Page 3-2
200 ENGINE REMOVAL
GENERAL
Details of the engine removal procedure vary
from one vehicle to another. This section
provides general guidelines for removing the
engine from the vehicle.
Before beginning engine removal, make sure all
equipment is available for use and has been
inspected for safety.
Vehicle Preparation
It is good practice to steam-clean the engine to
remove road grime, grease and oil before starting
work. Steam cleaning the engine and engine area
allows more detailed inspection and improved
workmanship.
Care must be used to keep moisture from
entering the air intake system. If moisture does
enter the system, make sure it is removed (dried
out) before the engine is reinstalled.
1.
Position vehicle on a flat and level surface in
an area with ample work space in and
around the vehicle. Ensure that a suitable
lifting device is available.
2.
Apply the parking brake and block the
vehicle wheels to prevent vehicle from
moving. Observe all safety precautions.
3.
Disconnect the battery negative (ground)
cable.
4.
Drain the air tanks.
Engine Removal
1.
Remove the hood and position it away
from the work area to prevent accidents or
hood damage. Refer to Hood Removal
procedures in the appropriate vehicle
manual.
2.
Place a suitable container beneath the
engine and drain engine oil and coolant.
Open the coolant drain valves in the block,
if applicable.
3.
Using an appropriate filter wrench, remove
the oil filters, fuel filters and coolant
conditioner.
4.
Loosen clamps that secure the air intake
tube to the turbocharger and air filter.
Remove the intake tube.
5.
If vehicle is equipped with air conditioning:
a.
Using A/C refrigerant recovery and
recycling equipment, recover the A/C
system refrigerant.
b.
Disconnect the A/C compressor
discharge hose at connection near the
radiator support.
c.
Disconnect the A/C line at the
receiver/dryer.
d.
Locate and disengage the electrical
connector from binary pressure switch
on the receiver/dryer.
e.
Locate and disengage the electrical
connector from the low-pressure cutout
switch in the A/C refrigerant line.
6.
Disconnect the upper radiator hose from the
engine coolant outlet fitting.
7.
Disconnect the lower radiator hose from the
coolant inlet of the oil cooler assembly.
8.
Remove the clamps that retain the coolant
overflow tank. Remove tank.
9.
Disconnect the chassis-mounted charge air
cooler inlet hose at the cooler.
10. Disconnect the chassis-mounted charge air
cooler outlet hose at the cooler.
11. Locate the engine coolant temperature
sensor and disengage the electrical
connector, if applicable. Remove sensor
harness from the radiator support.
12. Remove fastener from the bracket that
secures the radiator fan air clutch solenoid
valve to the radiator support. Set the
solenoid valve aside.
13. Remove the retaining bolts from the radiator
support rods at the radiator support.
14. Obtain a lifting device (chain fall or engine
hoist) and support the radiator.
15. Remove the retaining bolts from the radiator
support mounts.
16. Remove the radiator from the vehicle using
a lifting device and an assistant, if required.
5-101.bk Page 2 Friday, March 17, 2006 11:05 AM
Summary of Contents for E7
Page 1: ...E7 ENGINE OVERHAUL AUGUST 1997 ENGINE 5 101...
Page 2: ...Page 0 front fr5 Page 0 Friday March 17 2006 11 04 AM...
Page 5: ...E7ENGINE OVERHAUL MARCH 2006 2 5M REP AUGUST 1997 10M MACK TRUCKS INC 1997 ENGINE 5 101...
Page 13: ...ABOUT THIS MANUAL Page ix ABOUT THIS MANUAL front fr5 Page ix Friday March 17 2006 11 04 AM...
Page 15: ...TABLE OF CONTENTS Page xi TABLE OF CONTENTS front fr5 Page xi Friday March 17 2006 11 04 AM...
Page 24: ...Page xx NOTES front fr5 Page xx Friday March 17 2006 11 04 AM...
Page 31: ...200 SPECIFICATIONS Page 2 1 SPECIFICATIONS 5 101 bk Page 1 Friday March 17 2006 11 05 AM...
Page 55: ...200 ENGINE REMOVAL Page 3 1 ENGINE REMOVAL 5 101 bk Page 1 Friday March 17 2006 11 05 AM...
Page 58: ...Page 3 4 NOTES 5 101 bk Page 4 Friday March 17 2006 11 05 AM...
Page 90: ...Page 4 32 NOTES 5 101 bk Page 32 Friday March 17 2006 11 05 AM...
Page 91: ...200 BENCH PROCEDURES Page 5 1 BENCH PROCEDURES 5 101 bk Page 1 Friday March 17 2006 11 05 AM...
Page 158: ...Page 5 68 NOTES 5 101 bk Page 68 Friday March 17 2006 11 05 AM...
Page 159: ...200 ENGINE ASSEMBLY Page 6 1 ENGINE ASSEMBLY 5 101 bk Page 1 Friday March 17 2006 11 05 AM...
Page 240: ...Page 6 82 NOTES 5 101 bk Page 82 Friday March 17 2006 11 05 AM...
Page 272: ...Page 8 10 NOTES 5 101 bk Page 10 Friday March 17 2006 11 05 AM...
Page 273: ...200 TROUBLESHOOTING Page 9 1 TROUBLESHOOTING 5 101 bk Page 1 Friday March 17 2006 11 05 AM...
Page 292: ...Page 9 20 NOTES 5 101 bk Page 20 Friday March 17 2006 11 05 AM...
Page 293: ...200 APPENDIX Page 10 1 APPENDIX 5 101 bk Page 1 Friday March 17 2006 11 05 AM...
Page 295: ...200 APPENDIX Page 10 3 E7 LUBRICATION SYSTEM 5 101 bk Page 3 Friday March 17 2006 11 05 AM...
Page 296: ...Page 10 4 200 APPENDIX E7 COOLING SYSTEM 5 101 bk Page 4 Friday March 17 2006 11 05 AM...
Page 297: ...INDEX Page 11 1 INDEX INDEX FR5 Page 1 Friday March 17 2006 11 04 AM...
Page 302: ...Page 11 6 NOTES INDEX FR5 Page 6 Friday March 17 2006 11 04 AM...
Page 303: ...E7 ENGINE OVERHAUL PRINTED IN U S A ENGINE 5 101 MACK TRUCKS INC 1997...