clean the bore and dislodged H ring or new H ring if required with Loctite Primer T Then apply Loctite RC 609 to the bore and to the H ring outside surface 4 Use service tool J 41683 to...

Page 161: ...ever are not centered The offsets are described as follows r No 1 bushing Installed with the front of the bushing flush to 0 030 inch behind the front face of the bore There is approximately 1 8 inch...

Page 162: ...Page 146 REPAIR INSTRUCTIONS 137 Figure 137 Camshaft Bushing Locations 5_106_00 bk Page 146 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 163: ...aligned with both its oil supply and oil feed passages in the cylinder block either the camshaft bushing will fail or the components lubricated by the bushing feed will fail from inadequate lubricatio...

Page 164: ...rtant If the front bushing is misaligned lubrication oil flow to the front bushing and journal will be blocked The rear bushing does not have any cylinder block oil passage to align with the holes in...

Page 165: ...ushing bore has no oil holes to align with the bushing oil holes so simply install the bushings with the indexing notches at the 5 30 and 10 o clock positions Refer to Figure 141 and Figure 142 141 Fi...

Page 166: ...143 Auxiliary Shaft Bushing Alignment 4 Using camshaft bushing removal installation tool J 21428 01 4 and the appropriate pilot adapter 3 install the bushing 5 Check the bushing surface for burrs cau...

Page 167: ...k Incorrect recess will cause misalignment of the oil supply hole resulting in insufficient lubrication of the journal Also any bushing protrusion will allow the thrust washer to seat on the bushing a...

Page 168: ...eal groove and it is recommended that use of the crevice seal be discontinued in all engine repairs or rebuilds whether or not the liner has a crevice seal groove SPECIAL TOOLS REQUIRED r Depth Gauge...

Page 169: ...sidue to ensure that the Silastic bead seals and bonds properly 4 Position the cylinder sleeve 1 in the cylinder bore 5 With the palms of the hands placed on the upper end of the cylinder sleeve 180 d...

Page 170: ...is fully seated use depth gauge J 26948 or equivalent to check the flange height above deck dimensions The specified dimension is 0 023 0 029 inch 0 584 0 737 mm The measurement should be taken in the...

Page 171: ...REPAIR INSTRUCTIONS Page 155 147 Figure 147 Cylinder Sleeve Fire Ring Configuration 5_106_00 bk Page 155 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 172: ...876 mm Cylinder sleeve ID minimum 4 875 inches 123 825 mm The cylinder sleeve ID may be a minimum 4 872 inches 123 749 mm due to close in from press fit 148 Figure 148 Checking Cylinder Sleeve for Out...

Page 173: ...w 4 in the spray nozzle bracket 3 3 Position the spray nozzle locator tube 6 in the cylinder block oil passage 2 and using torque wrench J 24406 or equivalent tighten the retaining screw to the specif...

Page 174: ...1 and 6 5 and 2 3 and 4 150 Figure 150 Spray Nozzle Patterns Using piston cooling nozzle spray position set J 39045 1991 and later check the direction of the spray from the nozzles Refer to Figure 151...

Page 175: ...flywheel SPECIAL TOOL REQUIRED r Flywheel Housing Timing Front Cover Locating Pin Driver J 37712 REMOVAL If it is necessary to remove the front cover or flywheel housing locating dowel pins do so as f...

Page 176: ...ver has made contact with the block the dowel pin will be at the correct dimension above the block surface 152 Figure 152 Round Dowel Pin Installation BLADE TYPE DOWEL PIN INSTALLATION 1 Position the...

Page 177: ...check further for cracks This process requires special equipment and application methods 4 Using standard machinists inspection practice check the crankshaft to ensure it is straight 5 Measure the cr...

Page 178: ...ve a hole in it to accept the dowel pin If an earlier version flywheel or torque converter drive flange without a dowel pin hole is used for replacement it must be reworked If it is necessary to rewor...

Page 179: ...eeth If the gear is defective it must be replaced REPLACEMENT Refer to Figure 155 1 Using a suitable puller such as J 21834 4A or equivalent remove the gear and key The threads in the end of the crank...

Page 180: ...hafts were manufactured with a repair sleeve installed on the flange The repair sleeve is usually not noticeable and is finish ground to standard flange size If the repair sleeve is damaged or becomes...

Page 181: ...ter toward the engine The chamfer on the outside diameter of the wear ring must face away from the engine The crankshaft wear ring is a shrink fit on the crankshaft flange Use wear ring installer J 38...

Page 182: ...nto the threaded hole in the center of the installation tool 5 Remove the wear ring and installation tool from the oven or hot plate and immediately place in position on the crankshaft flange Push the...

Page 183: ...facing a flat style flywheel it is very important that the machine shop NOT leave a step on the friction face outer diameter adjacent to the clutch locating pilot There is an undercut relief in the co...

Page 184: ...ation is dependent upon engine horsepower ratings Some late production high horsepower engines use the offset key P N 54GC31 Make sure that the correct camshaft key and positioning is used for the app...

Page 185: ...n offset key positioned to the right or left depending on the engine model If an offset key is used be sure to note the positioning of the key so that it can be reinstalled in the same position Make s...

Page 186: ...only the heat method procedure below for both new or used parts Do not use a press to install the gear HEAT METHOD CAMSHAFT GEAR INSTALLATION Refer to Figure 162 1 Using a suitable contact type cleane...

Page 187: ...162 Figure 162 Camshaft Assembly Components 1 Camshaft Gear 2 Camshaft Captured Thrust Washer 3 Camshaft 4 Key 5_106_00 bk Page 171 Friday August 4 2000 11 17 AM BDC for engine manuals and specs http...

Page 188: ...when handling the heated gear 7 Using a quick steady motion push downward on the gear until the gear is fully seated against the cam shoulder surface The heat expanded gear bore will begin to transfer...

Page 189: ...ol the weight of reciprocating parts Connecting rods fall into two weight classes M1 or M2 Initially the classes were identified by the respective M number M1 or M2 stamped onto the connecting rod bea...

Page 190: ...RIST PIN BUSHING REPLACEMENT If the wrist pin bushing is found to be out of tolerance it should be replaced Refer to Figure 166 To replace the bushing 1 Position the rod in a press with the piston pin...

Page 191: ...lignment of the connecting rod for twist or bend CONNECTING ROD ALIGNMENT CHECK 1 Position the connecting rod in a connecting rod fixture Sweeney 945 6041 or equivalent Use the appropriate mandrel and...

Page 192: ...he wrist pin bore pedestal of the crown and the piston skirt are stamped FRONT and must be installed facing the front of engine A radius is cut in the lower edge of the piston skirt to provide clearan...

Page 193: ...re that it is positioned squarely in the sleeve 2 Using thickness gauges check the ring end gap Refer to Fits and Limits in the SPECIFICATIONS section for end gap tolerance All rings to be used should...

Page 194: ...ss gauge check for excessive wear of the oil control ring groove side clearance 1 Position a new oil control ring in the groove and insert a thickness gauge between the ring and upper land of the groo...

Page 195: ...nt distortion use the proper size piston ring expander PT6587 to place rings in the piston grooves 173 Figure 173 Piston Ring Expander PT6587 2 Stagger the piston rings so that no ring gap is directly...

Page 196: ...the cylinder location They must be returned to same cylinder from which they were removed 175 Figure 175 Piston Markings 3 Using a generous amount of clean engine oil push the piston wrist pin into t...

Page 197: ...e Plug Installer 1 1 16 inch cup plugs J 34687 r Valve Seal Installer J 42453 r Valve Stem Seal Remover J 39460 Inlet and Exhaust Valve Removal 213 NB GENERAL INFORMATION Current production engines us...

Page 198: ...REPAIR INSTRUCTIONS 176 Figure 176 Valve Spring Rotator and Valve Seat Insert Combinations 5_106_00 bk Page 182 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https barringtondieselcl...

Page 199: ...are easily identified by the steel retainer band around the top of the seal lip The guides have three sharp ridges machined into the upper outside diameter surface refer to Figure 179 for excellent se...

Page 200: ...gure 176 After removing the valve springs removal of the existing valve stem seals can be accomplished easily and quickly by using the J 39460 Valve Stem Seal Removal tool Failure to use this tool cou...

Page 201: ...a resurfaced head 6 381 inches 162 077 mm When the deck is resurfaced fire ring groove and valve seat insert dimensions must be re established following the procedure in Fire Ring Groove Cutting Fire...

Page 202: ...n capscrews can be reached as shown in Figure 182 Install the spacer washer and wing nut Lightly tighten the wing nut The cutter base must be free to move 182 Figure 182 Fastening Cutter Base 3 Place...

Page 203: ...ot visible insert two 0 008 inch thickness gauges 2 between the cutter head 1 and base 4 5 Adjust the cutter head J 37719 until it bottoms out on the deck surface of the existing fire ring groove Tigh...

Page 204: ...ensure proper groove depth always adjust the cutting tool height when cutting the next groove Valve Guide Replacement 213 EP INLET AND EXHAUST VALVE GUIDE DIMENSIONS Refer to Figure 186 r Valve guide...

Page 205: ...to Figure 187 187 Figure 187 Measuring Valve Guide Bore 2 Use a depth gauge to check valve guide extension Refer to Figure 188 188 Figure 188 Checking Valve Guide Extension 1 Exhaust Valve Guide 2 In...

Page 206: ...wear cracks or other damage Clean the surfaces thoroughly and check the ID measurement VALVE GUIDE INSTALLATION 1 Insert a new valve guide into the valve guide installer J 37809 2 Oil the OD of the g...

Page 207: ...e seat 3 insert face angle 1 Inlet 20 30 15 Exhaust 30 0 30 r Valve seat insert diameter 2 Inlet 1 832 1 831 inches 46 533 46 507 mm Exhaust 1 693 1 691 inches 43 002 42 951 mm r Valve seat width 4 0...

Page 208: ...ment tool 1 measure the distance from the cylinder head surface 2 to the point on insert where the groove will be ground as shown in Figure 193 This point should be approximately 0 060 inch 1 524 mm b...

Page 209: ...er head 5 Attach the collet to the T handle and shaft assembly 6 Position the collet in the valve seat insert so ridge of the collet will be inside the groove Turn the T handle to fully expand the col...

Page 210: ...ION 1 With the valve seat insert removed from the cylinder head clean the surface thoroughly with a wire brush 2 Check the surface finish for smoothness Check the counterbore diameter Figure 197 with...

Page 211: ...valve inserts 30 0 30 Always use 30 degree valves with 30 degree valve inserts and 20 degree valves with 20 degree valve inserts Excessive wear and possible failure will result if 30 degree parts are...

Page 212: ...ng the valve seat inserts and before installing the valves Valve Spring Inspection 213 MB 1 Visually inspect the inside surfaces of the spring coils Also feel the inside surfaces of each spring for an...

Page 213: ...s shown in Figure 201 3 Thread the puller into the end of the nozzle holder insert and use the slide hammer to remove the insert 201 Figure 201 Removing Injection Nozzle Holder Insert INSTALLATION PRO...

Page 214: ...cks or other damage Also check the pin diameter and installed height REMOVAL PROCEDURE Remove a broken pin as follows Due to the hardness of the valve yoke guide pins drilling and tapping must be done...

Page 215: ...ead for drilling or tapping damage 205 Figure 205 Valve Yoke Guide Pin Removal INSTALLATION PROCEDURE If a new valve yoke guide pin is required apply Loctite 635 to the pin and use guide pin installer...

Page 216: ...be used If a cylinder head has been placed in a hot chemical tank for cleaning and degreasing the pipe plugs must be checked for looseness If a plug is found to be loose the epoxy seal has been broken...

Page 217: ...uel passage at the top front location of the front cylinder head Tighten the plug to the specified torque 6 lb ft 8 N m 4 Install a 1 16 inch NPT pipe plug in each end of the cylinder head Tighten the...

Page 218: ...k valve seat angle Also check stem length diameter and condition 209 Figure 209 Valve Dimensions 1 Inlet Valve 2 Pyromet Exhaust Valve 3 Seat Angle 20 Inlet 30 Exhaust 4 Minimum After Grinding 0 130 i...

Page 219: ...ly important when both the valves and the valve guides are new With an on engine seal replacement pre lube the valve stems with clean engine oil while moving the valve up and down prior to installatio...

Page 220: ...rs Use tool J 29294 B to install the keepers 7 After the valves are installed check each inlet valve for head height above the cylinder deck The protrusion dimension for inlet valves should be 0 0425...

Page 221: ...sary Refer back to the Valve Seat Insert Installation procedure in this section 1 Inlet Protrusion Above Deck 0 0425 inch 0 009 0 007 inch 1 0795 0 229 0 178 mm 2 Inlet Valve 3 Exhaust Valve 4 Exhaust...

Page 222: ...to properly position the rocker arms Refer to Figure 214 and Figure 215 The shaft assembly is disassembled as follows 1 Remove the C clip and flat washer from one end of the shaft 2 Remove the outer r...

Page 223: ...stall a flat washer and C clip 1 on the shaft to retain the exhaust rocker arm 8 Lubricate the inlet rocker arm 7 and install it on the shaft 9 Install a flat washer and C clip 1 on the shaft to retai...

Page 224: ...her 3 Locating Screw and Lock Washer 4 Standard Adjusting Screws and Jam Nuts 5 Exhaust Rocker Arm 6 Mounting Bracket 7 Inlet Rocker Arm 8 Shaft 9 Capscrews Short 10 Washers not used if equipped with...

Page 225: ...the washers on the shaft one on each side of the mounting bracket 7 Lubricate the exhaust rocker arm 5 and install it on the shaft 8 Install a flat washer and C clip 1 on the shaft to retain the exhau...

Page 226: ...housing 1 Flat Washer and C Clip 2 Spring Washer 3 Oil Supply Screw New Style Design with Integral Check Valve 4 Adjusting Screw and Spherical Jam Nut 5 Exhaust Rocker Arm 6 Mounting Bracket 7 Inlet R...

Page 227: ...g fixture 2 Remove the oil inlet pickup tube and screen assembly not shown Before inlet tube removal note the orientation of tube for reassembly purposes Inlet tubes are positioned differently for fro...

Page 228: ...4 Housing 5 Key 6 Pump Gear and Shaft 7 Oil Pump Housing Cover 8 Gasket 9 Inlet Flange Plate 10 Capscrews 11 Plunger 12 Relief Valve Spring 13 Relief Valve Cap 14 Idler Gear 15 Thrust Washer 5_106_00...

Page 229: ...necessary 7 Insert the pump gear and shaft and thrust washer in the housing check for free play by spinning the gear If any binding occurs check the housing and gear teeth for burrs nicks or other da...

Page 230: ...g Idler Gear Assembly Side Clearance Check Backlash Check Refer to Figure 219 Check backlash between the pump gear 3 and idler gear 2 with a thickness gauge 1 r Low Limit Insert a 0 013 inch 0 33 mm t...

Page 231: ...valve housing 10 Install the pump inlet flange plate 9 and gasket 8 on the housing Secure the plate with capscrews 10 11 Install the oil inlet pickup tube and screen assembly Because the inlet tube m...

Page 232: ...ed operation under these conditions may result in severe engine damage 221 Figure 221 Removable Bundle Type Oil Cooler Assembly 1 Gasket 2 Coolant Outlet End Cap 3 O Ring 4 Mounting Flange 5 Clamps 6...

Page 233: ...ounting flange 1 and secure the plate with mounting capscrews 2 as shown in Figure 222 b Install a steel plate 2 with a rubber gasket on the oil outlet opening Secure the plate to the housing 1 with t...

Page 234: ...gasket 21 on the bundle end 7 Apply Permatex gasket sealer on top of the gasket 21 before installing the inlet cap 20 8 Install the coolant inlet end cap and secure the cap with six capscrews 19 9 Ti...

Page 235: ...broken EUP hold down bolts will result in a rapid pop up of the pump from the bore Should this occur the unit pump tappet spring seat can dislodge from the plunger foot The plunger however is retained...

Page 236: ...r pulled from the unit pump bore as described in step 2 slide the retaining clip into place The flat side of the clip goes into the retaining clip slot The plunger must be positioned as described in s...

Page 237: ...lubricate with clean engine oil 9 Reinstall the unit pump into the engine using the procedures as outlined under Engine Reassembly in the REPAIR INSTRUCTIONS section Fuel Injector Nozzle Cleaning 222...

Page 238: ...ed under the respective bench procedure sections of this manual are reinstalled here as assemblies Failure to follow the sequence of operations listed may result in damage to components or personal in...

Page 239: ...ain Bearing Insert Part Numbers and Locations 1 Locating Tab 2 Bearing Insert 1 Upper Insert 646B348 Lower Insert 646B343 2 Upper Insert 646B345 Lower Insert 646B343 3 Upper Insert 646B345 Lower Inser...

Page 240: ...nsert in the bearing cap bore Figure 234 The insert must be installed dry The lower bearing inserts do not have a hole or a groove They are stamped with the word LOWER Do not mix the caps or inserts T...

Page 241: ...crankshaft The obvious color difference of the previously used bronze steel washers is no longer present making it difficult to determine which side of the washer is meant to be installed against the...

Page 242: ...sections on the center bearing cap aluminum faced side toward crankshaft and install the cap Figure 237 Torque the capscrews to specification 210 lb ft 285 N m using torque wrench J 24407 or equivalen...

Page 243: ...its and Limits in the SPECIFICATIONS section 16 If the end play is out of specification remove the thrust washers and install properly sized thrust washers as required to bring the end play into speci...

Page 244: ...arance is determined by measuring the width of the crushed Plastigage with the supplied gauge 2 Place a section of Plastigage 2 on the journal to be checked and assemble the main bearing cap 1 to the...

Page 245: ...ide 2 3 5 6 and RH side 5 and 6 6 total are 80 mm long 1 r RH side FRT 2 and 3 2 total are 110 mm long 2 239 Figure 239 Buttress Capscrew Locations 9 After obtaining the proper main bearing clearance...

Page 246: ...ings into the ring grooves until the tool contacts the surface on which the piston crown is resting 6 Position the upper bearing insert into the connecting rod Align the tab in the bearing insert with...

Page 247: ...n tool 1 to keep it in contact with the cylinder sleeve as shown in Figure 242 use a hammer handle to push the piston 2 through the tool Continue pushing on the piston until the top ring has passed in...

Page 248: ...ngs may result Before pushing the piston all the way down in the sleeve check to see if piston cooling nozzle 1 is aligned with the nozzle clearance notch 2 provided in the lower end of the piston ski...

Page 249: ...eads of the rod cap capscrews and secure the cap 3 Angle torque the capscrews to 30 lb ft 41 N m plus 90 degrees using torque angle gauge set BT 91104 or equivalent The angle torque method applies for...

Page 250: ...using machined surfaces capscrews holes and dowel locations for cracks or wear Replace if cracks are evident Before installing the flywheel housing examine the crankshaft flange for any cracks surface...

Page 251: ...using part No 35AX1489 r Eight washers used with ductile iron housing part No 271AM5008 Service replacement flywheel housings are the standardized flywheel housing The new appropriate mounting hardwar...

Page 252: ...ssion with respect to the engine flywheel and crankshaft 247 Figure 247 Flywheel Housing Installation 4 Apply an even coat of Silastic approximately a 1 16 inch 2 mm bead to the flywheel housing mount...

Page 253: ...lace The machined dowel method requires that crankshaft and piston assemblies be removed Flywheel housing runout specifications are as follows r Runout checked with an alignment bar installed through...

Page 254: ...e Do not remove the seal from the sleeve before installation The installation sleeve provides a smooth surface for the seal as it moves from the tool to the crankshaft flange 1 Thoroughly clean the su...

Page 255: ...dry the crankshaft flange 3 Apply a thin even layer of Loctite 609 to the circumference of the crankshaft flange Do not lubricate the lips of a Teflon seal before installation Teflon seals function mo...

Page 256: ...es of engine travel engine timing and three stamped locations 120 degrees apart for valve settings as shown in Figure 256 The flywheel still has pump timing marks to accommodate application to both E...

Page 257: ...n and alignment studs on the flywheel mounting surface at the rear of the crankshaft 2 Install the flywheel mounting capscrews in the exposed mounting holes At this time tighten the capscrews finger t...

Page 258: ...iliary Shaft and Camshaft Bench Procedures in the REPAIR INSTRUCTIONS section When installing the camshaft it is easier to remove the camshaft guide from the camshaft after installation when the idler...

Page 259: ...emoval The camshaft must be rotated so that the installation guide faces up toward the cylinder block pan rail The crankshaft must be rotated so the No 6 connecting rod journal faces down toward the c...

Page 260: ...n and the hub correctly aligned with the mounting bolt holes place idler hub against the block and verify good mounting hole alignment Figure 264 264 Figure 264 Hub Correctly Positioned on Block 2 Ali...

Page 261: ...components 7 Tighten the bolts evenly to specification Do not use an impact wrench or other air tool to tighten bolts Auxiliary Shaft Installation 212 CV Before installing the auxiliary shaft in the e...

Page 262: ...ndition as covered under Lubrication System Components Bench Procedures in the REPAIR INSTRUCTIONS section Because of differences in the E Tech and E7 gear set helixes it is important that the correct...

Page 263: ...ont cover 1 Apply a light coat of Silastic to the timing cover mounting surface 2 Position the timing cover on the cylinder block mounting surface 3 Secure the timing cover to the cylinder block using...

Page 264: ...e seal on the seal installer J 37715 2 adapter in combination with J 37715 A with the solid portion of the seal outward toward the tool 2 Position the tool over hub and into the seal opening 269 Figur...

Page 265: ...r a hub key and precise alignment 4 In a quick even motion push the hub onto the crankshaft 5 Install the hub washer and capscrew Tighten the capscrew to the specified torque 330 lb ft 447 N m using t...

Page 266: ...ate August 1999 the shoulder studs at the timing cover and flywheel housing were changed to shoulder capscrews part No 421GC289M and approximately fourth quarter 1999 the shoulder studs with a separat...

Page 267: ...on the oil pan rails with the ribbed side facing up 3 Beginning at the center of the pan at one of the rectangular tabs align the rubber locating cones with corresponding holes in the pan rails Figur...

Page 268: ...refully in position on top of each cylinder sleeve Check that the design of the fire ring used is the correct match for the cylinder sleeves installed 3 Position the partially assembled cylinder heads...

Page 269: ...are two cylinder head capscrew lengths 198 0 mm and 225 0 mm 6 Check the alignment of the cylinder heads by placing a straightedge against the exhaust manifold mounting surfaces Figure 276 Using a fe...

Page 270: ...NSTRUCTIONS 276 Figure 276 Cylinder Head Alignment 1 Cylinder Heads 2 Cylinder Block 3 Straightedge 5_106_00 bk Page 254 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https barrington...

Page 271: ...ation 214 EG MANIFOLD STUD INSTALLATION Apply Loctite 272 to the cylinder head engagement threads of all exhaust studs prior to installation Lower exhaust stud holes intersect with the push rod holes...

Page 272: ...ts must be installed dry no lubrication 3 Position the exhaust manifold on the mounting studs and secure with nuts Tighten the nuts to the specified torque r 55 lb ft 75 N m for 10 mm nuts r 65 lb ft...

Page 273: ...ab of grease to hold it in place An alternate method is to drop the washer in the nozzle holder sleeve bore as shown in Figure 280 Make sure the washer type gasket is centered and lying flat in the bo...

Page 274: ...properly aligned with the alignment notch in the nozzle holder sleeve push downward on the handle of the installation tool driving the nozzle holder into position Refer to Figure 283 283 Figure 283 No...

Page 275: ...ench J 24407 or equivalent 285 Figure 285 Retaining Plug Installation Push Rod Installation 213 LH Check the condition of the push rods before installing them Replace any rods that have loose ends are...

Page 276: ...the bottom surface of the button head On the E6 E7 and E9 valve yoke the top surface of the adjusting screw area is 0 145 below the bottom surface of the button head Refer to Figure 287 for an illustr...

Page 277: ...they are seated on the valve stems The exhaust valve yokes on engines equipped with the J Tech engine brake use an actuator pin assembly part No 421GC41M in place of the standard yoke adjusting screw...

Page 278: ...in position on the rocker arm mounting bracket for each cylinder head and tightened to specification 5 lb ft 6 8 N m 2 Make sure that all 12 push rods are properly seated in the respective lifter soc...

Page 279: ...ENGINE SETUP AND ADJUSTMENTS section 291 Figure 291 Rocker Arm Shaft and J Tech Engine Brake Components A new oil supply screw assembly has been released for the J Tech engine brake This new screw inc...

Page 280: ...ce b Install one end of the spacer gasket into the seal groove inboard side approximately 1 4 inch 6 4 mm from the end of the groove c Guide the seal strip into the groove around the circumference of...

Page 281: ...pecified torque 16 lb ft 22 N m 293 Figure 293 Valve Cover Installation Oil Fill Tube Installation 1 Add a bead of RTV sealant on the mounting flange around the fill tube opening 2 Position the fill t...

Page 282: ...cylinder block 2 Install the four isolating washers on the studs and install the cooling plate 3 Position the EECU on the cooling plate and install the isolating washers and fasteners Tighten fastener...

Page 283: ...the air compressor mounting flange 2 Check to ensure that the lubrication oil supply tube 2 is in place and position the air compressor 1 on the mounting flange If the oil supply tube is lost the air...

Page 284: ...e EUP O rings with clean engine oil and install the No 1 EUP into the cylinder block Figure 296 Minimize oil above the top O ring to avoid weepage of excess oil trapped above the top O ring onto the c...

Page 285: ...ten the fuel inlet tube sleeve nut 2 The fuel nozzle inlet tube assemblies are identical for all six cylinders 3 Connect the line 1 at the No 1 unit pump Tighten the clamping screw and sleeve nuts to...

Page 286: ...tes or V bands are loosened for angular orientation of the compressor cover or turbine housing ensure that the mating flanges are tightly seated and that the fasteners are snug but will still allow co...

Page 287: ...mp mounting flange 2 Position the pump on the cylinder block and install the three mounting capscrews 3 3 Install the refrigerant compressor support bracket if required on the front of the cylinder he...

Page 288: ...ocedures before installing the threaded spuds into the filter adapter Refer to Figure 301 1 Apply a continuous bead of Loctite 609 or 271 around the circumference of the spud between the second and fi...

Page 289: ...0 and insert the capscrews into the mounting flange Do not tighten the capscrews at this time 6 Place a gasket on the water pump mounting flange 2 7 Lubricate the threads of the two mounting capscrews...

Page 290: ...d gasket on the mounting surface 2 Lubricate threads of the capscrews 5 with clean engine oil and secure the front coolant manifold section in place with the mounting capscrews Early production engine...

Page 291: ...34 N m using torque wrench J 24406 or equivalent 8 Ensure that the couple is properly installed and secure it in position with the clamps Tighten the clamps to the specified torque 38 lb in 4 3 N m 3...

Page 292: ...area and the seal to prevent premature failure of the new seal A sealing lip that has been turned back cut or otherwise damaged will leak and must be replaced The lip faces the front of the engine 2 R...

Page 293: ...ing capscrews 13 305 Figure 305 Thermostat Housing Installation 1 Capscrew 2 Coolant Conditioner Adapter Assembly if Equipped 3 Check Valve if Equipped 4 O Ring 5 Thermostat Housing 6 Thermostat Seal...

Page 294: ...onditioner filter one full turn after the gasket contacts base Use tool J 24783 to tighten Fuel Filter Adapter Assembly Installation 231 PB Refer to Figure 306 and Figure 307 1 Install the fuel filter...

Page 295: ...condary Filter Fitting Out 2 Secondary Filter Fitting In 3 Primary Filter Fitting Out 4 Coolant Manifold 5 Air Inlet Manifold 6 Mounting Bracket 7 Primary Filter Fitting In 8 Fuel Filter Adapter 5_106...

Page 296: ...inlet line Figure 309 as follows 1 Place the inlet line in position on the engine and loosely install the capscrews attaching the line to the water pump 2 Install the flexible hose coupling and two c...

Page 297: ...ion Removing Engine from Engine Stand 200 EA 1 Attach a suitable lifting device to lifting points on the engine 2 Position and attach an engine hoist to the lifting device operate the hoist to place t...

Page 298: ...pipe and slide completely onto the pipe to allow installation of the oil cooler Also loosely install both the hose clamps 5 Install the filter assembly pedestal onto the stud with the forward end of...

Page 299: ...Gauge 2 Turbocharger Lubrication Supply Port 3 Oil Cooler 4 Oil Supply Port for REPTO Turbo Unloader and Remote Mounted Oil Filter 5 Oil Temperature Sensor Port 6 Oil Pressure Sensor 7 Mounting Capscr...

Page 300: ...secure the engine to the engine mounts Tighten the capscrews to specification 3 Remove transmission jack from under transmission 4 Install the clutch linkage and bracket retaining capscrews 5 Install...

Page 301: ...outlet fitting on the engine 25 If the vehicle is equipped with air conditioning a Connect the A C refrigerant low pressure cutout switch to the wiring harness connector b Connect the binary cycling c...

Page 302: ...s allows additional fuel to drain from the hose through the cylinder block and out of the internal passages On chassis with remote mounted fuel filters remove the fuel hose from the cylinder block fue...

Page 303: ...the bottom 1 4 to 3 8 inch of the bore preventing installation of a new lifter The damaged bore area must be cleaned up with a file stone or emery paper before the new lifter can be installed Use car...

Page 304: ...lacement unit must be calibrated as described under Electronic Pump Calibration in the Engine Setup and Adjustments section This will ensure optimum engine performance 6 Reinstall the heat shields Cam...

Page 305: ...er and holds them in position Refer to Figure 315 315 Figure 315 Valve Lifter Tappet Holder Tool J 37720 C 3 Remove the two 12 point capscrews 3 that retain camshaft thrust washer 1 Camshaft may have...

Page 306: ...e lifter bore by aligning the lifter flats with the H ring flats As the lifter is seated it should be possible to rotate it slightly from left to right With the engine in the chassis the valve lifters...

Page 307: ...41682 213 CAMSHAFT IDLER GEAR INSTALLATION Before installing the idler gear hub assembly determine which is the top mounting hole on the hub The idler gear is held in place by a flanged hub mounted t...

Page 308: ...haft This is called a hunting tooth system 3 Slide the idler gear onto the hub assembly with timing marks facing out 4 Position idler gear timing marks so they align with the crankshaft and camshaft g...

Page 309: ...gine Brake Housing Assembly To prevent breaking or dislodging of the control valve snap ring the J Tech control valve components have been redesigned to incorporate a new style collar which replaces t...

Page 310: ...tionally the new style collar and outer spring are not compatible with the non current control valves Use of the collar and outer spring with the old style control valve will result in no braking func...

Page 311: ...in excessive valve lash can result in the valve lifter H ring being dislodged or partially dislodged If an engine has had such a failure the affected cylinder must be checked for proper positioning of...

Page 312: ...ylinder only partial dislodging has taken place but H ring to lifter engagement was maintained Proceed to step 6 for repositioning of the H ring r If the H ring is more than 1 4 inch 3 175 mm higher t...

Page 313: ...the flywheel and the No 1 piston is on the compression stroke The flywheel has three stamped locations at 120 degree intervals for valve settings Yoke and valve adjustments must be made under static...

Page 314: ...xt step is to find the three locations where the valve adjustment marks should be Put a temporary mark chalk grease pencil paint etc at each of the three locations Proceed as follows 1 Beginning with...

Page 315: ...performed in the normal manner with the rocker arm adjusting screw For the exhaust valves it is still necessary to adjust the valve yoke first then the rocker arm lash Make sure that adjusting screws...

Page 316: ...an improper adjustment and engine failure will result 5 Turn adjusting screw an additional 1 6 turn 60 degrees clockwise A 1 6 turn is equal to one flat on the adjusting screw locknut 6 Hold the yoke...

Page 317: ...en the rocker arm and yoke on the No 1 cylinder 2 Turn the adjusting screw until a light drag is felt on the thickness gauge 3 After setting adjustment screw tighten jam nut to specification 40 lb ft...

Page 318: ...24407 or equivalent Do not allow the adjustment screw to turn The J Tech exhaust rocker arm adjusting screw spherical jam nut is a through hardened nut When tightening these nuts be aware of the foll...

Page 319: ...e piston adjusting screw to set the lash It may be necessary to back off the adjusting screw slightly to remove the thickness gauge However be sure to return the adjusting screw to the proper position...

Page 320: ...o the outside terminals 5 Install the gaskets in the cylinder head valve covers and position the covers on the spacers 6 Install six mounting bolts in each of the cylinder head covers spacers and tigh...

Page 321: ...read sizes and torque specifications Do not use an E7 English pipe thread sensor in place of a metric straight thread sensor or vice versa Doing so will result in thread damage to both the sensor and...

Page 322: ...il Do not fill the filter through the center hole it must be filled using the outer holes Lubricate the gasket with oil and install the filter Engine Lubrication System GENERAL INSTRUCTIONS A lubricat...

Page 323: ...ime until fuel is seen at the inlet hose fitting This should take approximately 50 hand pumps Excessive hand priming after fuel is seen at the fitting may make the engine difficult to start 4 Reconnec...

Page 324: ...ughout the entire run in procedure in order to detect any problems that develop Constantly monitor the instrumentation displaying functions of the engine and support systems and record all readings If...

Page 325: ...SPECIFICATIONS Page 309 SPECIFICATIONS 5_106_00 bk Page 309 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 326: ...234 kW at 2100 rpm E7 310 330 E TECH Power at Governed Speed 310 hp 231 kW at 1800 rpm Peak Power 330 hp 246 kW at 1500 rpm Maximum Torque 1 360 lb ft 1 844 N m at 1100 rpm Torque Rise 50 percent Engi...

Page 327: ...nt 728 cu in 12 L Bore and stroke 4 7 8 in x 6 1 2 in 124 mm x 165 mm Coolant capacity 13 qts 12 3 L Sleeve design Wet dry Compression ratio 16 1 1 Fasteners and threads Metric Flywheel housing standa...

Page 328: ...ith positive rotators 20 degree seat two per cylinder Valves exhaust Poppet type with positive rotators 30 degree seat two per cylinder Valve lifters Roller follower type Oil filters Two spin on dispo...

Page 329: ...MSHAFT Bushing Free OD 4 0045 4 0065 in 101 714 101 765 mm Bushing Bore in Cylinder Block 3 9995 4 0005 in 101 587 101 613 mm Bushing Press Fit in Bore 0 004 0 007 in 0 102 0 178 mm Bushing ID Install...

Page 330: ...ufacturing the cylinder bores are honed with a torque plate simulated cylinder head installed 0 004 in max without torque plate installed 0 1016 mm Sleeve OD at upper pilot diameter 5 5040 5 5030 in 1...

Page 331: ...4392 in 11 1481 11 1557 mm Yoke Guide Pin Installed Height 1 848 1 918 in 46 939 48 717 mm Valve Seat Width inlet and exhaust 0 051 0 081 or 1 16 1 64 in 1 295 2 057 or 1 588 0 397 mm Valve Seat Inse...

Page 332: ...ance 0 0022 0 0045 in 0 056 0 114 mm Gear End Play 0 003 0 009 in 0 076 0 228 mm JACOBS ENGINE BRAKE Slave Piston Lash Adjustment 0 015 in 0 381 mm OIL PUMP Gear to Cover End Clearance 0 0035 0 0060 i...

Page 333: ...in 0 025 0 203 mm Crankshaft Gear to Idler Gear Backlash 0 001 0 008 in 0 025 0 203 mm Dowel Pin Holes both in cylinder block 0 4987 0 4997 in 12 6670 12 6924 mm Dowel Pin Hole round pin in front cov...

Page 334: ...1 0795 0 1778 mm Valve Face to Deck exhaust 0 021 0 007 in 1 5334 0 1778 mm Valve Stem to Guide inlet 0 0015 0 0035 in 0 0381 0 0889 mm Valve Stem to Guide exhaust 0 0025 0 0045 in 0 0635 0 1143 mm V...

Page 335: ...o Cyl Block Mounting Screw 80 Dry 108 Dry AUXILIARY DRIVE Aux Shaft Gear Retaining Nut See NOTE 1 AUXILIARY SHAFT GEAR RETAINING NUT INSTALLATION on page 328 300 Dry 405 Dry Aux Shaft Thrust Washer to...

Page 336: ...ounting Screw 40 55 FLYWHEEL FLYWHEEL HOUSING AND CLUTCH Flywheel Hsg to Cylinder Block Screw 170 230 Flywheel to Crankshaft Screw 185 250 Clutch to Flywheel Mounting Screw 40 55 Transmission to Flywh...

Page 337: ...Pump Cover to Housing Screw 15 20 Oil Pump to Cyl Block Mtg Screw 40 55 Oil Pump Shaft Driven Gear Retaining Nut 60 81 Oil Pump Inlet Ftg to Oil Pump Hsg Screw 35 47 Oil Pump Pressure Relief Valve Ca...

Page 338: ...Jam Nut See NOTE 5 VALVE YOKE SETTING on page 328 33 45 Valve Rocker Arm Shaft Locating Screw 23 31 WATER MANIFOLD AND WATER PUMP Water Pump Shaft Locknut 80 108 Water Manifold to Cylinder Head Screw...

Page 339: ...or Standard SAE J536 Type F Hose Clamps Air Inlet Systems 38 4 Oil Drain Systems 28 3 Water or Coolant Systems 28 3 Hi Torque Heavy Duty Worm Clamp 80 9 T Bolt Type Hose Clamp 50 6 Pipe Plug Size Torq...

Page 340: ...ssis 64MT2118M 1 2 inch NPT English pipe threads 23 lb ft 31 N m Dash Gauge Coolant Temperature Sensor 64MT2112M sensor only 1 2 inch NPT English pipe threads 23 lb ft 31 N m V MAC III Coolant Tempera...

Page 341: ...1 50 86 117 14 2 00 80 109 16 1 50 133 180 16 2 00 124 168 18 1 50 193 262 18 2 50 172 233 20 1 50 270 366 20 2 50 244 331 22 1 50 365 495 22 2 50 332 450 24 2 00 459 622 24 3 00 421 571 27 2 00 666 9...

Page 342: ...18 16 1 50 144 195 16 2 00 135 183 18 1 50 210 285 18 2 50 187 254 20 1 50 293 397 20 2 50 264 358 22 1 50 395 536 22 2 50 360 488 24 2 00 498 675 24 3 00 456 618 27 2 00 722 979 27 3 00 669 907 30 2...

Page 343: ...151 16 1 50 184 250 16 2 00 172 233 18 1 50 268 363 18 2 50 239 324 20 1 50 374 507 20 2 50 337 457 22 1 50 505 685 22 2 50 460 624 24 2 00 636 862 24 3 00 583 790 27 2 00 922 1250 27 3 00 855 1159 30...

Page 344: ...2 After run in procedure in sequence back off each capscrew individually until free Then retorque same capscrew to 205 lb ft 278 N m NOTE 4 EXHAUST MANIFOLD TORQUING Torque exhaust manifold nuts to 35...

Page 345: ...342SX32 Oil filter sealing gasket Clean engine oil Holding metal parts in place MACK MG C grease or petroleum jelly Vaseline Valve stems and guides Dow Corning BR2 Plus Multi Purpose Grease Engine fro...

Page 346: ...s suitability for that job Proper installation is as important as the selection of the correct fastener Improperly installing a correct fastener is just as bad as using an incorrect one Undertightenin...

Page 347: ...determining the millimeters per thread For example a bolt with 0 8 pitch would have 125 complete threads in a 100 millimeter section 100 mm divided by 125 threads equals 0 8 and a bolt with 1 0 pitch...

Page 348: ...Page 332 NOTES 5_106_00 bk Page 332 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 349: ...SCHEMATICS DIAGRAMS Page 333 SCHEMATICS DIAGRAMS 5_106_00 bk Page 333 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 350: ...RAMS ENGINE SYSTEM SCHEMATICS FLUIDS FLOW Cooling System Flow Diagram 338 Figure 338 E Tech Cooling Circuit 5_106_00 bk Page 334 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https ba...

Page 351: ...S DIAGRAMS Page 335 Lubrication System Flow Diagram 339 Figure 339 E Tech Oil Flow Schematic 5_106_00 bk Page 335 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https barringtondieselc...

Page 352: ...ge 336 SCHEMATICS DIAGRAMS Fuel System Flow Diagram 340 Figure 340 E Tech Fuel System 5_106_00 bk Page 336 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https barringtondieselclub co...

Page 353: ...SPECIAL TOOLS EQUIPMENT Page 337 SPECIAL TOOLS EQUIPMENT 5_106_00 bk Page 337 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 354: ...er Handle threaded 3 4 10 J 21428 01 Camshaft Bushing Remover and Installer Set J 21588 Injector Gasket Retriever J 21834 4A Two Jaw Adjustable Puller J 22738 02 Universal Spring Tester Model MST 50 J...

Page 355: ...Burnishing Broach J 37719 Fire Ring Groove Cutter J 37720 C Tappet Holders J 37721 A Piston Cooling Nozzle Spray Position Set for 1989 1990 production J 37809 Valve Guide Installer 3 8 inch J 38048 E...

Page 356: ...PT2210 14 Hex Key Wrench PT2210 3A Counterbore Cutter Plate PT5025 Universal Dial Depth Gauge PT5025 11 3 inch Stylus Extension PT 5027 Cylinder Head Block Straightedge 36 in PT5035 Flywheel Housing D...

Page 357: ...J 38500 63 Serial Link Jumper Deutsch to Deutsch J 38500 630A Pro Link V MAC III Diagnostic Cartridge J 38500 1500C Pro Link Multi Protocol Cartridge J 38581 Connector Test Adapter Kit J 38582 Termina...

Page 358: ...Page 342 NOTES 5_106_00 bk Page 342 Friday August 4 2000 11 17 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 359: ...INDEX Page 343 INDEX Index fm Page 343 Friday August 4 2000 11 16 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 360: ...UNTED CHARGE AIR COOLING TESTS 67 CLEANING AND INSPECTION 136 CMCAC PRESSURE TEST 68 CMCAC PREVENTIVE MAINTENANCE 70 CMCAC TROUBLESHOOTING 67 CONNECTING ROD AND PISTON BENCH PROCEDURES 173 CONNECTING...

Page 361: ...GINE FINAL PREPARATION AND OPERATIONAL CHECK 306 ENGINE INFORMATION PLATE 10 ENGINE INSTALLATION 284 ENGINE INSTALLATION INTO VEHICLE 284 ENGINE LUBRICATION SYSTEM 306 ENGINE MODEL IDENTIFICATION 10 E...

Page 362: ...4 L LOW PRESSURE FUEL SYSTEM 32 LUBRICATION SYSTEM 47 LUBRICATION SYSTEM BENCH PROCEDURES 211 LUBRICATION SYSTEM FLOW DIAGRAM 335 M MAIN BEARING CAP INSTALLATION 224 MAIN BEARING CAP REMOVAL 133 MANUA...

Page 363: ...HARGER INSTALLATION 270 TURBOCHARGER REMOVAL 113 V VALVE COVER AND SPACER INSTALLATION 264 VALVE COVER AND SPACER REMOVAL 118 VALVE GUIDE REPLACEMENT 188 VALVE LIFTER H RING INSTALLATION CHECK 295 VAL...

Page 364: ...Page 348 NOTES Index fm Page 348 Friday August 4 2000 11 16 AM BDC for engine manuals and specs https barringtondieselclub co za...

Page 365: ...E TECH ENGINE SERVICE MANUAL Includes Left Side Redesign PRINTED IN U S A 5 106 MACK TRUCKS INC 2000 BDC for engine manuals and specs https barringtondieselclub co za...

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