Content

Introduction

• Safety information
• Advisory labels
• Service procedures and tool usage
• Explanation of numerical code
• Conversion chart
• About the mack MP8 euro 4 engine
• Service precautions summary

Visual identification

• MP8 euro 4 engine model identification
• Engine information plate
• Engine serial number identification

Description and operation

• Mack MP8 euro 4 engine design features
• Engine components
• Lubrication system
• Crankcase ventilation
• Fuel system
• Powerleash engine brake
• Exhaust gas recirculation system
• Air intake system
• Variable geometry turbocharger (VGT)
• Cooling system
• Engine management system
• Glossary of terms

Component locator

• MP8 euro 4 engine component location views

Troubleshooting

• Engine symptom diagnosis
• Troubleshooting technique
• Noise and vibration
• Engine checks and tests
• Special tools
• Camshaft sensor depth, check
• Camshaft timing, check
• Crankcase ventilation, check
• Cylinder head, pressure test
• Cylinder liner and piston wear, check
• EGR cooler, pressure test
• Engine compression, test
• Flywheel housing runout, check
• Oil cooler, pressure test
• Rocker arm, check
• Thermostat, check
• Valve guide wear, check

Maintenance

• Lubrication system maintenance
• Special tool
• Oil level check
• Oil and filter change procedure
• Crankcase ventilation system
• Fuel filter replacement
• Fuel filter change
• Cooling system maintenance
• Special tool
• Coolant drain outlets
• Coolant filter
• Drive belt replacement and tensioning
• General information
• Automatically tensioned system

Repair instructions, part 1

• Engine removal
• Special tools
• General instructions
• Removal
• Engine disassembly
• Special tools
• General instructions
• Mounting the engine on a repair stand
• EGR crossover piping removal
• EGR venturi tube removal
• Cylinder head (valve) cover removal
• Engine wiring harness removal
• Timing gear cover removal
• Camshaft gear and vibration damper removal
• Rocker arm shaft removal
• Valve yoke (bridge) removal
• Camshaft removal
• Unit injector removal
• Starter removal
• Turbocharger removal
• EGR hot pipe (cooler inlet) removal
• EGR valve removal
• EGR cooler removal
• Exhaust manifold removal
• Oil filter housing removal
• Coolant and pump inlet housings removal
• Cooling duct cover and oil cooler removal
• Drive belts and fan hub removal
• EGR mixer removal
• Crankcase ventilation (CCV) separator removal
• Fuel lines and filter housing removal
• Eecu and cooling plate removal
• Inlet manifold removal
• Tandem pump (fuel and power steering) removal
• Air compressor removal
• Flywheel and pilot bearing removal
• Power take-off (pto) assembly removal
• Flywheel housing removal
• Crankshaft rear seal removal
• Timing gear train removal
• Timing gear plate removal
• Alternator and refrigerant compressor removal
• Thermostat and cover removal
• Coolant pump removal
• Cylinder head removal
• Crankshaft vibration damper and fan pulley removal
• Crankshaft front cover removal
• Crankshaft front seal removal
• Oil fill pipe and dipstick retainer removal
• Oil pan removal
• Front engine support removal
• Block stiffener plate removal
• Oil pump removal
• Piston and connecting rod assembly removal
• Main bearing cap removal
• Crankshaft removal
• Cylinder block reconditioning
• Tools and equipment
• Piston cooling spray nozzle removal
• Cylinder liner removal
• Block cleaning and inspection
• Liner height measurement
• Cylinder liner installation
• Flywheel bench procedures
• Flywheel ring gear replacement
• Connecting rod and piston bench procedures
• Connecting rod — piston disassembly
• Piston inspection and cleaning
• Piston ring inspection and replacement
• Connecting rod — piston assembly
• Cylinder head overhaul
• Tools and equipment
• Inlet and exhaust valve removal
• Cylinder head cleaning and inspection
• Valve guide replacement
• Valve spring inspection
• Injector sleeve replacement
• Expansion plug replacement
• Valve inspection
• Valve installation
• Rocker arm shaft bench procedures
• Description
• Rocker arm shaft disassembly
• Inspection
• Rocker arm shaft assembly
• Camshaft bench procedures
• Camshaft inspection
• Cooling system components bench procedures
• Special tools
• Oil cooler reconditioning
• EGR cooler cleaning
• EGR cooler pressure test
• Engine reassembly
• Special tools
• General instructions
• Crankshaft installation
• Main bearing cap installation
• Piston and connecting rod assembly installation
• Oil pump and block stiffener plate installation
• Oil pump pipes and strainer installation
• Front engine support installation
• Crankshaft front cover and seal installation
• Timing gear plate installation
• Cylinder head installation
• Camshaft installation
• Timing gear train installation
• Unit injector installation
• Valve yoke (bridge) installation
• Rocker arm shaft and engine brake installation
• Flywheel housing installation
• Crankshaft rear seal installation
• Flywheel and pilot bearing installation
• Oil pan installation
• Oil filler pipe and dipstick pipe installation
• Power take-off installation
• Timing gear cover installation
• Coolant pump installation
• Thermostat and cover installation
• Coolant pipe installation
• Oil cooler and cooling duct cover installation
• Oil filter housing installation
• Exhaust manifold installation
• EGR valve installation
• EGR cooler installation
• EGR hot pipe (cooler inlet) installation
• Turbocharger installation
• Starter installation
• Air compressor installation
• Tandem pump (fuel and power steering) installation
• Inlet manifold installation
• EGR mixer installation
• Eecu and cooler installation
• Fuel lines and filter housing installation
• Crankcase ventilation separator
• Crankshaft vibration damper and fan pulley installation
• Alternator and refrigerant compressor installation
• Wiring harness installation
• Cylinder head (valve) cover installation
• EGR venturi tube and crossover piping installation
• Fan hub and drive belt installation
• Removing engine from engine stand
• Filters and miscellaneous components installation
• Engine installation
• Special tools
• General instructions
• Installation

Repair instructions, part 2

• In-chassis part/component procedures
• Camshaft bearing brackets, replacement
• Preliminary steps
• General information
• Camshaft inspection
• Bracket replacement procedure
• Final steps
• Oil thermostat and pressure safety valve replacement
• Pressure safety valve removal
• Oil thermostat valve replacement
• Crankshaft front seal replacement
• Special tools
• Seal removal
• Seal installation
• Crankshaft rear seal replacement
• Special tools
• Neoprene seal removal
• Neoprene seal installation
• Teflon seal removal
• Teflon seal installation
• Crankcase ventilation (CCV) separator replacement
• CCV separator removal
• CCV separator installation
• Oil pump replacement (in chassis)
• Special tools
• Oil pump removal
• Oil pump installation
• Injector copper sleeve replacement
• Tools and equipment
• Preliminary steps
• Copper sleeve removal
• Copper sleeve installation
• Final steps
• Turbocharger smart remote actuator (SRA) replacement
• Preliminary steps
• Turbocharger SRA removal
• Turbocharger SRA inspection and installation
• Final assembly
• Unit injector cleaning
• Preliminary steps
• Cleaning and inspection
• Final steps
• Valve stem height measurement procedure
• Valve stem seal replacement
• Special tools
• Preliminary steps
• Seal removal
• Seal installation
• Final steps

Repair instructions, part 3

• MP8 engine setup and adjustment
• Special tools
• Valve and unit injector adjustment
• Checking and adjusting timing gear backlash
• Engine final preparation and operational check
• Filter element installation
• Engine lubrication system
• Turbocharger
• Cooling system
• Fuel system
• Engine operational check
• Rebuilt engine run-in procedures
• General
• Run-in check

Specifications

• MP8 engine mechanical specifications
• Material and dimensional data
• Engine component torque specifications (critical fasteners)
• Standard bolt and nut torque values
• Engine gaskets, lubricants and sealants
• Gasket and seal reuse
• Lubricants and sealants

Special tools and equipment

• MP8 engine service tools
• Special tools for engine overhaul

Index