Content

Introduction

• Safety information
• Explanation of numerical code
• Conversion chart
• About the diesel engine

Visual identification

• Engine model identification

Description and operation

• Engine design features
• Glossary of terms

Component locator

• Component location views

Troubleshooting

• Engine symptom diagnosis for mack aset engines
• Camshaft timing and lobe lift checks
• Chassis-mounted charge air cooling tests
• Cylinder head and cylinder block leak test procedure
• Engine brake tests

Maintenance

• Lubrication system maintenance
• Fuel filter element replacement
• Coolant conditioner element replacement
• Oil coalescing air filter replacement
• Drive belt replacement and tensioning

Repair instructions, part 1

• Engine removal
• Engine disassembly
• Cylinder block reconditioning
• Crankshaft and flywheel bench procedures
• Auxiliary shaft and camshaft bench procedures
• Connecting rod and piston bench procedures
• Cylinder head overhaul
• Valve rocker arm shaft bench procedures
• Lubrication system bench procedures
• Cooling system components bench procedures
• Fuel system component bench procedures
• VTG system bench procedures
• Engine reassembly
• Engine installation

Repair instructions, part 2

• In-chassis part/component procedures
• Electronic unit pump replacement (in-chassis)
• Camshaft replacement (in-chassis)
• Exhaust valve yoke pin and valve rotator inspection and replacement criteria (in-chassis)
• Valve lifter h-ring dislodgement and alignment inspections (in-chassis)
• EECU and sensor service procedures (in-chassis)
• Cooling system service procedures (in-chassis)
• EGR system service procedures (in-chassis)
• VTG turbocharger service procedures

Repair instructions, part 3

• Engine setup and adjustments
• Engine speed and position sensors installation and adjustment
• Engine final preparation and operational check
• Rebuilt engine run-in procedures

Specifications

• Engine mechanical specifications
• Specification footnotes
• Engine assembly lubricants and sealants
• Engine drive belt specifications

Schematic and routing diagrams

Special tools and equipment

Appendix

• Fastener identification
• Torque wrench use
• Turbocharger failure and actions required to avoid repeat failure

Index