Motor Mp8 Mack 2

REPAIR INSTRUCTIONS, PART
1.
Assmb e lhe slii'ener plale wilh N lasl6nc. Do NOT 8nd
2. Asemblelhe oi siher, ;udioni

ccsov
pEs6u@ pipes inlo lhe pp as
NO'E
fh6 6ngin6 siilfning fame aachlnq f4tene6 are ONE TIME USE ONLY N&
lasleers musl be installed.
The avilable lool, 9994649, ca ba usd io hold slifening lEme i posillon wfile
slide th oil pessure pipe inlo lhe oit punp, posilion lh pip llanqe lo lhe ct4inder block, nslall the lastnfs and torqu'lighren to 6pe6ili@tion.
Posilion lhe o I ccsder ppe lo ihe sklrls f lhe cyllnder blo*, lnstall the hsteneE and lorqetighten to
lnsrallthe oil pf$uB pip and lh6 cfo$o@r ppe bet) tofqu+lghtenlng the
Using a lorque w rench, lighle lhe alaching faslnB in squnc6 amording lo
6smbl lh otl slrainr and oil pickup pipe- Slid the oil pickup pip inlo lh oil pump, posirion rhe oil srfaner ro ihe n9in6 stifning fm, insrall rhe IasteE and bJqu'lighlen lo
Oil Pump Pipes and Striner
lnslallation
[219 MU,219 NT]
1,
Bepacelheo tngsonlheol pressfe pip, oi! suclion pipe and oil dosever plpe. Lubricate the O-dngswith 6ngine oilbetoe
o o
o o
NOTE
spate th oil suclion pip lom !h oil stEiner as needed lo place the o,finq. clan and ispect lhe oil stEier, suclion ppe, cos$@r prpe and pr6ssur pip ror ccks. Feplace il
FEPAIR INSTBUCTIONS, PART

Front Engne Support lnstalation
1299
Gvl
loni enqi ro rhe qlindef lishle hsleneB lo specilillo.
the
1- l m@d, dsenbte
block and
suppo mounring bfaokel
NOTE
Tho bdckl also setu4 as lhe /C
@pre$or
2.
Assemble lhe lon engine suppo.! onlo lhe bl@k moudd bBckts ad islaLlth sit Using a lolque wnch, tghle all lasteneA i sequen@ ro sp6ilicarion.
3.
l2
Pr6r. sp*ar stes
170
2.
Apply 2 mm (5/g lnch) bead ot lvAcK approred salcone selal to th r6ar lc ol lh der ac@ding to the patern
NOTE
Make sure lhai the cnkshft lonl @ver and block tlanges are cleaned thoroughly b6lor6
Crankshatt Front Cover and Seal lnstallatlon

[211
JBl
1.
Pla@ lhe cnkshaft lronl cowr wftn 6pacer. 9998170, in lhe cenler o a llal sufface. lnstal a cErkshaft seal wllh plaslc rlng n lhe cnkshalt lrcnt The spacer ng prryenls the pls1ic fing lrcm sljding olf' carelully lap the crankshatt set int lhe lronr cor with d tl, 68400021 , and handte, 9992000, unlii lhe cEnkshaft ls le@l
ns
mr
*d
2 mm
(re
inch) bead o'
MAcKppr@3 siticone
REPAIR INSTBUCTIONS, PART

3.
Within 20 minuls ol sealanl applcalion, inslall lhe font wer to the ngine bl@k. Cenle.lhe cEnkshaf ll 6vr againsl rhe c.ankshf usinq lhe pl4lic fig.
4.
lnrall lhe font @wr
Note that
the6 a
F.uE245-FE6vdriqusqenc8
For arlif typ (a), rhe
lnsla ll
lnstallalon structios pply:
tolNirg
5.
Ih e bois wiihoui 1ghGh g lh em Using a stEighrdg ru e, make sure the cder is flush wilh the leer da ol
RemoE the plaslic ring fom the crankshan hub. Dn@ in lh6 cnkshaft sea wilh drll, 48400021 , and handle, 9992000, unlil lhe d ft bnoms against the cnkshatt.
For lrr rype (B), the iolrowlng irslllton inslructoN apply: lnslallthe bolls in bolh boh ho es lhal al gn lh cove lo lhe @@t posltun. Tiohtn by hand so lhllhe cder is led, lnsiallihe remaininq bo[s.
NOTE
For lho laler lvp @ver, the tef hand hol is smallerand lhe righr-hnd hole is ovat. Thts change a lows the laler mrer io b coreclly
5.
Usng a torque wn.h lighlen the capscrews i sequonc6@dinq lo
BEPAIB INSTRUCTIONS, PART

Timg Gear Plate lnstallation
1211
AAI
NOfE
Roiale the engine b ock so the rear sur'a@ is al
NOTE
fthe
cyrnder head is lnsralled atrer lhe riminq geaf plale i6 in pla@, do nol apply shfn in lhe cylinder had ra uniil dy lo as*mble lhe
1.
Clean lhe limino qear plale on bolh sids. Clean lh @lacl sulcs on lh nqine blocknd cylindehed. Bm@ealing compolnd fom rhe grcoE on rhe englne
inch) bead ol 342SX33 3. Apply a 2 mm MACK appr@d sili@ne sealanl (A) lo lhe lronl la of lh plal adording lo lh
6/e
4.
with 20 inutes ol ihe appliiion ot lhe sealanl assemblelhelming gear paie orer
lianmnl quides, 9998267, lhal wee lnsialied lnlo lhe blok at disassembly.
NOTE
Sealig @mpound musl be applied oursde the aoM in lhe limino o plal. This causs lh excess @npound lo be iofced down lffo the sb@, whicn a[@5 b betersalinq.
5.
Wilhliming gear p ate i posilion @rguide pins. inslall n4 liminq qea. mounlno

6.
Uslng a iorque wnch, tighin lh afia.hing laslneF in sequen@ acedig lo
Cylnder Head lnslallation

[213 EVI
NOfE
Cl@n away excessive sealing compund betor The cylindr had b heavy. Do NOT allpl to mtatt le cytndr hd wiihout the hetp ot ar asisint and lhe us ol a suitbl ifinq
dd@. FsiluEto h*d thls warnlng may r6ult ln seve personal jury nd
NOTE
all lracK had g*kts arc p@ated and do not equire ay lyp ot ddnional s6ling compound,
1.
lrncssary clean lhe unit injetorcopper sle6vs wilh brush J 428a5-9 and extenson J 42445 1 wth J 42445-2 5 :nslalled lo pfolcr lhe fue paseges. fhess bols 16 ailbl in kil J 4245.
7.
lnslall the compressr slud wnh a new sealing ring and n4lasleel
Fieure
2sr hj*br
cpFr srp{e
crnnq
NOTE
Wilh any cleaninc ol lh unit inictoB, uder no ctcuslncea may @lary we brushes hand wife brushs orsimilarl@s be used th inieclor nozle. Us ol such rools poses a ns k thal the injclor holes @uld be &maged and b ocked, eusinq p@er delivery probrems. lnslead, use a q soakd n pEf n or
a.
Rmore alignment guides, 9994267, Im
REPAIR INSTRUCTIONS, PABT

2. lnsiall ful lnlector bo plqs, 9994251
.
6,
App y a 2 mm th
Ensuro thal ths ngin block nd dtrk ar clean and iree lom any dirt, qfeae or ol.
silimn6 s6lnl
1cr n th liminq gar plate {as sh@n in lhe illuslalio).

NOTE
ioq
Tlre cylinder nead musl be ue-liq hrened wilhin 20 sealanl hs be6n app id.
(164 nch) lhck bead cil 10 e sudace at tho sde ol
Caelly l rhe cylindd head and indall the head lifting tool a3a001aa. ched< that ihe guide washeF on lhe eqine bl@k and cyli.de. head aE clean and lree or rusi.
ffi*fl3fi
FiguB254_elnlApplldl.nhMHadb
5.
ll in Place, de th cy indr claping lools, 9s96966, Iom
ns
head gaskel on lhe enqne
9996966
NOIE
Check that lh seals are coreotly posloned wilh lheir hoes all tBd.
There are pohls embo$ed in lhe qasket lhal will lempoErfy polect th6 sals im th had. Th66e wi I be @mpssd whe the head bolls a. lighlened.
The hd gskl should be dlscaded ilthe head is Emoved. A nN sasker should be u6ed whn rh hd is l$nd
FlquE253_cy[ddlnrcl,mplnqTml3
REPAIB INSTRUCTIONS, PABT

a. Caelllly lower cylndr hsd aboul I mm (3ts inch) lotuad ol th qr
mouling plale unlilil makes colcl wilh the cylindr had gaskel. Pfe$ lhe cyllnder head againl lhe linig g6ar corer and lhe guide washeB ar rhe efi side. (Ihf a lwo guide w$he6 or lhe ctlinder block and on6 on lh cylinder head.)
Teporry rnsrall rhe adjosrablo idrr qar hub ad lnsrt bolr lhrough the limng qear
plare and rhe adjlstbra idre. gear hub. Tighl lh bolts b a5 +15 N.m (63 i11 lb-) lo dw the 6ytlnder head
NOTE
h@d botts a tightened.
OTE
A
th@-slep prcce$ is used tor inslallalion ol lhe
10. Check the ndilion

ll is li6l l@e@d onro lhe bl@k dek and qsket, about I m (3/3 hch) bNad oi rhe geaf plare. A5 r is Iowered,lhe quide washeB ensue ppd alignl ol lhe cylidr had wirh rhe bn slde ol the cylndef block.
of lh cfinder head anachig pscf4s and lublte the heads (und6id) ad rhds with crean engine
NOTE
D NoT o r rh rhreds in th hr6rr<
Oce lweed, screG iserled lhouqh th adiustbl idlr qar hub nd plal a used io draw lhe cylider afrard
11, The cylinder head cap*rews ust ot b

used 016 lhan fi@ times. Mark the cylinder head @pscBm by punchig lhem,
lh6lnalslp,lhe head bot6 are inserted and tighlgnd lo spcllicalion, securinq lhe cy rdef head io ihe block.
ln
12.
lnsert lour cy indr had capscws lnto l@alions 24, 26, 2a ad 30. Tighlen lhe mpsc@ws to specilcation.
ffi
13. Remo lh cylinde r head llfr ing b racksl. 14. Torque-lighlen a nd angtetghten att cyt d I
head cap*rews squn.e io
15.
lnslal lhe laslee 6 secur g lh liminq gear p 16 to th rear oi lhe cyl nder had. ghle lhs lsleeF to specifcalon.
Ensure that lh cnkshalt is t th6 lop dad
cenre (Toc) posilion and 4sembe the camshalli camshail gar nd dmper c6rdiq ro ih inslrucl ons undr Itnt4g

Camshatt lnstallation
1213 CHI
Th c3hlt s h4vy. Do NoT llpl to nslll lh cashll wilhrd th hlp ol ar ssistant or th use ol a sulable flting de!ce. Falture to heed thls warng my resut n severe peBon.l injury nd
ll rcmov6d, islaLlthe canshati bearng saddlesiolhe odginal posilions. Calully lap lhe bea ng saddles onlo th e guide pins using a soit-la.d ha until lully sealed.
2, lnsenlh6 mshafi low6r bearings and appry aceefous c@1n9 ol clean engine oil lo lhe camsha barlngs.
3,
6,
lnslalllhe camshai uppe baring inseds lh.nshafr bea g caps, bricle th beannls ad lsiall lhe bearig caps lo lhe
ito
respeclive beaing saddles. Use a soflaced mallet t sal th b6rig ps d$ th6
Make sur lhe b a bing insrt on each lowr berlng saddle. The beafng insefls ai lhe No. 7 camshat jouhal haw lnlgEl
lnsen and hand igh1en lhe dhaust slde bearig cap bolts and lighien lo spdlicalion. Fjnal liohlnina lo lh speiled lofque %lue wlll be done laler when rhe rccker arm shafi is insralled.
3, stallrhe bearing ep pess i@r (1wo rqukd) al lh numbr7nd lhe number bea q ps s sh@n in lh8 illusllion.
1
NOTE
fhe lootis used when adlsting thtimtng gar
backlash when lhe ocker shafi assembly is
ot
4.
C ean and inspect the canshalt usinq
solwnl and comp@sed ar
Lower ihe camshafl caretully into place on lhe lower bearlnq edd es and move lhe lifiing lool, 45109034. Folal lhe camshaft bY hand io nsure tho emshaft is nol bding on the l@er berno saddls.

Timinq Gear Train lnstallatlon
3.
NOfE
Apply liQhr coal ol clean engine oil lo all pats
Assembb rh adiusrbr ib; b@loem 3 in Figurc 260), hub, bushins, lhrusl washer and laslereG o the plate. Hand llohin lh
DO NOI ovdlight th aw lastenets when instalkg ay ol the ga ln the tnng qeat tak. ovejgl,tenng the hstaets an @M sriwad fh@ds i lh ct4indd blk.
Mlkg ^caurroN
1. As*bl6 r4 o
dnq on lhe chnkshafr

FisuE
2.
Apply a llm ol ol io lhe O ring and ssemble lh chnksh gar on lh cnkshal hub.
e - adlus*
t6
| 7.Af
rd!r
&r
Df
NOTE
Leaw two flne lo6e luming lhe cEnkshatl wilh
3.adjGbbre
dsGs
I Gd,
rden Pur
hec<f
D,e
4,
Chck lal lhe @mshatl is posilioned at
Figu259_cEnk3hliGsrlaHubtrsbly
REPAIB INSTRUCTIONS, PART

Align lh punch mrks on lh camshaft ga leeth 10 slddle the algnmenl hole in lhe riming geaf plare and inrallrhe camshan gear wirho lhe peras shan n Figur 262- lnslall 1ie clamp plate lool, J 4451,1-1?\, using fositior B of th6 gaug p ate 1oo lo scufe the camshait ge to the mshalr and loosely inrall the rwo
Femove lhe aliqnmenl pln nd clmpplare lool from rh camshatr gear and lnsrall rhe v bdlon dampgrand clamp plale using lasleners- Tghln th lastenec io
n4
NOfE
Mafk the bolrs ro aid ln righrening rhe borts degre rclalion sp&ilicalion.
10
th
a.
hselta0.1 mm (0.004ich)thickhess gauqe. Adjur rhe idler geaf so thar thele is slighr prssu onlh lhickn6ss gaug. Tiqhten ihe bolts bV hand onht
6.
lnsed the alignmenl lool J 47,150.1, ii lhe hole in lhe cylnde r hed 10 engaq e lhe cshatl gear eelh w lh lhe d ol le lool in the slol of the clamp tool- ll may be necessafy to forare rhe camshafr unul rhis omuB. Wilh lh6 alignmnl pin prcp y p6ilioned n theclanp plale sloi, checkihat lhe camshail TDC mark is slll po6ilioned boreen lh lwo limig mafts on lh6
9.
Femde lhelhickness qauqe.
t'oTE
a sllghl resislance on th6
F4u263_can.hfG.l'iniqlla*s^liqnmnl

10.
lnslall the J ,1451,1,5 clamp asmbly tool 10 th timang oear plate- S6re the hotd-down asainsl a adjusrab e idler gear s the adluslabl idl6r q6a dos nol rctaie.
'V66
11. lnsrallrh
maqnlic srnd, 9999696, and dlal idltor, 9999643, $ that lhe 1ip ol th dial irdilor resls o a 1@th ol th
Ched< the qear bacJilash by rotalinq lhe @mshati gr back and torrh s iChtly ro measu lh backlash. For backlash specilicatton, ler to ihe SPEctFtcATtoNS
12-
ll th backldh measurement is olt ol specif@lion, adjust th6 sr llank cleaBnce
Losn lhe J 44514 5 ddp ssmbly iool rrom rh djustable ldrer gear hub. Loossn r adjustab e der Oear hub $r4s slighlly. LoGening the hub sc@s wllalih idlrqearlo be movd slighlly irvoui nom lh m6ha nsert a 0.1 mm (0.0er inch) thicknse gauge on lhe prssue side ol the adjusrable ld er qr toolh and cashafl qear loolh by using ller gauge hldr J 44935 ad J ,t4514,6
Wh ile holdino th adjuslable ld le r
gear
shaft gar,liqhlen, but DO NOT lorque lh adjuslabl idler ged hub

c 5mp
in aoa nsl the thckne$ qauoe and
Fein6lall and tiqhien th6 J 44514-5 a$embly tool against the

I g.
Remove th leeler guq from lh adjustabe dler gear and camshn Fecheck lhe backl4h, Wilh lhe spcilied b@klashallained repla@ 6ach adiuslabl idlr aear hub M.ew with and lighlen the scrows to spelicarion one ar a rime so rhe anained backlash is nol dslurbed.
15, Tiqhten lhe inlemediale se6l (doutl

id r) mounlng bols in
seque.ce to
16. lnslalllheauxiliaryidlergearonlothtiino 17. Bemovelhobea

45109204.
og cap
ns
pre$ tools,
13. rnsiarlthe
inrermediare idle (double idLer) gearsel (2) to lhe timing gear plare, us nq
Unit lnjector lnstallation

1221 GPI
NOfE
used, il musl be lited lo lhe
1. f
ously pericred, insla I prolclive sleeve, J 42435-25, ad clean the unll injeclor mppr d4 wilh lhe app@priale
not
pr*
FisuE
2t rnkrdr.
dr$
(eude
rdre4
G'rd
|6
etumpDre
ir
14. Checklhalnt
idlr gearmarking allgs with the markinqs on the crankshafi oer leelh. Frquc
te
un
hEdor coo@r
sreeve creaninq
NOTE
Afr cleaning lhe @pper deM, carelully inspe.t the inside sulace ollhe sleeve, espcs ly lh bonom sulace wh6r lhe injeotor seat is ocaled. Any emainir g contaminalion is u na.ce olabte and musl b removed. Also, if lher6 is any indicaton ol a discrepancy lhal rases conceh aboul slabilityoflhe sleere lor ruse, repta@ il
FEPAIR INSTRUCTIONS, PART

Betore Busing a i.jector, cle inq js rsquird to nsure suilability tor use. Berc're doing ar'y c aning, rhe injelor tuel inlel and oullel ports nd lh6 elcrical connecor opening musl be covered lo prdl dnlminarion lrom lhe cl4ning pfo@ss- Also, lhr musl be no Lower o{ing sialled n lhe lnlecior Relrto'uNlT INJEoToF oLEANING'on pag6 244 lor
3.
0
FsuE 21
Ren@ lhe boe

9S94251.
proieolion
deM, hFdor
Nde G*H
OTE
Som ea y pbduclion MP3 engines ced lhe orjginal design coppr dms with iniegEl laised bead ar rhe bonom or rhe copper sr66v. rhis dsign dos NOT use a gaskel llat washeD between lhe njecior tip 5nd the @pper slewe, These oriqinal Eisedead d6lon copD6r sledescan b idnrir ed by a single groo@, orno gbove al all around ih8 uppr circumieence,
Fiqu 270
Unft
rndor Borc PErdion
sre#
uni lnlsdo'
Prcrdion
lr.'rnirlnlebeE
The curent prod uclion 'flal-botom' design @pper sle4esi whch reqi me gaskt (llat ssher) r lh inicrr rip can be identmed by lwo groov round th uppr circunleen@ ol
4. lnlall6w
O{ings on lhe unil injecloras
. .
Upper Lower
nnS
larS dlamelor, violl
ring
smalldla6i6r, violl
5. Lubre boih Ojlngs and fis cyl ndr head injcror bor wilh clean engne o1.
hstarr a e inieclio noz e gaskel {ital washer) on the ijclor, usinq hand lorce to push il @. lhe lp and down uii it is fully seated againsr lh bofiom ot the injecror Do NOT use gas6 or any olher nale a lo secure lhe gaskel to lhe jetor the gskr ust b inslalled dry Three sal pojections (sripp6) on rhe inside dlameler ot lhis gaskel rctai il to ih injclor during
Fsur2
copF.
srd.
tshwn snmd ror
BEPAIB INSTBUCTIONS, PABT

NOTE
A rwied g4kel (llal washeo havinq a lhln blac( rubber maling for impMd saling was implemenled ln pbductlon beglnlng ld-auqusl 2003. Serul.e replacement qaskels n@ have ihe rubber coaling, DO NOT remove lhe rubber The qaskel (llal washer) is passembled on new
10.
Ensure rhar th ijdtor rcldr @nllecbr is @ntEl betreen th hh springd wilh qual space on borh sides. ll rhe haess is insillod, pluq in lh njecior electrical @nnector nlll tully enqagd. Push in the @nnec!o. unlil you hear a dilict'tlicl\.
7,
SLip
of corct l6oth olo lhe
lhe injcior hold d@n and n4 srew lnll nieolol
o
Fioue274-Erd crconn*brbrunnh,dr 11.
Using lorqu wnch, lghlen lhe hold dow scw in daqs to speflicarion.
Fiore2n-Unft nidorRdiner
1 nltuf
Nod
DM %k I 2 udrhFdr
12_ When placjhg lnil iniclo6, lhe @nlol unil musl be prcqrammed silh lh6 injcro/s ldm @des, The code is plnled on lop olth unit injector lcl cal.onneotol The prcgrammiO ls pfomd 6inq vCADSm and is ne@ssary lo ensub lhl 8qin limina and emission levels a
.s
Make sue that lhe inletor ts einstatted lo lh same cylinderfom which il Ms rered (or inieclor lrim ds will need lo be rep@gEmmed h ihe EEcu).
9. Cenler lhe unl njector ben@en tha sp nqs and rhen plsh down on the
injclor using hand pre$re lo seal lhe O rings. Hand lighln lh hold-down
lnf
Elv
:3
:E
nil
NOTE
Th unil iniclor hold-down scra musl be roplac6d whenvr il is rcmMd l.om lh hold doM d cylinder head
Fisure
rnjedq frm
ed6
BEPAIR INSTRUCTIONS, PART

NOTE
Due to the Engin El&lronic Cnlol Unit (EECU) sell learnng pbrity, it is nemssary lo es1 eahed EECU Pametrs aftr sruicing some enqne ielaled mmponents. This lhe EECU lo lern the nd @ponnts behavioi After sedcinq s cop ete, pelon lh "Land Dala Fesef l6ated in
yokes on rheir rcspeclive d tke suf rhal lhey afe pbpery
Rocker Arm Shattand Engine Brake
dlM
lnstallaton
[213 LPI
1.
Oillh vl yoks and lh camsha lobes

Using lhe lilling toot, a5109250, and an Gsislanr, plac lhe shall wilh fockef arms in poslon on ihe inboard sido ol lhe camshaft
ll rBinstallinq an ineclor inlo lhe san ocatio, rcproomm nq is not quned.
2.
13.
Fepear rhe insrallarion sreps tor the
NOTE
valve Yoke (Brdqe) lnstallalion
t213 NVI
enqne bke, ihe exhaust an inleg@ ulve and pisron.
NOfE
Usd yokes have slablishd wear patterns. Yokes belng retured 10 seflic musl b inslalled
in lhe same cylinder ocalion
lro which they
2.
Lubrile ihe ilp ol a valve stem wilh a small dop olc an ngine oil. LubriBr6 lhe yok so.*ets with a smatt drop ol clean e.glne oiln each oe.
IDB
Fsu,22
Fodershfi
a*bthdr'dr
Fdef shar a*mb y
t,
3.
Femo@ lhe titling bot. Then, istatt and tlghlen lhe mker arm shatt boils Inb al a lime, across lhe enti shatt so thal lhe shail does nol bmme dislrred bnt
*dy
.r
NOTE
take sur lhal the rocker arm shan is sealed pfopery ln ihe guide dowels ol the oamshft baigcaps. On engines equjpped wilh an ongin bEk, em@ lhe fesiinls (rubbef bands oflie slaps) secufig lhe exhaust Mker

7.
Torqu-lighlgn and anqle-lighlen all camshaft beadng p ad ckr an shal bo[6 in sequence a@rdlno 10 spdfcaton.
NOfE
The bohs have llmired reusabrrg and must be makd (A) wilh a punch ch lim lhey ae islalled i sedice. Bolls wilh lour punch mrks when remNd been lighlened live imes
he
Lub.ical lh .kr arm
bl 8.
5, lnsen e bng lasleneG (Nos. 8-20 in Fgre 279) lhuqh the shafl, camshan bearing cap6 and inlo lhe ctlinder head.
g.
Feplace lhe O{lng al the botlom ot lh 6nsine b@ke conrrcl@ (f equpped wrh enone bke) oro now adaDier
NOfE
On egines withoul th engine bEke, an ot ltow adapter is used place ol the oil mnl@l valre. lt is mounld in the eme localio on lh cytinder head nd is installed in lhe same mannerasth enqine b6ke cofrtrolvdB in slps S rhrough 13. fhe adapler p@des oll to the bckor shaft-
9.
Clean ths nsins brk control val oil plpe ad @p ace lhe O-nngs, Lubn@le lhe pipe hol i lhe b.*r am shaii and lh Oiings
1 1
Postion lhe
@ntol vlvg on lh cylindr
l0- lnsn 6
12.
o
lpip lnlo lhe oi holeollhe engine bke cofrtol valre.
Align lhe englne bke oil pipe and wilh lh hol in rh r.ir sh.fr
Or nq
NOTE
Mak6 su ihr lhe
Ojing
is s@ted lully i ihe

NOTE
ak surerhe enqine bake oil pipe
15. ll inslalled, eposition ojing

is
lully
rhe luel injecior hmss ovr lh conlrol vdre and secure qilh high lehperature tie strps (943472).
'
13. lnsrllrh6 mnlrolvlve
bolts ad tighten lo
14. rrharnes isinsralledon

conlbl
EIE
enqine, plug harnss conncror
irlhe
Flyrheel Housing lnstallaton f211 HDI

lnspecl lhe llyrheel housig ma.hied surices bolt hole! nd pilot lo1ions lor cEcks or wear, Feplace the housing il .acks 16 widnl.
1.
Thoro! qhly clean tho sealing aa in lhe llywheel sinq and the sealinq sulco aqinsl rhe crankshall, Apply an even 2 mm (164 inch) lhick bead ol MAcK-appowd sealant to the liming gear plai side ol the fyrheel holsing ac@rding to the patter shwn.
2.
NOTE
The llywheel ho using mu st be inslalled whh in 20 minules ol lhe sealanl being appled.
NOTE
li ihe enQlne Msorg nally buill wllh lhe onger idler gear bolts, lhe llyNh61 housing may need to b u pdaled lo block lre dler qear boll hole w lh a plugandw6herfrcm pluq kii21090322. Uselhe followinq prccedu r lo thrad lh hole and nslall
a. b.
Using a 3/4 16 UNF x 11.5 lap, lhroad lhe hol indicled in Fig!re290, Apply lhad locling .mpound (Loclrle@ 2z or qu len1l ro rh reads ol lhe p uq,
lnerr rhe plug wirh washef and tiqhren ro spcilicalion.
c.
Fq!rc2s9_Flwtlfi.Gi.qsal,i'Ap.ljolion
NOfE
Be sure lo apply beads oi salanl around the holos in the bo$6s s shM inth qEphic,
femporari y irstall glide pins in lhe l$o lower llyryhee hoLsng mouding holes ilhliminq
3.
Wlhin 20 inuis ol lhe application ol lhe salanl, a$emble the tlylvheel h ousinq de r the quid8 pins n lhnminq oar plale. Femow the
and hnd-t ghln the aching bolls. quide pins d inslalt lh
5.
6
7.
4. lnsrl
Using a lolqu wrench, liqhten th atlahinq bolls in sequnc ac@din g lo specif .a1lon.
te
Femove any
exs
sealanl.
lnsIalllhe limig gear plate to the iywheet

housing bohs (ilem 2 in Figre 291).
NOfE
llem 1 ss lh6 powr sleering and tuet pump mounling and is not insia led al this
h6m 3 smures lhe rear engine mounl lo lh ilyryheel housing and will be instalt upo islalllion inl th chassis

2. 3.
f emover/inslaller
Lubricat lhe seallips wilh clean engie oil.
lnsenlhe handle, 9992000, in lhe

9994233.
AcaurloN
|repe.x lhe rcnNt/rstal @elully. At datuae lhe loal \|I d4ttay lhe ffi|.
4.
Posilion lhe n4 seal on lhe dn'f, mak ng suf thal th saL !s lumd i rh pppr dkeli. cafelully tap the seal into lhe llyohe el housing uslng ihe handle and d ritl unlil lhe dr fi enly conlacls th cEnkshalt
NOTE
Position the drift so lhat it does ot iierleG with rhe alignmenr dowel durlng insrallario. The rear cEnkshaft seal dplh is sl by lhe d loolwhen
1 Pore sbs'inq Aturrinq 13. BsarEqhs
I
|
Mdn, ro
Fr!}hel
ndN
Crankshatt Rear Seal lnstallation

[212 JH]
1. li ol
p viously done, lho rough ly clean lhe sealinq slaces ol lhe yryheel housing and lhe cnkshaf qearwheel.
t2
5.
Ff Ma sar mratb.
lnspecl lhe seal inO ior proper sealinq.
FEPAIR INSTBUCTIONS, PART

Flywheel and Pilot Bearing
4.
lnstallation
1212VCl
Wilh lh aid of lhe 1wo lifig bohs' (r10x 100), pcirion rhe iyvhgrowr lh dowetpn and atignment studs onlhe f'ryheel mountlng surla al the ear ot the
AcaurroN
Aterre
balance
hol6 n t
a
fackg,
anyy hel th
ctutd1 Bida
dtled
@]JJ6
rcbalans by
Mchhe shop.
NOTE
On vehicles equ pped wlh an aulomallc ansmiss on, il may b ncssary 10 inslll dllferenl componenls lo ihe fywheel relalnlng hsleneB Feter io lhe Automalic Tbnsmi$on D v Arsngemnl Assmbly lnslruclions 5-902,
\+
)
1.
Clean lhe sulace in lhe pla.es where lhe flywhel li6 llush gist lh cnkshafi Clan rhe tlywheel, Ch4klhal lhe qroded surfaces lor the llyuh66l snsor ar clan
Fqu
2es
Fh*r r.d.lldio
lnsla I lhe ywheel nounling bo ls in lhe dposed mounlinq holes, Ai lhs tme,
liqhlen lhe bolts ligFlighr only,

6.
Femove the two alignmant studs and nsert lhe re main ing mou nting bolts.
BmoE the plug lro ths llyryhel housinq and inslall cEking1ool, 3aa00014, nd a
lake sulhallhe fywheelguid pin i6 @fecly insled in lhe eEnkshafr gr wheel. Ensure lhalihe@ is no damaqe of leakaqe ai th a cankshft seal. 3. lnserihro liqnmenl sluds in lhe oEnkshan llanqe to ad nstatttio.
I
8,
,--5'
Using a toquo wnch, in sequence ac@rdino
BEPAIB INSTBUCTIONS, PART
,AcautoN
Do tut lghten aqa@nt seq@natty. Dokg@@nre t n meven lwee allgnt. Falut to h@d ths @ut@ @n @lt n se!ere
9.
FemoBlh cEnking lool, lnsrihe plug. Using lool asembly, 9991S01 and 9992564, pllol bearing in lh6llywhoel inslalla
n{
@ @
t@t
FisuF 24
AcautoN
Fot lhs enge, llo shap ing s Eqircd on lhe pilot b@ n9. Do Nof substute pbt b@n@s lhal do nal beat lhe @tred pan nunb bt f's awliBion. Fzilute tc, h@d ds aon ay Esut k sete ensre danase.
- @'
sNo. Galsa
12. Crlully jnslalllhe
llywh l psilion sensor with ihe approp ale shim(s) and new Ornq. S@ure the sensor with a boli lighlned io spcmcaion and plug in lhe
11.
Ch ck to r p@pr
cleadc using the snsrdelh gaooe lo delermlne l shims are equ red ior sereor dplh. Th6 nywhel pos lion sonsor cleance speciilon ls 0.3 1.0 m (0.0118-0,0393 n,),
llywhel-lo-positi senso r
a. b.
Boiare rhe enqine using the lllrvheel a lmlh ol ths fwhl loolhed whel is algned with lhe
tuinq lml unlil
hs6n bol inro lhe sener bo@ until the ouir pai ol the i@l is lully sated asainsr the llywheel housinq.
Locen lhelhumbscw ol the tool and pushlhe innpa t the lool unli il conlacls toolh ol lhe loolhd wh61.
Tighten the thmb screw to scurc lh Ca@lully remow ihe lool irom the sensr bore and observe the ocation ol fte sl6ps biween rhe inner and outer portlons ol the tool:
llywhoeL
. .
Bolh steps bdN lh suffa@ ol Ihe l@l = no shims equned.

One step blow th6 surla ol rh Iool = one sh m quid.
Boih slePs ab@ the surfac6 ol the l@l : iwo shis reqed.
BEPAIR INSTRUCTIONS, PABT

Oil Pan lnstallaiion
I21r NBI
1
Apply a 2 mm (0.079 inch) wide bad oi lrAcK-apprcred slant ar th *ams bereen lhe llyvhee houslngand lhelhtho g6ar mounling plale, Alsq appya 2 mm (0.079 inch) wid bad ol slnl al rhe seams belweeh thetmlng Aer mounling plale and lhe enqine bock.
3.
For plaslc pa appli.alions, nsl I rhs oil pan seal inlolhe gb@ ol the ollpa. Check thal the sal lo@lnq tabs a prcperlyliqned and seald jnrh localig
holeson
lie mounnqfanq.
2.
Applv a 2 mm (0.079inch) bead oi MACK approled sealant lo lh seam belwn lh lrol sel over nd the blo.k
REPAIB INSTBUCTIONS, PART

4.
For steelpan applicalions, inslalllhe oilpan qaskel on lhe oil pn ilange. check thal tha qaskel lo@1 ng labs are properly allgned and isened in the .orcl hds on lhe
f
l
6.
ghre rhe borrs lm lh mid;b dd oul@ds in oder 1 -4 as shwhTorqu&lighle rhe bolrs ro specillcati. Flnish bv chckino the loque tor bolts A
NOTE
lnsiall lhe tbnsission oil .oo 6r bEckr studs i l@arions marked prwlously,
7.
lnslalllhe oil drin pluq and lorqu-nghlen lo
LcautoN
Do not u@ a @ppet washet with dtan ptug. At$ys u@ the steel
NOTE
5.
Wilh assistance, pGitbn the of pan to th engine block and nsrallrhe bolrs ma*ed A nd B. Tofquo-r qhln rh6 bolls lo
Do nol use alr lools whe inslallingihe
oildin
3.
Ensur rhal ih 1 2 localinq pins on the seal ar popery seabd inlh6l@alino holes in
NOTE
Use ca lo
pr*nl
damagelolhe oil
NOTE
a sur lh oil pan seal is properly plced bslirr
The oil pan must bo istallod wilhin 20 minules of lhe sealanl being appled.
harnBs is inslalled, reconnect lhe ott level/lepealure sensor mne.lor lo lhe

lf
Q)(

Oil Fller Ppeand Dpstick Pipe
Power Take-Off lnstallation
'
lnstallation
1
O r ng on lhs oil lill lube nd inslalllhe tube to lhe sde oftheollpan. lneallrh oilfi lrube lasrenerc and rlghrenlo lnsla I a
nw
li equipped wilh a ptuer iakg'off (PTO), inslall the asmbly lsing this pbcedure.
1
Lubicale and Nemble a seal i lhe ln the PfO ssmbly housing.
qrcM
2.
lnstall a new O dng on lhe dlpsnck tube, rhen nsrall rhe iube and secu fe wnh lhe laslenr lnslll rhe dipslick.
2.
Gsmb
lhe PTO ssembry o the llywheel
3. Fwheer Hds nq
3.
Usingalorquewrcnch lighlen lhe lasteners ac.ord . o lo specilicalio.

Timing Gear Cover lnslallation
1211
1
4.
AAI
I cowr on lhe fyvheel housig al the rear l th6 q/lindr had. lnsiall rh fsreE mrkd 1 and 2
Posftlon ihe
liig
go
Apply sealanl in the botlom corne whe the limirg gear plale and lhe llywheel houing mI. Als apply s6ala.l lo lh6 lop of th6 liming ger plale (in t_Le corner) next to th cylinder had.
2,
lnsrall rhe riminq qeaf
@Er sea s and
5.
lnstall lh nming qar rer a ignment toolsj 451 11422 A and 351 1 1422-8, to lhe cylinder head and liming qed cover as illusrrald. CNr suda.e must be lush with lhe seal sulace of lhe cylinder head.
NOTE
fhe liming gear cover must
b6 inslalled wilhin 20 mindes ol lhe sealant beiq pptied.
3.
Apply sealt to the matlng sces of the

lnslalllhe femanlq faslen6,3, 4 d 5. Toque all ol rhe liming gear cMr lasten6rs Rmw lh liming @@r .lamp l@ls.
8. Posilion lhe @r supporl brackel onto the r fth ngin and inlalllhe supporl brrck l l'srsnB i s.x.
9.
2.
Check tor prcper enshai paito'n sensor clance using lhe senerdeplh quq, 43400031,l dlBie it shims are required lor ssn$r dplh.
lnstallallti slp3. P-clampl and olher 6lainB Esd lo r6slrain lh ngin6 harnesses, ol lnes and c@lanl lubes lo lhe
a. b, c.
Fott6 lhe ngine unlil a loolh of lhe @mshai i@thed whel is aliqned uilh
bo unlil 6 oulr pn ol tre gauge is lully seated aqahsi the nhhq gear
Looen lhe lhumb ol lhe gauge and Psh th inrpa oflhgaugin until il colacfs a tooih d ln loolhod
lnse lhe depih
qauqe inlo lhe sensor
$r4
Tigr'in rhe thumb CAMSHAFT SENSOB DEPTH, CHECK
$f4
io
*curc the
1. Be@
lhs plug lom lh6llyuheel holsing and inslall lhe fywheel lurq lool.
Calulry ro lh gauge fom the camshaf sesor bor and obsetue lhe localion ot steps belwen ihe inn6r d outer pdionsol rhe gauge:
. . .
Bolh sleps bel@ lhe sula@ of ihe gauq6 = no shims required.

Oo slsp blow lhe sula@ ol lhe
qauge = on shim qund. Borh steps abM lhe suce ot lhe gauqe = lwo shims equi6d.
(d,---
-5r
Coolanl Pump lnstallation
@ @ @
3,
l.slall lhe camshaft positlon sesor wlh lhe apppnab shr(s) and n4 ong. secufe lhe sersor with a boll and plug in lh
[ 215
SW SG, SBI
l.
2.
lf remded, placelhe c@lnt pp b66 plale in posilion al rhe font ot the cytinde block and install the mounling bolts. Tighle the bolls to speoil@ton.
Prcss a selinq dhQ inlo lhe grod ol repla.emenl @olanl pump. the
ns
3.
Posilion lh6 placmrl coolani pump hpellerhousing on the base plalo and a ion
NOfE
rake sur6lh sealinq ng reains seaied h ihe qbde of the PUnP imp6llrhous nq.
4, 5.
lJse caE to hsre that ihe seal ng r ng @mains pbpeny sealed and inslllrh6 mo ant pump bolts and lighle lo
Poslion lh6 l6nsionr pulley on lhe f.ont of lhe engine and nsialllhe tension$ bolts. Tlghlen lhe bolls lo specication.

Thermostat and Cover lnstallation
[215 NU, NG & LD]
[215 SWI
Coolant Ppe lnstallation
UPPEB COOLAIII PIPE (BYPASS) HOUSING

1
Lubricato nd asmble a 4 seal in the upper coolanl ppe housing llng.
l Ct,nderHd
3.Th,mo,Lar
Uss cocus cloth 10 rmow ny sulac nicks, buft, sharp edges ad lool arks fom lhe rhermoslal @ver and d/linder head.
uppercoolant Pip housing
Lubn.al lh inner suda.e ol lhe co@r

3- lnslall lh nw lhmGral.
NOTE
Make sure lhai the tubber
*al
remins proD6 v
4- Pcilio th lh6moslal
cver lo lhe .ylinde
head and inslalllhe bolls. Using a lorque wnch,liqhien lhe lasleneE an a cross
paliem acerding lo spcilicrin.
FrsuE
o1
upper cooranr pp
hsba
on
Using lo que wren. h, lghlen th upper coolanl ppe fa$enere in sequence aoding lo specinatun.
Asseb
e lhe
lan rng b6ck6l lo the upper
using a loque w@nch, liqhten th lasteneE ac@rdinq to spcicalion

PUMP INLET HOUSING
1
2.
Oil Coolerand Cooling Duct cover

r-he
Lubndeand assemble nssealing ngs

on lhe pump inbr pipe ar
joinr wjlh rhe
[215 Dw' 2r9 EPI

The oll coolor msl be atached 1o the cooling duct cover belo aftaohing the @r b lh
Plae lh inlel housing in posilon belwen th6 uppereolantpipo and the pump inlei. Replac and lubficale I sea lno o finos.
OIL COOLER INSTALLATION

1
Using a shlp pick, carBlully remde lhe rubber sear (norded qasket) the grcove n lheoilcooler c@er, il notalady done. 'fon Clean lhe cover of ny din, adhesives ad inspect for danage l lhe *a inq sulfce. Ale, inspecl thecyllnderblockad ensure lhesaling sulae is clean and undamagd. lnslall a
2.
nN
lomed
g*kel
in lhe g@ove
ol
NOTE
3.
lnstall the Ma hsleneG and tiqhlen lo specilicalin, Thn, inslallrh M10 faslen6r 3d liqhbn to specifiatio.
Apply a imal mout ol slicona saLant in lhs sea! grcove lo hold rhe seal in prace durng as*nbly. lnslalllh wilhin 20 minules ot
mq
NOTE
housing trange 10 lhe pump flrsl
3. lnslallnq oil6lers6alng
O-nnqs breen lhe oi cooler ahd covel lnslallrhe sealingojings nto lhe grooves the cover

1.
COOLING DUCT COVER NSTALIATON

Feplace lhe Mler pump inler hbuslng lormed ubber gasket wlih a ew gsket, Lubricle nw gaslel upo ista laton.
2.
Wilh assislance. sel the c@ling duct cder assembly h plce. lnslalllh upp
NOTE
This mouilng lo@l on is sloted lordtsrmnr.
3.
Using lh assmb y lool, 3a300022, push the cover loeard lo cmpss lh lomed rubb gaskel al lhe waler pump inbr. hsla
the upper iahl corner

5, Using a lorque wrench, tqhien the tasteers i sequgnc amoding ro speitiellon.
l4lener
NOTE
A small pe.e ol
lnslallrhe oi @derll@ plate over the oit cooler Tqtfen ttnaB 1o spcilicalion
kep
lool fool is pressig aqainsl.
tl srock should be used b fm deiormlng th slamped cwer that the
frsu6 3
cooins oud
ca$ adjudm
rdl

4.
Adiusl 6wr as quid rwf nrr lasrnfs r
3. lnslalllhe gasket to the engi. btock

lnsrall rhe oil li[er housing onro rh nsina block and posil on lhe rear pipe. Torqle lhe
NOTE
The uppr cenler mourninq location h6 liqhtr ldee than olher mo1i0 locaiions.
lnslall lh fsl6nrs to rhe ear pipe n the olt fller housng. Toque the bolls to lnstall the lont ppe wilh n4 seals bellee lhoi fllerhousngandlheil@oercovei
5.
slart
a I
realnlhg m@r lastene6 ahd
lolqle
g}nen bsleners to
specitilion,
Oil Filter Housing lnstallalion

[21e EPI
hsla I the ea pipe lo lhe oil @oler cow a new gaskei. Place lh rlaining clamps in posilion on lhe oilmolerducl cde, insla I lhe iasleneG and lighlen lo
wlh
7.
hstll all hrd pipes (molaff and oil) lo lh
ollcooler@rel Beplace and lubricate all O{in$, Alsq Bpla@ sealing w6he6forlhe banio finino on lh oil@oler
sealinq
covei Tiqhlen banjo lilinqs to specifications.
2.
gskl
lnsialllwo allgnenl pins to holdlho in place ard 10 aid in lhe alignmenl oi
-),

Exhaust Manifold lnstallaton
1214 EGI
NOTE
The xhaust manilold mounling laslene6 can be used lire lmes uless the mnffold ls bino rcpla@d.lflhe manitold is being placed, use
1,
2.
Clean lhe manilold mounling suriace on lhe
o
1.
Tmporily inslll n alignm6d slud at each exhaust manfold fanqe bcalon on lhe
Mibrd s ds
(ftbl)
2.
cv ndsr
Hd se
(wih
NOfE
This is don lo hold lh manifold whil posilioning the manifold gaskels lof nslallalon ol lhe bons
4.
Apply nli-siz.ompoud to the threads and under ths h6ds or contacl sula@s ol ll lhe mnilold lasle6
NOTE
o'
ae\
,o
3.
(_ll
Anli-siz hlps p@nt iasiener oxidatio cofosio and duces ficlion lo help acheve the inlended clamp load o the componl whe 1 qhlning rh hsleneF to specifilion.
5.
lnsiall lhe dhausl mniild oEr lhe alignmenl plns. l6tllfastnE wilh spacers in lh low. holes, Now lhe upper alignmnr pnsen b6 mowd oe ala lme and @placed wnh ounling lsleneF and the
F'Urc3sAlgnmdPhh3blllio.
lnsrall nw qakets olo lhe wilhthe sa side lacing lre
NOTE
Mk surelhe sp@ r seated p@pe y in themdilold siep bore hole locxon.
Exhast man lold laslene6
bB usd up
NOTE
The qaskts r malkd "MANIFOLD SIDEI 10 aid i nsla lation. Mak su@ lo da@ this side ol lhe gaskel lMrd lhe exhast an told. The gEphil libn side ol lhe gaskel laces lhe cyllndar
6.
Tiqhlen lhe ls16n6rs lo specitilon.

Turbocharger lnslallaton
[214 SCI
Lcaurror,
Use oity ev md aryove.t gaskets at the w aB at. oil 4d dhaust Mnectare a Le tuftnchatg. Avaid the @ of *alng d jakt rpods ar a| langed @nec1ore.
fhopuoh .leatress s rcquted. Sna pades se @vee b danage il nducled dutkg hgh-speed opetut. B te to plug the inlal and ltel po/l' wh|e ha ndI in g th e tu tuocha ry q.
Aftt nptens qhe ea*t)ly, ll the tutbocharyet ol paege wnh dean eryke ol belote sbnN lha Nke. Befer l the ptacee undet Tutbocharyet n he ENGNE PBEPABA|ION AND
z
1.
tnspecl the i1ake nd exhaust systems leading to and l@n lhe lurbochalgr lo mke suG there is no foreign lelal incudig bis and ooe lining fagments. Clean the coiact suface o the *hausl manifold, oil lurn/d@ln back p p and Relaln the polectl@ ps @f the lubochaqe. po s lo keep deb'is and dl oulollho lurbdharger as gngine
lnsrallrhe rurbochargertlanqe nurs and spacers ro rh Bxhausr mn lold and toqe tohien to specilletions.
NOTE
app y ai-seze compound t lhe thds nd undr lh conl.i surls ol lhe laslnrs
apply ai se2e frpoud to lhe thads and under lhe heads or conl,aol sula@s ot the fasleneG. Anli-soiz hlps ptwnl hstener ox dalio. @clon and redues l clon ro help achiwe lhe ntended clamp load on the componont when lighlening lh
to 5, 'aslene6 lnstaf nee
speciielio.
h gh temp1u gaskets betwen the tulbo fange and qhausl
6, Psilion lhe lubocharqer and gaskels aqainsl rh Bxhausr manilold.

a.
lnstall the lrb@hrgr oil Errn pipe (lower) with a nN oaskel.
Exhaust Pressure covernortEPG)
lnstallation 234 gD 1.
Lower lhe EPG housinq inlo posirion btuen lhe exhaus! ppe and lurbocharqr lnsrall a
ho usin g
2.
nM hiqhrepehtu o6kt EPc

and xhausl pipe.
9.
lnsral the oil suppt line (uppe4 wilh a new gasket. Totque-lighlen tho bolts lo
/AcautoN
Pra-lill Ih tutbodger wlh cl@n gjre oi. Salhg the egie wiktut oil pressure and a Ary" lubaaget @ dmage lhe luo.
3.
Tighton lhe clamp atiaching lhe pipe lo EPG housina.
dhausi

4.
lnslalllhe dhausl clamp lom lhe EPGrorubocharger
Siarter lnslallation
1272
DHI
The staner is held ln plcs by nuls assembled Nr sruds irerld in the br.k rr sr'd
ii
Using a loque wrcnch, lighten repla@t siuds a@ordhg lo spcicalion.
2.
Asseble lh sner on the sruds in lhe
5.
Coneclthear spoly lie to lh EPG.
F.go343_shghbraon
3.
Using a torqu wEnch, lghten the nLns ac@dnq to spejlicarion.
REPAIR INSTRUCTIONS, PAFT

Air Compressor lstallation
1261 CKI
2,
Asemble lhe alr copr;ior on ine moonring llange ollhetimiq gar plate.
1-
lnsiall a nNseal inlhe alrcompEssor housinq houlihg fl ange.
3.
Using a lorque wrench, iighleh ihe atlaching
ls
i two slages
aeodlnq lo specitlcatl.
lnslll1he cmlanl lins lo lhe
ai
5. lnslall the lubication ties to the an
LL)
Tandem Pump (Fuel and Power Steering) lnstallaton

[231 AA,262 EBI 1-,nsiall a na Ong
in the qrcove on the
2-
lande pump mounlinq llange. Assmble lh tndem pump on lhe lttaheet
Fsurc
7-r.nd.
Punp (Fuer
'nd
p.r srs
nq)
3, Using a bque wrcnch, tighten the attachig
hsteneB accordinq tospcilicalion,
REPAIR INSTBUCTIONS, PAHT

lnlet Manifold lnstallation
[214 HD] 1. Usinq a 6haD plck, carelullv renove ths rubbr sai (nolded qaske0 lrom the groove
the lntak nailld, il nol alrady done. Clean lhe anifold ol arry din, adhsivos and inspeci lor aw damaqe io the sarq sulace Also, nspecl lhe cylinder head and ensue the 8alinq sudace is clean and
n
2.
lnslall a rubbor s6l (moldd s6kt) lnto the gl@e ol lhe iffake manhld.
ns
NOTE
Apply a m i imal amo unr ot silcone seala nt in rhe s@l growe lo hold lhe seal nplacedu ng a$ebly. lnslalllh ild wilhln 20 lutes
Torqle-righren the iniake manilold bolts in s6q u nce lo sp ecifi@lio..
SeuBlh 6noin hamsslolhe inlake nihld usi.g pdiously rmowd ai lmpElur6 sn.or localed on the lop oi the inlake and *curelhe hah* wlh li6
lsill rh eLeclrical conecto. to the charge
3.
Posirio the intake nanifotd onlo lh lwo pGviou!y imlalled aligrmenl pis. siarl hro molntng bolis with mounring space6lo hold ihe man lold in plac, ihen r6move lhe alig nm rn pins and install the emanno mahld bolts wilh spB.
(Bocr) sen$'
aoding
Using torquo wench, I qhlen the sensor io spec licaton.
NOfE
use scf6m wllh mounling spacefs when nslallrg lhe lake mailold.
f4

Englne Prehealer/Spacer
lnstallation
[214 HL] 1. Cln lh lomd $aling sudae on rh intak dilold, ai preheargr or spacr, and
2.
Posilion lh6 inll adeprr and inlr ir pehearer (rf equpped), of spacer brock wrh n4 gaskers onro rhe inrake anilold, Nexl, $an $e bolls lo hold lh Gsmbly lo lh
EECU ad Cooler lnstallation t230 EKI
NOfE
The squnc6 iwhich lh lul iinr ELve housing, luel lines and EECUar6asmbled on lhe engine depends on the Vpe ol enqhe sland usd. For ngin slnds rhar use an adaplef plate atched lo th llt sid6 ol lhe engine, lhese .omponenis cannol be sialled untlaltd lh 6ngi hs b. mwd lrcm lhe fepaf sld.
Ful lEsh lrm the tank serves as @otant tor lh EECU. Th6 mol6r @nnets into lhe line carynq
Figu65_ll3lAdpll
using a 1oqu wrech, tighten lh lstgnB i a crcss patlern a@ordlng lo specitldlion.
lnsrall rhe lan nq suppon bEcket mounrng fsl66r Torqu-tqhl6n lh boh l
equapped, postt on ad isttt th intl air phearer relay bE ker (wlrh lay atrached) 10 ths mounring surla@ on lhe inlake manbld. conne.t and seu the pMr and ground cables marked al
the luel lrcm the lank inl lhs lu6lpump.
NOTE
lake sure the @olinq plar and EECU matng
1.
PGilionlhe EECU on the engine btok and insiall ihe unling la6tee6.

NOfE
ike su lhal rubber isolatoE re corectty nsialled and thal lh grcund sl@p is gounded
10
4.
Uslng alorque sr6nch,lighte1h hstenere in squence adordinq to spcication.
Fuel Lnes ad Filter Housing
lnstallation NOTE
Thesequencinwhichthlulf ltrhousq, tuet
lines and EECU areassembled on lhe enqin depends on lh Vp ol engine siand ced. For engine slands that lse n adpler plal ana.hed lo lhe lft side ol lhe engine,lhese compon1s cannol b instl sd uff I altr lhe engine has been removed lom lhe epair sland.
Usi.q a loque wrench, riqhlen rhe fasieners adording to specil ca1 on.
Assembl lhe coo 6ron lh EECU. When pcilioning lhe module, ake sureihallhe snalgmund sl@p al lhe uppef rstf oi ihe unil s properly secured nd prcssd in
NOfE
FisuEs
1,
F.r Firsf nd HoGnq
asbt
Asemble lh tul finer housing onlh6 btock.

Using lorquo wnch. tghten the taslnerc
2, 3.
acmding lo speciliEi on.

Allach lhe ppe bellveen the sde ot the hd al lhe raf ad the lilte.hous ng.
5.
Lop.P,eure Fler
sppy Pump (Mounrd ro
Poref
Atach the line lo the bl@k with a P-clamp,

cylider
lnslalllh iul rlum lin beren rhe h*d at lh lorn and lh lifter vlw
lnsrallrhe line ro rhe bock wrh P-clamps.
Crankcase Ventilation Separator 1. Clean lhe cankse venlilallon sepato

malinq sulac o. lhe ngine btock. lnstalt a rubber askel iffo {r s6pa6ror
n4
lnsrall lhe lue I relu rn line conect lng the liller Etue housing lo th EECU di lnsrall lh6 lul supply and r1un I nes belween lhe lue pump and thelillr
U3ing aloque wE6h,lighlen lhe bahlo llttlnqs accordino to specif calio.
2.
Assemble the sepabr on lhe blck and

1.
Assmbl the .Enkshafl vibration'damper nd I puloyon rhe clshail hub Ging
NOTE
3. 4.
5. 6.
ioque wnch, lghlen lhe lasleneB ac6rdig lo specif calion Assemble lhe ouel hose on lhe separalor ou el conneclor ad instal hose clmps.
l.rsing a
ljslng
a torque wrench, liqhlBn
the
clamp laslenerc ac@rding !o
sp4l*on.
Fduress.FanDvePu'le'.ndc
hc6
Assmbl 1e lnler hce on the separator inlel and prpa fo re cov6r connslion
in a iulu@ slep,
lnsiattho* ctamps.
7.
Using a lorque wench, tlghlen the
h66
clamp taslnerc c@.ding lo
sp4itilion.
t2 t3
viraion onpr
c,nrshaft Hub
Crankshaft Vibration Damper and Fan Pulley lnslallatlon

[212 RB,2'16'tA]
Using aloquewcnch,tghlenlhe ataching l6lneF in sequence in two stps
AcaurroN
When handling a tbnton darpL b a6tul na to daage ll fo6kg. Denls ln the auer hsng sl rcndq the danpet inefecfive. rhe
a@odhg to sp6cilicalion. 3. Asseb e lh fonl engine p@er lke of (FEPTO) il equpped. Tighrn rhe atachlng last6nc in sequenc in ldo sleps a@ordina ro spe.ilication.
vb@ danpe. @nnol be Epated. Failure to h*d hs autim nay re'u|t in see engine
lnspecllhe vibElion damper lof dents, ncks or llu d leaks in lhe outer housing. ll any oi lese are widnr, rhe dampermustbe reptac6d. Duelolhe clos cloaEnce beveen lhe damper housing nd lhe rolorinsids, denrs r nrcks nayeuse conlact belween lhe two componenls. Fluid loss will dele oate lhe dampeiq eftucl oJ rh
BEPAIR INSTBUCTIONS, PART

6.
A*emble the allernalor and reriqe;l compGssoron lhei pads.
Fqure 3@
FDnt E qiru Po@
Tar.r
(FEProl
Alternator and Ref rgerant Compressor lnstallation

1271
C8,264 DP1
I |
s.
m 6mp,sor
Enan sppod
6. Mounrm
Bccb|
Fron'
Assemble lh allmalo. mourinq brackel onlo lho cylind6r block. Ighlon ih6 Iastere6 a.cordang to spelicalion.
2,
usinq alorque wrench, lghlenlhelasleefs aoding lo specmcatun.

ll a hrnBss is installd. secuely connect the eLectlical wi nqslaggddu ng
ll emoved and nol ppiolsly installed, $mbl6lh lronl ngin supporl mounling bckel on lhe cy inder block. This brackel also pr@ldes lhe mounlinq poinls io lhe
Using lorque wBnch,lighln lh lasleneB lor the bckei nd ccording lo
Assemble lhe be I pulleys on lh llnaror and compressor hubs, r reved.
ou
lf mNd, assemb e the bett tensio idter

Using a lorqe wrench, lighlen lhe
lalene6
cordino to specf
cr on.
REPAIB INSTRUCTIONS, PABT

Wiring Harness lnstallaton
l3 1.
wqHafss
Roule ad pGition the harnss on fie engine noled durlng di6a6sembly,
2. 3. 4,
lnsn lh unil injclor ponion ol lhe h.me$ throqgh the hol l the tllnq gear housig.
Connecl ihe hamess lo each iiectf.
2.
cLrclva
Conneclthehamessiotheengibk
mnlrcl valve t lnslalld.
Usinq hioh-lmplue wne es. 983472, aliach ihe harness lo lhe cyLinder head.
ahe nernal podon ol lhe w ng hame6s is encGed in a@fdion lubinq. Thr afa svEl unils ch of which s tilled wlh end connecto6 thai permn .oveniont st n ging jininq ad allachmerl lo the block in rious localions.
CONNECTING THE EECU
6. t nol previously done, caelul y ror,lo lhe wiring harness @er lhe engine brake control valve. secure the hafnss lo lh cnrfol Blve as shown i Figu 363. ik suro thal lh hams is pGilioned lo the sde of the boss al the lp of the Elw assmbly.
Chck l\ lnsio. ol lhe lermanal on n6cto I pns shq ihe tsl pins rol kit 999000a.
NOfE
ll lerminal pins are damaged or
/AcaurroN
Do Nof mute the hames o@ the bos at rhe lop o the engine tuake @nlrcl hlve. Therc s nat enough deatatu belween the valve ad the wive @ver far lhe hatess when rhe @ver is insblled. fhe hatress usl be psioned lhe sde af the b6s ro awid da@ge o the hahess.
coroded, ep ace
2.
Caelullyengagetheupperadlowerwiring haiess conncroF lo lhe EEcu. vrify lhai

lhe connecloG are lalched and propedy
Ue aE to entute hat the EECU teminat pks aE slaqft an.l undanaged,
^caurroN

lnslallation [211 JBI
1.
Cylinder Head (Valve)
Cover
C ean lh g6kt saling sllace ol lhe cylhder had. The sula@s shuld b clr of ay dil or debrls and lee ol any oil.
2.
lnspecl lhe gaskel lof damage. li @plamnt is necssary caEtully plc a e gdk6t int the channel, kio su lhat I s propeny *aled and tollds lhe @nrour of rh chan|.
3.
lnslall lhe bolls lo secufe lh6 wiing hafness
FlguEscyn.&fH*dcovlG'3kt
3.
Appry a 2 mm i0.079 nch) bead of MAoK
Cnnecl th vanous leminls as lagged al di*ssembly lo ll ssnso6, rslays d componenls such as ihe stailef, allernalof and lli96nl cmprcssrmong olh6.
5. Anach rh clamps lo hold lhe hamess on lhe
salanliolh areawhere lhe liming @ver ndlhecylinderhoad mi. This paning lin is on bolh sdes of the cylider hd. Calully posilion lhe valve cover on the cylindsr h6ad and make su lhal lhe seal
remans
pope
y std.

4.
lstlllh sp ngloaded bolts n lhe utve covei Tofqe tlqhlo lha @l cover bolts in sequen@ io speoilication.
Fan Hub and Drive Beli lnstllation

[216 AAI
NOTE
The cylnder head cdr musl b in$aned wilhin 20 miutes ol lhe slnl beinq
The boll springs povde e@n tesion on lh
1.
Pla@ lhe i hub brckt a$embly n pos lion al lhe f@nl of ihe cylind$ had and block. lnslalllh mounting tasleneG and lighle 10 sp4jfi calion.
5.
lnslallh lastnB securino lhe c@nkcse venlbnon tube and bcket lo the vd@ cover and inlake manitold. Torquerlghlen lh fslnc lo specilicalion.
NOTE
lspetthecEnkcase ventllatin lubOjing and
t1&soryodBd
Pue Bor'
rssiomf
Plce lhe 1 d ve and pup driw beh lensoneri posirion on lhe coohfn pump housing. lnslatt lh6 tasleners and lqhten l
ll nor kedy done, ptc6 rhe a@essory drire bsll insioner m pGrlonon th6 cylindef block. lnsralllhe l4tee6 and
Check lhe @ndll of borh of rh ridisr A/c/ltemalor ad waier pumpan belrs. Check tor dry cEcks or scuf marks nd @Place wilh nd blls I ny ol these
Prlhe ac@$ory rouling d8cal, bure lhe Llo/alteralo and lan/water pump betts.

7.
Using lool J /14392, pry lhe bel lensoner eay fom ihe ran and wtr pump dnw beh
and insralllhe belt. Relass lh lnsion and
Removing Engine ftom Engne Sland
6.
Place a 1/2-nch Elchel or speclal lool
t200 EBI
J492inlha@essoryd vebelllnsionr
nolch. ls1lllh6 dfive belt by pryi0lhe lenslonef away fom lhe bell lo li4e lhe lnsion on lh adiste! nd llow th blt lo srip io ihe l/c @npfes$r purry. Felea the lsion and rmove lhe tod .
qglre ls very heaw an. at@e u wr he exnise.l whle t is belng fted lrcn the stan !. Faitut to u* pp qlipent aDd ,allure to keep yo bo.,y ct@t ay re tt
fhe
in
gre 1.
eiffi p*@I
shoLt
la d sr.rdly ahft out of
nury ot.l@th
tE
Atach engine lifung ioo s J 47033-1, J 47033-6 and J 4703a4 as lottows:
a. b c. d, .
centerengine liftiq barder th cylindr head cwerard instal lhe cl4is pin. Connect th cnl lifiing bar clvis lo lhe chain on lhe hoisl.
S id lh
eys nd
Placelhe lfing chan toihe gin tift s*ure lhe chain lo th6
Slde th rr lifting plare inlo the @nter
lifting bar and islalllh6 pin. goll on lhe flot sectio ol lh 6ng ne lifting bBckel lo lhe cylnde hd d installth6 pin in lhe bai
Torqu'lighlen litt ng bracket hslene6

1. r
U* ony the chns, ctvB dnd tiking plae provded wilh th* specal tals. Fail* Io h @ret sp@lal too @nponents ny Iw lh gre to fa, @u.ng 4 @5 pet@nal lnry rlth.
Supportlheweighl of th6 n9in6 usinq a mobile ll@rcEnesuch as OfC 16.1313 or equivalentcrane capable ot lifing lhe ngi. Posilion th6 cEn and hook up l
ble. Baiso lhe cnno slighrly ro apply rension rolhe chain. the bar as as 3. With the lifting device now suppo ing rhe ngie wight, @mov the mouling
nl akady don e, asser; bl thd lottowjns oompoenls onlh6 ngine using lhe p ocedu fes cove red ea i6r in this 6eclion.
. I .
Enginewkins harn*
cfakcase ventilt on lubing EEC|Jandcoolinqplal6 lullines Cra.kcase venlilalion sepalor

Fuel llter valve husing and
d6e
pos
fasleneBlrom the enqne stnd.

pla@ lhe engine in a suitable supporr ck or insiall rhe engine i Using
theenlhe hoisl,
lhe @hicle (se Fo,h /rstlrli, in lhe REPATR TNSTFUCIIONS, PART 1 secrion).
Flters and Miscellaneous
Components lnstallation [219 EV,2t5 LDI

This seclion coveG lnslallation ol lill6B nd olhr componenls thar might gel in lhe way 01 olher a$embly opaiions and to which nlhing is
NOfE
Ths sequ6nc in which the luellller hl@ housing, tuellnes.d EECU ssembled on lh6 nq n dpendso the lype l6nQin sland u@d. Fof engin slands thal use an adapler p at attached lo lhe len sd of lh6 ngin, rhese cpo6ls cannol be nslalled uti aftflhe engine h6 b$n fomoved t@m lhe repa siand.
i . Eno n6 w?iq
Hamess I 4. EECU
I 6.Cankasvrn
I
2.
s+mbr
Assem ble th fu ll-llw oil tilte lo .onlacl Plus 3L/4lo I lurn.
6 and
tig
htn
3. Assemblelhe bypasso nlernd Ughtenlo contcr plus 3/4 lo 1 lur.
assmble lhe coolanl flternd tghren 10 cont1Plus 3/4 lo 1 lurn.

ENGINE INSTALLATION
Special Tools
General lnstructions
Dtails oi rh enqine insla lalion p.ocdue Ery lfom one hicle to snolier This setio prdidos gene@l guidelin6 Jor insralling an MPB enqine in
NOfE
R6rer to th SPECIFICATIONS section
lnirfro boll lhe laslnB m.lioned
lor
be
NOTE
Belore insiafing lhe enqin6, mak8 su equipmet a@ inspecred lor sfety and
Some groups ot musl be tlqhtened in a spcilc sequence, Paflens ol sequence are also 'aslene6 specied i the lorquo spcili@tion seclion,
ou
lnsrallation
1.
Positlon the vehiclo 0n a
fat, lwel 6u.lace
Apply lhe parklng brako ad block ihe
wheels.Obse@allsatelypreautins.
Th engine 3 obvously heavy and difcult lo handle. Obtan a helper and prdde a sitable lftlng devlce to support il sally during iBrlltion- FailE to hedthis rrnig y
es
ir sve pbonal njury
whl i.sratlng the engke, wat h lot abstucls lhal ay ktae. such ae engne and chass @rnpel' bhcke.ls, clanps and other pas atached to the lqe and @b. Flurc to heetl hB 6im n6y Esult in sevee danage to he ghe al other @p4ts.
1
^caurroN
hsral lhe rEnsmr$ron ahd, u]eind a lorque wench, 1 ghlen the lnsmissi ltaching screws cerding 10 specilicalion,
12. Wlhdaw lh6 lEnsmission jack.
a. b,
lf haual lE nsm iss io n. atlach lhe uich linkage ad bfacker Giaing
Cryrlh valv mchanism and garlin wlh a suitable clolh or simlaf covedng 10 p@enl dil and debris lom enleing lhe
3, Aiach the ngina lifting tool, J 47034, lo e e Oine. Secure lhe enq lne llftlng tool to lhe ircnl ol rhe cylinder head and ro lhe rear al
lf aulomatic fansmission, attach ihe tofque conrener accss panl and
Aflach the h@d esl crossmember ll

15. Conect slartBr wnes and cables,
Attach th
persie
ng hoses and
thelywh6el housinq. Adlusllh1oo to

17. AIlach lhe exhausl syslem brakels. Aliach lhe exhaust syslm lo lhe Ensurc aI bofts a'.t ns arc @rcy posl one.r priot to rong th gre ho the engne st.1, Fallwe to proply lnaan an bIts nd pre l lh ngn. lifting tool en rcsult n petsorat njury .ltor ddh.
4.
Usinq lh ngine iiftinglool, J 47034, and wlih lhe ald of the helper, lifi and lower lh
The rdlor and CAC sseFbly ls hdy and dficulllo handle, Prcvid sutabl lifiing deve d hlpr lo supporlltsalelydurng lnslallation, Failur to hed this waming may Esult in severc Dersonal nury.
19. Anach ihe adialor and CAC 6sembly.
5. Alig n lh ng ie wilh lhe I ransmsslo n.
lnslalland, using a toque wEnch, tiqhten lhe rear engine suppon aftaching screws amo dinq 1o s pe.llcatlo n.
lnslall and, u6ng a loque wech, lighlen lhe lt enqin6 supp aiaching scr4 a@ofding 10 specllication
To
OTE
Femo@lhe engine litl.o lool lrcm lh
all@ Jr chssis anlculatlon in s6ver6 service appllcatlohs, tho lan ing rubbefsea dos notlil ilush agaist1he shroud on cU modetchasss. A qap of 15-20 mm (0.59 4.79 ich) disls belween the fonl lac ot the aluminu tan nng lh back lac f lh rn sh.' 'd
App y n vn 2 mm (t64 inch) bead ot slanttlhe joinr lines between the
cylider head ad tholiming
Er,
NOTE
stalllhe va@ 6vr wilhin 20 minules oi
10.
lnsl lrh varv cvr
BEPAIB INSTBUCTIONS, PART

29. IttheBhicLs
@ndlio.9:
is qupped
wlh;
"
a. h c. d. e,
21- Co.necl E fan aclualor 22. Connecl lhe engine c@lanl lemp@lur
Conct lh /C comprGso di$harge
conner
rhe
Jc ln6
p@ssu@
al tho
Connel lhe
sl6h
on lhe
con6ct ih6low prsu cutour

Recharqe lhe NC syre wnh grant rccd6ry rfigErn usig dd recycling equipenl for R134A.
cl
30.
lnstall lhe nlei ar system componnls
23. All5ch
the chafge air @oler oullel the charge air cmlr inll
31. Connecl lhe nlel a.r healer , psenl. 32. Atach lhe oil and tuel tlle6 and lhe coolanl
33. 04.
Clos all dhins nd dain
24. Atach
Elwa
Connect all soso6 ad acluatoB,

oil and molant. lf aEilable, use @dal qtEclornjeclorwhen addnq olnt.
25. Aia.h th dolant dpanslon lank. 26. Anach ihs l@sr dilor lube. 27. Conn4l the eb h@ler and luel heer c@lanl rurn lines o rh ld6r Ediaror
24. atlach ih pper
radlalor lub.
36- Add
37.
Atiach the h@d, or pla@ lh lihd cab.
REPAIR INSTRUCTIONS, PART 2

rN-cHASSTS PART/COMPONENT PROCEDURES
This sclion psenls slandalone rcplacemenl opelions whch n b do in chasis with a comprere enqlne @fhau. The* operions
CAMSHAFT BEARING BRACKETS, REPLACEMENT (MACK MP8 ENGINE) [2r3 CJ]

This inlorti cd6 guidlins whe placing iaclory or aferrkl camshalr brino bEckets (lMr jourals) on ihe MAoK MPB
. . . ! . . . . . .
CAMSHAFgEAFINGBFACKETS, BEPLACEMENT
OIL fHEBMOSTAT ANO PFESSURE SAFETY VALVE BEPLACEEN
Preliminary Steps
retuved a@ss to the @.haft
CFANKSHAFT FBOT SEAL CRANKSHAFT BEARSEA! CBANKCASE VENIIIAfION {CCV) SEPAFATOF REPLACEI ENT OIL PUMP REPLACE'ENT INJECTORCOPPERSLEEVE
fh.
lllwing eFtunts md lo
b. bing
' t
CompEsion BEke Solenoid Valve

Camshaft Assembly
UNIfINJECfOFCLEANING
VALV STEM HEIGHT MEASUFEMENT VALVE STEM SEAL REPLACEMENT
General lntormallon
nubered 1 7, wilh malchina uppr and lower halves. Ae sure 10 nole and mark the 6respndino iournal numbeF and insralllhem i rhe cofecr *qun6 wirh marchd upprand lwer halves,
Cams hatl bearinq jou rnals are
DullhEngine Elctronic Codrl Uni (EECo) sell learig capability, il is nsBssary lo sl learned EECU pamelers atlerseruicng some
nain{l16d componnis, This llNslhe EECU lo lea lhe new conponsnts bhvior After sedl.inq is comp ele, pefom lhe 'Leamed
REPAIB INSTRUCTIONS, PART 2

Camshaft lnspction
To arcid
uneoe$ary derhati.o, coduct a lhoroogh ispclio ol lhe camshait bfor feinsralling ner fpracing lhe beafing bckei
Brackel Replacement Procedure
L
FgUl3fubB'ngBrcchlLkrHtr
WHEN BEPLACING FACTOBYINSIALLED JOUFNALS rt a camshaf jourar has sezed, Do NoT tlx rplcamnl baring bEckl wirh rh6 o rig lnal laclory-inslalred bearinO brackrs. This is bsause lhe oiqinal bearing bckels were alion bored whe lh 60in ws manutacluEd. A lsden bEckels must be
Bemow lh lower beainq b.kets usng a pry bar The rearnosl N 7 bckl n b Bnded by usinq a soft-hced manet and tapping sid lo sid. Crhealignmenl pins should come oll the cylnder hd with lh bEc*rs. lr or, remove the pins.)
Whe rptcing a cylindr hd. do nol mix bearing b6ckelswith original bnng bEckers |lom lhe old cytinder head. Use onlv new be n0 bckls on a nw cvlinder
WHEN REPLACINGNSTALLING AFTERMARXEfJOURNALS
ll the@ are aleady repla@nnt barlng bEcksl assmblies on the engn, ad on or ore assmblies re damaged all s*n 4senblies nusl be eplaced. Raplacmnr backt assmblies can be defillied by lh6 dal-shaped aliqnm6ff pin holes,
2. 3.
Clean lhe conlact sulacs of rhe oylinder hd and lhe l@e ba ng brckets.
For replacement bck6l assmblies usd ln lolions 2lhrough 6, both alignm6rf pin holes ar6 oval-shaped iof sidelesde adjushenl. For bdckls used in lo@lions 1 and 7, onealiqnmntpin hol6 is oval-shaped for l@nr-lo{ear adjushert ihe se6nd pi hole is ound wirh an ignmenl pln lrk th boaring caps lo lndile lhal allermaiket being back6t and cap ssmblies haE bn in$nd
Usinq a meiatstamp or e dric iching tool, mark th 4 beanng bckeis and caps wilh lhe nub6rs, 1 th@ugh 7, dlcalig the loclion r whch ech ssmblywilrbe
e as$
Do not
dces@ lc@ la pnch lhe ba.ker wh atkng rheit p6ilan on the ctndet had. Daage lo rponenE ca, resu.
^caurtoN
REPAIB INSTBUCTIONS, PART 2

lnslall 12 nM l@liro plns lh the pls kil ctlinder head ocalions illuslhled (Fisur6 378). U a plasc mallel so as nol to dahae the lomlina plns.
ar rhe
Fnal Sleps
lnstall ihe followig cpNnta which @re rcmoved fot @s to lhe ashak beang
bttukets (e dppto4iate cmporent lor insbnatun ptudrcs): ! Camshaft Asambly
r r .
1.
Compbssion Brak Solnoid VaN

Va
and Unn lniclor Adiushnr
Va v
2.
5,
Cdr A$6mbly lnsiall all prdiously rmowd bls to lh6 qbund (negatrve) bttery temrars. Strl lhe noine, check lo lks d ppr
lhei spocliw marked positions
lnsrallrhe new lower bea ng brackels al

on
ihe
6. Chec* lhal lhe bearing bEckels can siqhly on the localing pins.
m@
. .
Bckr Nos.
Braoket
1 and 7 shoub rurn sllghlly lodard ahd bad< at one side.
N6.
fiuSh
6 should
ove
BEPAIR INSTRUCTIONS, PABT 2

OIL THERMOSTAT AND PRESSURE SAFEW VALVE REPLACEMENT
Pressure Safety Valve Removal
Beloe aliehpthg to rehde lh6 oil pbssur salely El@, apply the parkirg bk, shifi ido ellaland horoughly d@n arcund lhe salely
Figu331_oilPresuEsleybfudbd
2. Clen
ihe cder and cll ndt block s@ling
3.
Fepl&e lhe O-ihq on the
6L
2'olP'sUesfelyvb
1.
Usng tho o Ivdw sekel J43051,remde lhe sally klve er and wlv6 as a uni. Ensur lhal lhe seal is de remowd wilh tha cover and w. Dispose ol lhe valre.
4. 5. 6.
'iguE3P-nemdngs.l.lyvawcdeldnng
lnsll a
n4
valve n lhe
cder
lnslal the new Elve and
tur
inlo lh
Usig a lDrqu wnch, lighlen lhe valve ac@dino to sDcilicalion.
BEPAIR INSTRUCTIONS, PART 2

Oil Thermostat Valve Replaceent
Belo allempling lo rende the theftuslat valve, apply the parking b6ke, shift nlo ne{n and lhoouqhly clean aDUd rh vlve head.
1. Femow rhe
rhem6r1 e norith.i oir tille. housing and diserd,
2,
3, srall a
nM rh.moslat vdw
wnh a
| 2.orPrc!&shtvE
Slart the engine ahd check lor loaks.

CRANKSHAFT FRONT SEAL REPLACEMENT
Specal Tools
Handls
D h Erious u*s (rb
25 mm
hob)
Seal Removal
1
Femove lhe fan b ade
lh6 lan clulch
2.
Comp@ss rhe berr re nso ne r (u shg J 44392) io lese pr6ssu on lh f and @olanl pump dd@ belland remow th6 blt.
Comp4s lh6 accessry belt lensioner (lsing J 44392)and rem@ lh d ve beLl lrcm rh vibBlion damper puttey, r6f'iqerf compfessof pulley ard alternalor pulley. lf equippd, rcmove lhe font engina PfO
Femove ihe mounring lasleneF thal secufs lh drjve bell pulley and bralion damper 1o lh crntshafi hub. SepraF rh pully nd

Seal lnslallallon 1. Clean lhe seal sealing surbce
the ckshalt lrcnl cowr nd lhe sealing suface ol the cfnkshalt hub.
2.
A$embl th handl6 (9992000) and lbnl mai seal removerlnsllLer (33300021).

Place a ew cnkshail flonl seal on the cnkshatlfbnl seal rmowrnslall.
3.
NOfE
The cankshaft lront sl
l 3 cEnk
hdfi
fub
4,
Posilion lhe cankshatl fronl seal
/AcaurroN
When handlkg a vbn danper be @@tut not damg tha housing. Dals k lhe td hoBg n rcndet the danpet ireect@. t
ro
cEnkshalt hb nd cEnkshaf font cowr Careiully dri@ the seal ilo lhe @rer unlil lh lool bonoms aginsl th cankshaft hub
dafuged, the viaion danper @nnat be

repaired and
Bl
be rcPl@d.
6.
Fem@ lhe 6rank6haft seal as tollowsl A, D lrl@ 3.5 mm (0.138 inch) holes in lhe etal rim l th crnkshalt llot s@1.0se lhe holes in the im ol lhe lmnt main sL rmoErnslaller
(33300021)saaulde.
NOTE
Apply grease on lhe end ol the dnl bil r chips lom geflinq ilo lhe enqie,
Using rwo
pr*nl
solhappig M5 screws ol sulable lengt\ anch lhe dnkshan l@nl 6ea removetislal er lo lhe seal.
c,
using Nvo
M 10
iasleneB ihfeaded lnto
r6mMrnsraller, remrye lhe
Femove the looland nspecl th6 seallo mak sur lhai i! is pfopefly i.staLled.
Pl@e lhe vibalion damper and lan pulley on the crankshi hub and iiqn lhe tuslener ho es. lnlalland ghln rtu mounna lalene6ln fivo sleps lo specfcaton.

cmp@s6 lile ac@s$ry bei rensioner (sino J ,14392) and insian fi driv6 b[ @r lhe cnkshalt pully tan d ve pu lley and
9. Conpress the lower bll lnsioner lusing J 44:192) od install the div6 boft Ner the ckshaft pulley, lan drl@ pulley d
Pulbyld,lio
l3
c'alshafi
Hub
7.
ll equapped, nstalllhe faslne6. Tighlen lhe
Fhu6
3e0
Dnw Bd rsn6roner ftor

CBANKSHAFT NEAR SEAL FEPLACEMENT
Special Tools
Handre *irh
vai
s usas {fib 25
horo)
nopno tvpa
si
(Esnrian
Neoprene Seal Removal
2. 3. 4.
lnslall lwo M10 screws to use as handl6s lo
/AcautoN
lEaw Do nc,t atn1pt to Enove the twh@l wjthtut lE heb of an assstaht a suta iflng devi@. eitue heed Lks @ut aY @tt k @vde kiuty d uapey
The
Fmore lhe llyryheel.
wh@l
U6inglhepuler,9990192, and the std hamr, 9s96400. caE u0y rem@ the
P*tut
1.
Elu ly rem@ lhe llywheel senso(
REPA]R INSTRUCTIONS, PABT 2

Neoprene Seal lnstallation
L
2.
CIn lhe llywheel, housng nd
ckshaf
Align proprly and 4semble lhe ew seal on ihe sl hstl r, S998238
N}
Freun
@-
Fwh.t ttuhnad
5.
lnsert lhe llyoheel mouff ns sc@s linger lighr. Rmove lhe M10 scfss l hsrt th remlnlnq ounting sr4s.
using a tofqu w@chi ighlen lhe moufthg scEws in sequenc6 acddig lo
Calully inslallthe llywheet s6nsr nd connecl n lo th haess

3. using lhe handle, 9992000, and lh seal inslallgr, ca@tully lap the seat nto the tlywheel houshg util th6 is @n contact.
Using lhe M10 scrows as hadles, wlh the help ol an Gsistant o a tnhg ddiE, asseble lh fyryheel o@r the d@d ad alignnent sluds on lh6 mount ng suface.

Teflon@ Sal Removal Tetlon@ Seal lnstallation
1-
whed s hav/. Do tul attepl lo etuve flywheel wlhaut the help ol a a*idant a suitane tiltng dqi@, Fa|u@ to h@d hs auti nay rcsult n sevqe pe6a1 kjLty and ptaprly
Ih
tE
^caurtoN
lnsialllh plat nd lhrust sw pa oll@1, 9990166, ro rhe c6nkshalt. fiohign lh 4sembry sc@ws *culy,
NOfE
firake suB lbal lhe plale ol the looL is pGilioned propo y in lh cnkshal inl6rnalgu d and is nt agansl the cnkshall belbfe lighiening lhe
L
2.
Remwe lh6 clulch Gsnbly

Ca@fuly rmoB lh llywheel
sesr
3, stall tlo M1O scr6m lo se as handl lo
5.
Usingie puller, S9S0192, and the side haer, 9996400, lully rmow lhe seal. Mak su thal the tools are lee ol
NOfE
fake cae not lo damag lh cEnkshan or llywhal soling srfces. Slant the tools inMrd lo gel a qood grip on the cnkshall rear 6eal.
lscldA$mbly
2.
lnslall the spa@r. a8aaofi 3. ot toot. 9S90166, on lh rhru6t screw.
NOTE
Ths spacr is imponad beause il delermnes lhe nstallalion deplh ol lhe cnkshaf @ar seal.
fap oul lh cEnkshalt ar sal. 7. Thorcughly clan lh saling sudaes oJ th nylvhBel, flwhal housinq and cnkshaft.
6.
REPAIR INSTRUCTIONS, PABT 2

3. Th8saling
nsla
lalion g that shuld b eft
ng is supplied wllh a
5.
hstall ft cowr and hadle o@r e assembly. cnlr rh c@ oEr he cBnkshaf feaf seal and thfd lhe handle l kp lh cover in poslion.
4.
lnsralllhsalwlhourrcmovingrh installato ring o@ lhe thrusl scw, sper
6,
Turn ih handle lo pre$ lhe crankshail ar seal ver lh6 cnkshal d inlo lhe lruheel housng, when ihe cdr bonoms
od qinsl the .pacer, the rear
sl
ts in
7.
/
Bem@ lhe c6kshall ar sal installation

lnsri rh nywhelmouting rcreB lthqer lqhl. Rmow ihe Mlo *ws lo inse the emaining moullng sctu.
e@E
1 1
sing a lorque wench, llqhtn th nounri.g in *quence a@odno 10
cafully inlall ie llywheel sen$r and
7N \+
\ ^
Ff.sss_Fl9$li*l|rel.lljlon

CRANKCASE VENTILATION (ccv) SEPARATOR REPLACEMENT
CCV Separalor Removal CCV Separalor lnstallation
'
1,
Clean the mounlingsudaces on th6 cytinder block and lhe CCV spaGloi
2.
1.
23_
gaskl, assmble the CCV Using a sepaElor on lhe cy inder block.

Usinq alorque wrehch, tighten th screws amording 10 6peclicalon. Anach r,h CCV hoses.
Turn on lha main swit6h, or
re
Dsennect th battries, or iurn of lh main

Clean the cylider block afound lh
3.
4. 5.
ccv
sepalo mounlig. Remow the
r@nnect th
ccv sepator fo
the
6.
Slart the enline and chdk for leaks.
OIL PUMP REPLACEMENT (IN CHASSIS) t219 MUI

Special Tools
FrpheelTunie
roor (BsnaD
o 311 O
'7'\'\''
i#btlionsyslm
2PUmpodlelP'pe
6. 7.
ll necessary, rctal th cBnkshan oul oi t wy usinq llywh61 turning lool, aBa0O014. Remove lhe oil pump lom lh brjna
p.
Oil Pump Removal

1
ll nol akeady done, remow tre oil pan.

Rmov the pump ilet pipe and straier
2. 3. 4. 5.
Oil Pump lnstallation 1. Clean a[ pans b be esed.
Bemde lhe php outlet plpe.

Reove lhe cbssder p pe.
2. 3.
Atlach the oil pup lo the No. 7 main Usinq a lorque wrenoh, liqhten the amordino to specicalio.
Beow lhe blod( stllee plat.
sc6
AcaurtoN
Weat gloves wh handng he ock stienet plat. h has .haP edg6. Faitu@ to heed ths uon @old Eslt in sMre pe@ml niurv.
AcautoN
Make cenak hat lhe b@ing ree s n g@d cohdin and propely insfaled on the bing @p. Faiue lo h*d hs auton nay esul in
everc mnp@eit daage.
Using w scrws ad assebly 1oo, 9994649, anach block slitlener plale lo lhe block. Oo NOT lorque-1ighlBn the M@ws
5. Lub cale and 4semble na O nhgson lhe ilt, crossowr and oul el pipes.

Asebl6 lh cro*@er and oullei
lhe pump housing ed instal ih molntng scrcws ro secufe rhe plpe lranses lo lhe
ppes n
12. Apply
Usig a lqle wrech, lighte th slif6nr plal *rws (incruding pipe llange scr&s) in sequence c6ding to spcifitio.
a. Assmbl6lhe inlel p pe and
rAcK-appoved seahn b lh wms bel@ lhe llywheel housing and timrnq geaf plale nd bhreen lhe mounina p at and lhe cylider block.
a 2 mm t5/64 inch) bead
ol342sx33
strainei Asmbllhe pipe and slEiner inlhe pump

housig and on lh block.
Usi.g loqu wrcnch, liqhln lhe @ordlng to specil et on.

11. lnspecl th oll pan sal nd
6c@s
rplae il jl nessary Lubricale and assemble th sear
appry a 2 nm (164 nch) bead or 342sx33 ,IACK appoved sealan to th *ms belw@n lhe lronl s65l 6ver ard the cytndr
14. attch lh ol pa to the cytindr btock,
Usingloquewnch,nghlnrhesc@wsln
seqeno dcdinq lospecilicalion.
AcaurtoN
Use a s,leel washer Do rct use a Wet @sher Do not u@ an npac wrcnch lo insta rha dan plq. Falu to h@d hs @uion nay resu? n
16.
1T_
Check sysl6m oil pre$uc through lhe pressure sensor poa. in lhe oil lller housing.

INJECTOB COPPER SLEEVE REPLACEMENT [213 Ev]
Tools and Equlpment
lledr
coF
sleN
r4 itu*dial)
rnjeb
copper
sre4 EnHior
unr hledo' P'ord'on
sr*s (&d'D
unr
ndd
Bo
cdb'y *anq Fqs
unii rnidor BoE
seaf
Pruo
(Es^riaD
))
uir
hje see
fp
(Esedd)

unr 16ftf sre&Fnamf (E$diar)
F *heerluriE d (Esdiat)
sreqnq
rm bf hr'a iq ui!rjd
t__-l
offi
unir
hiftre.rc cre
ino
K[ (EssrhL)

Preliminary Steps
fha lolowng
sl@@s
ovrl f @s
(@
need to be to tl njEclot @PFt Et'Gr'lE DrsassEMBLv or
.@po@ts
Cylidr Head Cover
Copper Sleeve Removal
1.
d6w6 is nt beig reoved lmedlately, nslalllhe pfoleclive plug inlo lhe unll njeclo boe or lh cyrindr head to pDlecl itl@m d6bris.
lf lhe injclor
NOfE
Twosealing
nqs are required lo coverlhe luel
3.
Bemow lh plug lrcm lh6 lwer i@nl side oj lhellywheelhousig and nsrall lhe llyryheel lurning tool. Turn lhe i ywheel unll lhe plston ls t its lw6st posilion in lhe oylinder.
Esue
2.
unr hFcbf Eo6 Pddi@ Pruq
lnsialltwosealnqrngs n16 ng lhluigallry
Fsur 4o5
Fwheer tumrnq roor
REPAIR INSTBUCTIONS, PART 2

NOTE
This is lo ensure lhat the @pper slede iappinq lool does ot damag the pislo. due lo tool
NOTE
Applying gas6 willcaplure copper cuttlngs and prryenl lhem l@m lal ing dMn inlo the oytinder
Estheluming lool
is we lqreased
belo
6- Thad lhe lap in small lhdemenls. Bemo@

the lap and w pe olf the grease ad opper sleev shags. Apply fsh greas, reinslall le lappng looland th6ad mo ol the copp6r sleve. C.iinue this process to thread lhe tap a I lhe w5y lhrcuqh lh copper slerye unlil no resslance is ilt nd the rap tr.sfeelrTppino in small inc@menIs and rem@ing lhe shavigs inimzeslh6 chance ol shavings talling into the cttinder and the sledo lurn ng in lhe cylinder head. Ensure lhal th 1ap is coplBlly through rhe
afl emPio l lurn th6 nwvh|.
4.
Adjusl the I nm rp s lhal il rds a mlnimum ol25 mm o t hch (dimension A) lm lhe ed ol lhe lappig lool.
NOTE
This slres thatihe tip ot the copper strye is lapped l the way throuqh,
FlguEoT_fpPngTodhddl'oi
AcautoN
tt the @pper sleere is not @nptetey tapped thto to lhe apenhA of the liD. an end p@ the tp nn brcak off and fall kto t cylkdet
ol
nlolhe cylnd fhtd rcsu ndanqetothe .ylindet p'ston. vatves ar turbochatueL
tueads are no c conplelely thtough the tp he cappet sleeve, lhe tp @n bak oll an t la
^caurtoN
ot
5. Llbrllo
the iip oi lhe
mm
7.
Femove the tap and lappinq t@

Usng the
chipcuum, remove any remaininq shavinqs lm lh coppr sleeve.
REPAIB INSTRUCTIONS, PAFT 2

L
lsiall lhe nddor boli in10 the ehd of the qrfacror rool. Adjust rhe bolr unrl ir exrends approximalely 22 mm (0.9 inch) beyond ihe end or the lool (dimension A).
AcaurtoN
Make e
steM
tip
cplelely into the 6ppet ele* belae atlenplhg lo rove l ar the np af the elee@
nay eak oft as
th ext.ror bo s tneaded
en siusty
t s
ewed.
Ths btatn danage the pston,
Fsur .oa
adusrino copper
sl*rc Enccbr
Eoh
10. T ghlen lh sl
scrw of lhe exlEclor lml lo secure the bolt- Makesu1atlhe set sc@ is seated against rhe llat pan ol lhe qt.tor
11. Plac6lh 6n.aclor
lool w lh lh boll inro th6 njeclor bore, Make sure lhe nut o lhe spndl is backed ofi so that lh lhradd end can be coplelely installed lhrouqhlhe copper sle4e 1 p, Hand lighlen unlll the boli bonons oul in lh dM.
NOTE
When lhe coppei deM is rmovd, mak sure lhal lne exlEclor bolt is extended at teast one thead beyond lhe coppr slede. It not, make sufe thal no paft oilhe copper dM has broken of nd lalln ilo lhe ctlinder
ue .n bds la Eo@ wet d@ws, ot danaae to lhe nectot bore @ t*ult_

Do not
^cautoN
REPAIR ISTRUCTIONS, PART 2

13.
Fem@e lhe leo @aliO rings ffom rh luel p6sage. using rhe chip euum, rem@ any remining dbis fom lhe injector bore.
\r
16.
lnslall lh nletor bore ealino lool (J 42885-25) ro prc1e6r rhe tuel pssge rea and prdnl db sfom enle ng, Use lhe unh njeclor hold ddn boll io seu6 lh
15. Usins lh
Using lhe bfush, clean the cyllnder hd
iicld bo wll6 lor lhe @pper
deM.
inislor
lhe @pper
sle*
bo@
cleaing kil clean seal of th -ylinder hd.
NOTE
Th ijcor bo sealig tool ust b6 us6d lo pBsnl did lrcm nlenna fte tuelpasege.
NOTE
The inje.lor bore seallng toor musr b used to prwenl dbris from elenq lhe iuel passoe.

17.
Using lhe brush, 6lean
opening n lhe cylind.
Copper Sleeve
1
Ensu lh pisron is at the lMst positlon i the cyllnder ll not, us6 lh ryryheel luming lool lo place le piston al its l@ost oGilion.
lnstallation . r
fr
Frqurc 4r4
:tr>.\/
crdnnq
hl*r fp BoE
Flsu15_Fly}hsdruninlftol
NOfE
Th injclor bor saling lml musl b usd lo prdent debfis lfom enrering the luel p6sge.
NOfE
This is 1o sNuB lhl lh @pper slese installation t@t does ot damaqe the piston du
when replacng lhe copper sleeves, l s impdanl lo check lhal lh .lewe bo in ihe cylindr hsad is lrs from any carbon dposils or olher Esidue 0.e,, pie@s ol O ing, eic,) beloe nstalling a wcoppr d*. Rclean ii
10
U6ing lhe chipEcuu, remove lldebris from lhs @ppr sle@ bore.
SEFVICE HINI
so can resuli in ey iirv.
19
Bemow he inleelor bore searins lool rom the cylinder head, Using lhe chip vacuum, row rry rminig deb s.

2.
BfoB inslalling the copper steeve, nspect tt fo ensure th6t It is th 6r@l pat.
AcauroN.
Failute lo u@ lhe proper bi can result n the bl btffikng of klo the cytnc! head.
3.
Lub cale a nw @pper sleqe Ojinq wilh c@lanl. lnslall lhe O ngth6mppr dee and lub cale again wlh coolanl.
Always use a
Place the
nN Oiig.
n*
@pper s ev6 on lh
Filure413-sred!n!Brvrl||afon
AcautoN
qelorc insta ing he slee@ on the sa atn t@, nsp@ lhe taol lo ensurc lhat n js he carect
l@1. The
sula@ lhal has a nachked crculat rcces. Use of a @l wnh a penedu flal bonon ay esult n dafuq to the pper seqe.
rdt
taol s dentiled by a
bonM
5.
Usng .alip66, measu@ ihe $edoing bil lo make sur lhal lhe pDper swedqing lool s u*d, Measuremenl shou d ad appmximarely 7 I mm. Also, vefily lhal the ength of lh6 Medgig bil is 10a mm.

6.
Thread th swdging bll complelely inlo llaringiool undl lt siops (linaertiqht).
ie
s.
NOTE
Swdqinq bil ca bo ordrd
spar pad if
cafelurry pra the sl4 insiallion l@l (wlh new copper deM anachd) inio the unil injeclor boe ol the eylrnder had. Carelully moE lhe .opper deae dMwrd irno lhe njector bor so lhar lhe $edging bn is guided inlo ihe injector tip boB in rh cylider h@d. Push downwrd on lhe islallalion lool using hand torce io move lhe coppei sled downwad until it bonoms L on lhe injeclor sle* seal n the bottom ol lhs iniclor bor6. Us lh unil ini4lor hold dow and bolt to hold ihe lool in pc lion. To nsur thal lhe @ppef sleere s bollomed i lh cy ind6r hd,lighln lh unil inietor hold down bolt io speilication.
NOTE
emo@ any oll lom lhe iiector hold down bo holes 1o a@id trydraulic l@k lor lhis slep and whon tho inieclof is lnsla led.
7.
Loosenlhe sdq ng b 1a0deqrcsbirc installing the tool n lhe cytinder hd.
Failure to l@en the s@dgng bit lhe bit bekg twEed ot bfaken.
^caurroNn re
in
a.
Lublcale the swedginq
REPAIR INSTHUCTIONS, PART 2

10. Fla lh coppeslede
by turning the nui (1) clockwlsewhrle holdlng lhe spindl unlil lhe swedqinq bil has been pul d compltlv
lhrcugh the copper sleere,
Falute ta hold he
^caurtoN spkdie an esuh
in a twisld
Flnal Steps
nstal lhe folowlng copo@ts whch were rcove.r fot @s Io the inlector copp
sl*v6 (@
ENGt|r'E EEASSEMBLV
lot
1 1
Remove the s ewe inslallrion rml from lhe
Cy inder Head Corer
NOTE
Itlhe inleclor is or being

UNIT INJECTOR CLEANING
Prelminary Sleps
Rem@ lhe ioll@ing .omponents rom th ngine (s ENGINE DISASSEBLY ior
Cleaning and Inspecton
NOTE
Since the lnil ijectors opeEle at very hgh tue injeclion pEsures,lh no2zlolip spEy holes ad lhe inmdiale aea around the spEy hols rehain cl6an and l6 ol @|bon depGls. This leaves the cap nut seai suffacB as lh nly sudas which requires a thorouqh cleainq.
. .
Cy inder l@d Cove Rocker
Arn ShanA$embly
clen rhe injeclor cp nut surface lnslalllh sling plug,9998251, inlo th uit iiector bore ol the cyl ndr hd io pfant dirt and debris fo entering lhe bo,
6lotl@s:
the njector
1. Fen@
lhe two Ojigs nd dscard th O{ings.
fo
2.
Covr lh O{ ns g@@es and the conplete arca between the qrovs with lap o equilenl lo prdent conlaminanls lrom q6lling inlo lh iniecloi opning lorll)e elect.il
3. Cdrlh
4Srde a
shoii scti of 6 mm {0.25 inch) lD hose over lie injeclor nozzle lip untl il covB apprcmalely halt lhe nozzle 1p length. Thls is cassary ro prcrecl lhe nole spy hobs nom dmaswhen claning lhe cap ul sal suface.
Fis
r23
rn:brrins nsdo' BoE sar.E Pruq,
r.rnjeddc6eNdsr
H@lrurn4 Nd6
rip)

5.
with th unil ijclor nozzle lip sp6y holes prolected, retullv d lh p nln seal sulace of hard caon deposits sing a wlb whsl. Apply oly ligh nominalprasu l hold lh wir whl agaiEt lhe injector suce tor short priods t llm.
cl6aD any @maining @rb;n tjsnd had lools slch a a hand MEper or medium
git
Ailer cleannq, ispecl th inicto. nozle cap nul seal6ufla@ bf pttiq or lald dage. lf lhe i! piting or olher danage,
NOTE
Piting on sufaces olher lhan th p nd s6ar does ol atfecr rhe tuncon ol rhe unir ijeciof and
3, 9.
Frsu6 425
lnsrall new
rings rhe gfooves o me
Lubncale rhe injslor Ojings wilh clean
Cr..nnq rl.0ror c,p Nor
s6r srac.
Fal Steps
lnslallth .llowhq 6pots on lh gine {s@ ENGINE FEASSEMBLY lor pcedur6s):
AcaurroN
dercy to @ qc*gve p@e n haldng l wlre wh@l aganst lhe nj.t p nut Eurta@. E@4@ lot@ @n dange ha cap n tuc, naking lB kject
mow.
rhe@onwi
be very had
Awd the
dfi@ o
. .
Rocker Arm Shaft Assobly
Cllinder4d Crer

VALVE STEM HEIGHT MEASUREMENT PROCEDURE
I213 FBI
On engins exhlbllng poor pforman, smok (ar imes) and a noriceabre enqe mss (wirh rhe symproms gefling worce as rhe engine gers honet, may be an indicalion ot valve seal
cssion. A d.6 in rdc (lv6 lsh) b6iw6en the val rocke and vlve yoke (bridge) can be measured al lhe valves 10 delermine ii seal e@ssio is occufinq. ll vdre sal fece$ion is suspscr6d, lh6 following p@edfe ca be sed 10 easue valve slem heighl, fo peorm lhis measuremenl. a val slm hlghl measumel sauss (lool No. 35112461) nd a depth icmeler are requed.
NOTE
For detaled inloration on rccker
am shft
rmovl and installalion procodures, reler to lhe applcable sclion ot lhis service maual.
I
3.
Femore
lheulre
yokes {bridses).
Femo@ conpornls as necessary 10 gain @es to lhe cy inder had (lw) creL
Remove the cylinder head cover and r@ker
NOfE
The valve yokes musi be installed on the same sel of vlws thal lhy wa removed lrcm. Beio@ femoving lhe valve yokes, mafk lhem lo idnlify lhek l@alion and orenlaon, A in@fecily hstalled vlve yok causs sdc eglne damaqe due lo a dropped valve. For propr valv yok removl and inslalLalion, fetef lo lhe appbpriaie *ctios in lhs sruic maual.
2.
rcmvng th teker 6halt as@nbly, allows the pist@s to drcp fton Ihe be of the ocket atns, lf a pstan drcps au, igtt not be tut@d. at n nay be dit'ficulf ta p6h he pjston fu|y back nto the borc al he rcclr am. Also, pislons are a nal-l lo lhe bciet am, and s nadve ent nk-Lp of atpts nust be avoided. A*endig tha @cket an shalt to lhe engne, or apeathg an qhe wth t Bngne ak pjss ot fully et@ed (ot ssns), rcsLlE n btakage al vahe tn @nponents and siq"iliBnt engine danage.
I 2. hbr
On nak6 quipped wjk an enqne bek, use suable ie sEps ehaniB we lo etk Lhe pi.ts in the t@ket fhe atch betwee tke pstore and rccket ams nust be naktaned, Felure L. s@ute the gine bke psts befo6
^caurtoN
a'
brF b'c

4.
Fm@lhescrews securng lhe unit hjecior ha.nss li bar lo the cylinder head. Slide lhe li bar outward to prwld suficient deaEn@ lor lhe lalve steh height m@surcmenr qauge ro be insialled orer rhe l@ springs. Do nol d sconnecl lhe harness nnecio6 lrom ttu unt iniclors o cul the lie stps lhat secu the han$
6.
Plae lhe valve slem helqk rigadlrcmff oause (loor No. 85112461) der the vatue
spring ol the vatu lo b measu@d_ Make sue lhe lool is lully seabd on a clean
NOfE
Mak sur6 lhE aB no parlicles ol ay knd bbveen the bottom of lh valv slem height measuremenl gauge and the eyllndei head sul@8. Parlicl$ belween lhe qauge and lhe cylinder hed slac r$olls in an
imnl
|1wnryH res
5.
Set lhe doplh m cromlr b A.l0 mm (0,319 lnch) ro meas!rc slem pfotusron-
il
FiqJE4_seD4jMi@mder

lve siem helghl esurnt gaug and
fre micomeler spindle
nole i, Ihere is clence btuee lh end ol and lhe lip ol lhe Plc lh dplh micromeler on lop ot lhe
ll lhere is claEnc brweenlhe tD ol lhe vaw slem and th lip of lhe depth micromeref spindre, rve hlghl is wilhin spcilicato.. Measure lh nxl lve sl6 highl Ginq lhe same
li El@ stem height is ls lhn 8.10 mm (0.319 ich), as ndrted by th lip ot th dprh mi.rcmete spindle corfacli.g lh lip l th vlve srm, lh valve seal is rece$ed, Fepla@mel ol th rlidr had is
n#$ry
Posnion lhs unil injcIor hamss lie bar lo ihe cylindef head,lnslalllhe sc@s and righle adording lo speciicalior. 9, nsrall rhe
vdre yokes to rheir
ginar
lnsla I lh rockr am shaft ssembly and emove the lalne scunq th 9in6 bEke pislons. Adjur vdE lash as 1l_ lslalllh cylnder had
@Ei
qah access
lnslall lh components lhat were removed to 10 the cvlid had covr

VALVE STEM SEAL REPLACEMENT [2r3 MVI
Special Tools
vr sFne compresor {EssiiD
Fwhed fninq
Toor (Esnriar)

Prelimnary Steps tvd f ae*s
fh fo owng
nee.r b be to th vIv sl $Is EN6lt'lE DSASSEBLV l pro@.urcs):
@poent
(* . .
cylidrHadc@r Focke. Am Shaft Assembly
Seal Removal
NOTE
When eplaciq lh vd sl sals, lhe pslons musl b al fDc when the are fele4ed so thal the ulves do nol dop inlo lhe cvlindr.
vd6
1, Usinglhelywhellurninglool,43400014,
3. 4.
Beore and
dl*ad
lhe valve ste seals.
rclale the c.kshafl so lhal the pslons are al TDC ior lhe appopr l pan ol cylind6B wh6 stom *ds are belno pla@d.
Uslng a dean clo1h, thoouqhly clea all egine oi of lhe lve slem and valve qulde.
Seal lnstallation
Applylhinllmolcleanngieoi lolhe outsid daneter ol th l@ seal guid lool

oa rhe n4 var@ stem soal lo void damaqe lo lhe sal as it is
and ro the sealing ips
NOTE
Do NoT apply ot 10 the ner suda@s ot th s6a thal conlacl rhe valve guide. These suriaces ust
2. 2,
Usinq lhe valve sprg @mpressor l@1, 9090210, prcss down on l,te springs (one al a lie) and .emove rhe valw rrainrs and spfinqs fo f lhe cylinder
Place th6 sa! qDid lml 8890001 posilion onlhe valve stm.
, in
3. Place a tue srm s6al in posilion over lhe guide lool ad onlo ihe vlve st6m.
Using lhe appoprial ed ol lh seal inslsllalion lool, 851 12460i seal the vatve slem seal o. lho vd guide by genlly lapping lhe nstallation lml wirh a ljghl plaslicor rubber mallel. when ihe slis tullyseat6d, a nomd"sp ng-bacL otlhe sealwlll occur, inq a mdmun gap of apprcximately 0.5 mm (0.02 nch) betrvee ih6 boltom of lh sal and lhe shoulder sula@ on theElw 9ud.
n*
Use proredve goggls or ye inury could
le
LcaurroN
salkg
5.
6kg
Us hty taps wik the haet when he sal o awid danage to the sea as wdl as tl lop thbet potli at ,re
g4
Usins lhe lw sprio compd6sdr, 9990210, installthe valve spring nd val@ relainB. CaBtully lap on the tve st6m wilh a pl4lc or rubb hammer 1o ensu@ iat lh lve leepeE aB pGlioned
NOTE
r@1, 851 12460, is deslgned ior MPO and MP10 enqines, lhe apptopriat6 nd of ihe tol lr lh ngine b6ing
use preict goggls or ey lnlury @ld
seal inrallarion
use
or MP7,
U*
6.
Mo lh6 wtu spring comp@$r to the cylinder ol th cylinder pai and epeal prc@doe. Foiate ihe cEnkshaf so lhat lhe th pions 16 ar TDc fr rhe nen cylinder
ndl
palr and pat lh6 prccdure- Conlinue on and repeal lhe pl@duelorlhenal
Final Steps
IhI
(ee
tl lllowing coponents vh.h werc rffiove.! ot @ss to llB valve slen seals
ENGNE REASSEMBLY tot ptuce.rus):
. .
Bocker Arm Shatt Assembly
c\,tinder Head cover

MP8 EURO 3 ENGINE SETUP AND ADJUSTMENT [200 EA]
NOfE
Due lo lhe Enge Eleclbnic Conlrol Unil (EECU)
sell-le
nnq capabilily, il is n.6ry lo learned EECU paEmelers rr sgflicinq soe engin{lald cmpnents. Ths allM lhe EECU lo larn the ew componenl s behvior Alld seMcang is @mpLele, pelfom lh "Lafned Dar R6l" ocrd in vcaDs.
si
Special Tools

rnrno
Gd cM Aiqnmd tul

Valve and Unt lnjector Adjustmenl [213 NB,222 KGI
GENERAL INFORMATON
NOTE
Focker 3 Fockr
4
Markedas E1 E6.
Mrkd s
v1-v6
apply th prknq bk blof biinq th engne ovei Remove rhe EMS er suppry luse lo avod stting rh ngn uniddioally- Mk su6 lhal lrr rrrsmission ls not n gear
Wilh lhe eqlnecold,60'C (1,10'D or l6ss, ch{k and adjusr the Elves and njecrof as req!ed lor each cylinder beloe moving to lhe nd], Foll@ ris soqu ece ol cylindeG wh6n d iusi na cleaEnces: 5, 3, 6, 2, 4 and 1.
1.
c.p
(4
Usingthellylvheeliuingiool,3a300o14, bar lhe enqin over manuallylolhe apprcpril camsh ma*ing fr

adJusimeni ot the nlet valres and iniclor for
Rrr sh.wn)
fimig ma*s
tor basic camshalt liminq and adjusrmnl of lh valves d u.ir injcroG a located at ihe lont of the @mshaft lust lotuard of lh No 1 fonl bearinq journal. Two llnes al lhe lop ollhe lrod benng cap mk lh alignmnl poinl lor pGlonlng ol the @mshan and akihg The top dead cenler (Toc) mrk is used for basic camshan tm ng. The TDC alk musl be beleeen lhe 1wo ljnes o the lonr camshll ba nq cap
2.
Using a Geler gauge, chec* the e ean@ ben lhe rocker arm adjusling sdew and the valve yoke (bndse) ol lh6 inll valvs. Beter lo Figure 436,
whenlhefly{heel sal0' (opdead centerror
The engine musl be cod,60.C (140.F) or r6ss, b6lor making rhese adjushers.
cmshalt nakings lor settlng ot valles
.d
@-
wrhout Powerlashr rMarkinSs 1 6 apply ro adiuslmenl of nll ENs, exhausl

valves and injecloG.
Wih PowerLashr": MarkiSs 1-6 apply lo djuslneni ol inLel valres and injoclors. MarkinosEl E6/V1 V6 apply lo adjuslet

3d@6nce is nol wilhin specllcalion, loose lll locknul and adiusl the 6leaance
lf lh EXHAT ST VALVE ATUUSTMNi
(Wlnlouf
POWERLEASHT)
4. 5. 6,
lo pweni luhing and lghlen the lockl to

Hold rhe adjusliq
s.
1.
n r@m
Al lhe curenl camshalt soiing u6ed lor the nlet vlws, adjut the exhalsl wEs
Recheck lhe clearance aller tlqhtenlng th6 Mark lhe @ker arm when adjusien ls
tolldnq th sam pr@edu@ descrbed ror adjusrmed ol me irrr varEs, H{)wef, rhe valv claBnce specilicaion is difisrnr.
UNfT INJECTOF ATUUSTMENT Th unil i.iclor adiushnl is don wilh lh enqine ad cahshaf n the sae poshon 6 for lhe inlel valve adjshenl on each 6ylinder
1,
Lo6en lhe lnjeclor rccker arm adluslng n and lurn lhe adiuslig scrw out (couniercrockwi@) lo felieve tbe proad. Turn the adjusrng scw h (crockwrse) uniir I I mly coniacls lh injcloi Do lol
scrw iam Trn lhe adjustnq scew ln a lrther (tour llals on lhe hq head).
240'
Malk
0@
e rccker arm whn adjushenl is
t slngo llywheliuming iool, bar the engineovernuallylo lhappoprale maing tof $e nexl cvljndeL adiusl lhe ilet %lBq unl inieclor and qhusi valv6 al
Fiqufs 437
adjudhq nh ntedor crence
Hold lhe adjusllng scre to prmnt il lrom iurning luarher and, using a torque wrech, nqhb rh6 jam nll ro spsmcaio.
t'rark the r@ker arm when adjushenl is

EXHAUST VALVE AOJUSMENT (WITH +BOCKER POWEFLEASHTT)
NOTE
The umbe6 o the camshalt preceded by a v ae used lo adjust lhe exhausl valves when lhe egine is equipped wlh Pore -eashrM,
I.
Using lhe lwhed lurning lool,98800014, bar lhe engine over so thal the appropriate V numb3r mafkinq lor the respeclive exhausl valve is be1{een lhe lines on lhe cashal
Press down on lhe rockr arm s shown in Figur 439. ll the rocker arm spnngsi the bk p sron spring should be pul ed ourwad al ihe same lime 4 lhe r@ker arm is pssd d@n lo make nd ensre @ntact wilh the valve slem. Use a sl@ng wie wilh a hooked end lo @lch and comprss lh6 spring. When the pislon spring is loosned tom its sear, rhe residual oil iilm raininq lh 6pr ng is punclurd, allowing lh adJuslment selnq to be moE accufale.
4.
lf clea.ance is nor withi specii cation, adjusr
e claEnc as rcquned, lsing shims
(Fiqure 441) plced top ol lh vlv yk6
a. b, 6.
Femove rhe shim fetainng screw and Emove lh shim(s).
Delrmin lhe rhicknessotlhe shim(s) quifed to malch lh measurd

Make sure lhai lhe vd@ yoke and shim(s) are 6lean. Place rhe shim(s) in position on lh valve voke.
NOTE
DO NOT use o lhan tuo shims. Shims are aEilable in 0,05 mm (0.002 inch) increnerns with lh lhickness ma*ed on lhe sutce. lt Nlo shims are requird io lk6 up lh cleaance, the shims should be ol neadv equal thicknss.
S3.
Measur e cleaEnce belwee the @cke pislon and the shim on lop ol th yoke lbridoe) as sh(M in Fioure440.
ah
FquE
er
Enqrn
conpEson BFh. adiu.r6

wirh rhe requifed sh(s) in pra@, hsian the rtainr *wseunng lhe shim(s)lolhe valve yok d liahln lo .pecilical on. Hold lhe toke securely while llohtenina the
6.
l.
Loose lhe sces holdinq th dle sprigs lo ae lhe spring lenson agdlst th ngin bbk6 ock. a.ms,
w v r@ker arm
Fecheok lhe clearance behreen th dhausl and lhe valve yoke.
SEFVICE HINT
Mark lh spel ve rccker arm as each va adiuslmnl is 6mplled.
EXHAUSf VALVE ADJUSTMENT (WIH 4-FOCKEB POWERLEASHT)
NOTE
The nlmbe6 o cmshafi prded by an E ae used ro adjusl rhe qhausr varves when the enoi. is quipDed wilh Pv[eashM.
Using lhe iLywheel lurn ns roor, 80800014, ba lh ngine over e that lhe appprial6 E umbermarkinq ! bnreen rhe llnes o th ionl @msha berins ep.
3. ieasu@ lhe clearance btwn rhe qhaust @ker am pislon and the shim on lop ol the valve yoke (bndse) shown n Fgurc 444.
Enginos quipped wth the Powe 6sh egine bEke have iwo rmkr ans workig in @mbinalion 1o mnlm1he qhaust vatres. They aE lhe exhaust rockef af and rh brake reck6r rn which are adllsted sepa@lely as
dekibed
in lhe lollowing
p@edu.

4.
ll cleance is nol wlhin spcicalion, adiusr lhe cleaEn@ as lollows, using shims lFigu@ 441) pla@d o Iop ol lhe lve yok
Adjusl ng Exhaust Fock. Arm CleaEnce
Usins th6 dial indicator wilh ngl ereson and b6 (9989876,. 851 I 1493 and 999s6s6), pac the iip ollhe dia gauge on the yk 6 clos as possibls io lh ro.ker afm yoke pad.
a. b, c,
Flemove lhe shim relaining screw
ad
@mow le 6him(s).
oerermine rhe Ihickness ol the shh(s) requircd ro p@ide lhe specitied
ak su@ thal lhe valw yoke and shi(s) fe crea. Prac th shim(s) in posnon on the va !e yoke and inslall rhe eiaining sre. Tiqhrn lhe scre lo spdilicalion.
NOTE
DO NOT se mofe than hdo shls. shlms a ailable in 0,05 m (0.002 inch) inc@menls wllh lh6 lhicknss mr*6d on th sulc6. lf lwo shims ae requircd lo iake up the clea.@, the shlms should b ol nea y quallhic<nes. Bhke R.cbr
Fisure 446
adtBrod Inh
Diar
lBAdusrinqscrew
S5.
Leave ih ller gauge
c. d, e
fghlen lhe tuckr am adjusiinq scr4

B unlil lhe dial shows that the yoke has beon pushed d@nward lo Loosen lhe rockr arm adjusling accordnq to sp6cilicalion.
sre
Hold ihe adjusting scrs lo prevent il rrom lurnn! lurherand, using aloque
wrench, 1ghlen the locknul to
i pla@ belrveen the exhaust rockor am pislon and lhe Elre yoke shim and adjusl the bake rccker arm
6.
Femove th dial indicator and the teeter

Usinq a leeler Oaug, checklhe clearance belwen lhe brake rocker rm rcller and the cam lobe. llhe clafance s ncrect, repeal the bako rockr arm clearanc
Adjusling Bke Bocker
Ah
clearnce
a.
Loosen lhe iocknLn A on the bBke fooker arm adiusiihq srew
a.
Mark rh respclivo .ocker
El@ adjuslmenl
am as each
OPEBATIONAL CHEC(
Ane lh vaLve and unil injeclor adjushenis have been compleled, .heck ngln opeEtion as
complled.
CONTINUAT'ON OF ADJUSIMENTS
Conliue lh prccdur by barig the englne to lhe apprcplale liiq marks and adiust na the vlves ad unit injeclors al each or lhe emiig cylandes. Fo lw th sl6ps dscibed bove to djusl lhe inlel and exhausl valves, and unil
For ngins equipped wllh lhe 4,rockr
1.
Usinq I he llywheel turio ioo, barrhe e9i6 owr anualLy nro @pl16 rerclulions to 6nsue lhal no pslonlo valw contacl ours. lf contct dos mcur, readjusi rh lves as needed BEFoRE
2, 3.
Po@flashN egine brake, lighten the ptate ng afiachnq screws b speci.arion after lhe vlv nd unil injeclo adjustmenls hav been
Slaftlhe engie nd bring it utj to ofa opeling lempeatuf. Or@ normal op1ing rmpeEtu is
lrind, ler lhe engihe idt6 tor a additionat tlve minules. Du nq thistme, the tctronic engie manaoem6nr sysrem (EMS) wjtt pdorm irs own eylindof blanclno j resulinq in smooth ngine idling-
sp
NOTE
oO NOT u$ ny r.o ol p@er onsum nq equipenl, such as PTo or air cond oninq, whon cyl nde r balancino isbeina cadedout
BEPAIB INSTRUCTIONS, PABT 3

Checking and Adjuslng Timng Gear Backlash (Camshaft Gear to ldler Gear)
Apply the parkng bak beloE barng th engne ovr Rno@ lh EMS p@r supPly l$ to 4oid slarling lhe engine nlntentlonally, lrrake sure lhat the
i@,_/_-'_=\
lransmisso
nol n ger
ad move the varve
RemoElh16rrainingsc@sandsp nqs @ef lom rhe cylinder

Dsconn4l lhe wiring harness leads al lhe unil inielors and camshalt sensor coneclor Plllthe hame$ outlhfouqh lhe
7.
3,
FemoE lhe .ompe6sor @olanl lines.

Loosn and rmow lh capsrws scu ng theiimhg qear er lo the cylnder hd. Renow lhe liminq qearc@rlrcm lh egine. lJse care wren remding the cder lo abid lh rubber seals falling inlo lhe
llywhee I housinq. Bede the ubber seals lbm rhe cover and dls.ard.
Loosen ad feore r6 six scrws scu ng lhe vibralion damperand qeariome mhan. Bemove lhe damper fon the shait, but DO NOT rmw6 mshall
3.
lnstalllhe gauqe plalet@1, J 4451{-lA.
6.
Usingrh llywheelturning tool, barlhe enqlne orer manually s lhal lhe camshail is posirioned ar top dd @nref (TDc) by aligning lhe TDc mrkon the eshaft with th liming marks on lhe No. 1 oamshatl
9.
lnsen$e a iqnmentbolin lhe hole in the liminq gear plale lo engaqe ihe camshf ga teeth wlh the rcd ol the toot in the stot of lhe 6lanp tool. Rolale lh camshati until

10, Tighln lhe bolt6lo specijicalion. Wlh lhe camshafi sl al fDc, lh doubl liming malks on lhe qear should be allgned sith
lhe malking hole i the qearplale.
Whil holdins th idler gear /n aqainst lhe lhckn6s gauqe nd emshaft qear, lighlen, bul DO NOf torqu6, rhe Tjghln r clamp $semby tool.
f.
11. nstallthe ctamp
asebty
toot, J 44514 5.
nstall a diar gauge against a toolh on lhe mshafi qear (Figufe 452), Wih the idref gear locked in posilio, @lale lhe camshan qear back and lorlh lo measur bacidash. The backlash readnq should be wllhin
Reheck lhe backlash, Wlh lhe spelffed ba.klash atainsd, rplac
each adJusrable ldler ger hub scf4 wlh ew and liqhten lhe sorss lo
Fqu6 453
rdl.. Gsa. Frank
crEnF Adiudns
14, Fmow rhe gauge plale loolss! nqlhe camshalt gar Use ca@ lo ensurc lhal lhe gear remas n p c dd pop yalignd
15.
Feistalllhe v btion damper on the gar nd cahshafi] lnsrallie six new mounling screws ad tighlen lo spcilicalion, APPIY a 2 m (5/54 inch) bd l MAo(-approved sealat on lh limina qear @r mounlig surfce and nsiall new
rubber seals (Figur 454).
13,
measuef$ is ut of spcifiron,adjusrrhe geartlankcleaance

i lhe backlash
a. b.
Looson lh clamp assembly looL. Loosen rhe @mshaft idler qear hub hub scBs will all@ lhe idlergearlo be mowd siigtfly in/oull@m lhe mshaft qear
scrss. Looseninglh
c. lnsela0.l m (0.004 inc h) lhickn ess
galqe on rhe pssufe sde ot rhe idrer and camshaft sar llh (Fiqur 453).
BEPAIR INSTRUCTIONS, PART 3

Using alignmenttoots, s5111422An; 051114228, ensurclhallheuppedlower seals are prcpedy sealed and lhal lhe upper suace ol the cv6r sflushwilhlhelopoi lhe cylinder head (poits A in Fisuro 4s5). lnslall lhe ihree remaininq cpscrws (irm 2 in Fiqure 455) and lighlen lo speciltlon.
Fe@necr rhe wing harne$ leads ai th unil jniclo.s and camshll snsor
appry a e@n 2 m (5/64 ich) bd or sealarr ar rhe joint lines (polnrA) berween lh cy ind6r had and the liming covel lnstall lhe vlv covr and r 16 rlain ng screws and splnos. Tighten lhe scs io
17.
Pla@ lheliming gear lh ngi..lnslllrwo Fiqfe 455) d had

ENGINE FINAL PREPARATION AND OPERATIONAL CHECK
PRIMING THE !I.tBBICATION
sSTM
1.
Afler Engine Overhaul Procedures

Filter Element lnstallation
Al
2. 3. 4,
Filllhe ensine crnkc66with lhespecilied quanli/ of lhe specilied qin o L Usinq a pressue prelubriror lilld wiln the specilied oil, p me the engtne tubrication syslem lbf a mln mum ol liw minutes.
Cheklhe cnnkse
oill4l,
ille6
li ne@ssary, dd oil to 6ach lhe FUL! mafk
and @olanl condilioneE mus!mee!
1. 2.
lnslall
Usio
airlihrin lh6 airfih$ housig. trqu wrch,lighln lh tlchig
nd
NOTE
Using a tltr wrerch, tighten
5, Aliach lhe nte6 lo lhe valw 6. Using a llerwrench. lighten
Engine Lubdcation System

An of lilm c@ls rclalnq pads and beaflngs ol n ov6rhauld 6ngin, bur rhis may nol p@ide sufclenl lubricatio. whsn lh ngin is daned ior the liFt lime, Followiq is the rMmmended pro@dui for oovidinq adqur lubd@lion
/Ac^urroN
Do rc nx bnds or typs ol htbdcars.
Chi@l addlv$ nay be Mr@att e and av ctlbute lo lhe t mtm ol 61udge, a.jd and
Falute lo heed lhis
ay rcsuft k severe
SERVICE HINT
vnous points on lhe engi lih6 may be opened, bul ii no use lhe olpssur snsor

Turbocharger
Fuel System
LcaurtoN
ll is n*essary to perfotm he sysbnl p@.l|btlDn pa@du@ anylme the rehicte has rct been apetd lot a petad dceedg 30 davs lo vaid daage to rhe twbochaqs Durkg ths en ded peod alt al wtl have dtned awv
l@
1.
he
bahg
and shah sudaces
Beforc wrkng oo ot nspectng a vehicte, set l pa*|ng bhke, pa@ th tnsmi*a io neutal .nd btock the whts. Fa|ure to h@d ths wahihg @n resuk n unexpctd vdrtd no@en and @4 peEonat jniuty
Rmove and iush th luocharge oit supply lj6wirh a suilabte, ctean, noilaabl solrenr.
SERVICE HINT
allowellenllo
run rroughrhehne b lurhany debris lhn blw lh I'ne dtu wirh .l comp@ssed alr
P*l
lo avoi.! potentiat tre had, do not seruce part ol th !l sys.b'm white snoklng ot tt lh prerc ol llams, spa*s ot hot sudaces, ot wheo woinq on an ooentinq gre. Fallurc to hed this wamng .an resull in lhe which can prcduce *verc
ary
inury
dealh.
/AcaurroN
A utbo.haryet lailure can rcsu n debns ctan@hng the t|rbochane oil supDty hne. is EATBEMELV tMpoRtANf to trt<h and thaoughly .iea. the hne pdot b sta1na Lhe enqne Faitue a haed th6 au an my n seveE Mparen and gne damge.
ffi.vp
tst
2. 3. 4.
.ew
W4t adequat ptutectl@ ctothins (tac sh14 h*w gloves, atrcn, etc.) when Mtng on d hot ensi;e to eu d a@intt bum .!ect contact vih hot fGL Fail@ lo heed Ihs wnng c i pe@nat nluty ot .reath.
lr
But
Feinratt rhe oit suppty tine. Pre lh lubrcation syslem tolowino lhe prccedufe d6sc bed eafte. in lhs section. Foil@ng ngine owrhaut, uselh diqnosticcmpuleto catibEtlhe vriabte
gemdrylurbochaqr
rorng. The engi. t car bcome active at .nylmeethoutsai.g. Fa[rto hee.Ilhs

wrning ca rsu[ n sewr peFonat iiury,
Do ot work nsrrhetun wth rhe enqine
Cooling System
1. Chck ihe @olig syslem. rake
su I piugs ad coolnl dEin quick dis@neds a nslalled and a light.

Mak6 sure lhe lhermctat is insla ted.
2. 3.
nfter Fill the system wth lhe econended
lnslallanqcoota
Belor turninqlh iqnitlon on. make sur no one ls nerrhein. Ftufe lo hed ts warniq ca fesun n svee peBont tniury.
1.
Check th lulsyslem lo make sur1hal au ennections re light.
NOTE
take su lhal all air is puEed fmm lhe cootinq
2.
Slat the egin and tun il al idte irr approximalely 5 minuleslo remwe a f fapped in the tuelsyslem

PRIMING THE FUEL SYSTEIIII
5.
Ch.* the luel syste
Usig lhe hand pnming pup is usuallyo.t necessary whn lhe luel syslem has air i il, or when replaclq llll6. Il ha.d p ming is needed, use the lollowinq po@dure.
snrclions ae liqhl.
NOTE
ll the engi6 dos nor sta iollowinethis procedufe, coniad your local MACK Truck
dtel
NOTE
Do nolcEnk rh ngine 6ntinuousylor more lhan 30 *mnds wilho d owinq lhe slarler lo cool lor 2 minules belween c6nks.
some slane6 are equipped wirh slarter prol@uon. ll the slaler lempealu is l@ high, slder enoaaenenl is lhibild to ptBnr slanr damaqe. Wail unll lhe slarter has @o ed to cank
AcaurtoN
sye@
punv
p@t
1,.
The ony ac@patle nethod af prmng the l@l s the hand pet punp. apptykg at to lE hEl ttnk using an aufiaty
1.
Unlock tho hand
mr pump by pushing
lhe handle n and lunhg t
pin.g enh@s ay .aus f@t fo leak past rhe p91v ptnp sal nla lhe anka@. Fale lo heed lhis autian nay rcsu1t k @veE
These
ptle lhe fel system is PBOHIBI|ED.
2.
Pump lho hand primr unlil lh force
ol
NOTE
whn lh luel 6yslem is completet epty, 200 or ore strokes may be nedd lo p me lhe syslem
afterrunnng tor
5 nnurs,lhe engne. lt its components and fuids wil be hot, contact wrh hor mpoents and fluds cn cam $verebrns. Flurero heedthlsrafringcan Esult ln severe peon.l njurv.
NOfE
There are NO bl6edippleslo be opened n oder
3.
L@k lhe pump bV pushino lhe handle lnlo lhe housing, lurning lt cockwiso and
Sbn lhe enqine and
un it ata icreasod idle lor aDp@xinalelv 5 miules lo remove an tPpd in lh lul svslem.

Engine Operational Check
1, 2.
3-
Remde alllools lro the engino Cone.l lhe batery b es (egative cable
Cler lhe
Bun-in pocedures Ey depending on eriod sed (i.., .ain dynamomeler. cha$is dynamoler or hishway run-in), Regadless ot melhod, however, always prepare fto ngin prop y blor sraninq il fof lhe li6t li.
rcrk area
ol
debls and p6onn1.
Bunln Check
NOTE
lnslll any addilional inslrumenlalion ndd lor
NOTE
is inponanl
b prop6r brk-i inilial striup ol the enone.
4.
5.
Siarl lhe eglne and immedialely increase lhe sped lo I 200-1 600 lpm. Du q lh bak-in p6riod, chdk lor eaks and monilor gauges lor sarshciory oil pre$u, erc,
OpeElelhe engine wilhin lhe

120G-1600 pm Enq6 for 15 minuls.
Th opedor should be iam laaf wlih the cofct, esiablished po@du@ for checting .hassis powr hfoe usinq the chassis dynamomlr method lor run i. Beler lo applicable chasis dynamomeler opeEling procedure. The operator must be obsetoanl nrugho lhe enlte run-in prooedure in order lo deleot ny
NOTE ulillhe
DO NOT alLow the enqlne to dfop io idle speed 15 minule break-in period al 1200-1600 rpm h6 bn compl16d.
Conslanlly monilorlhe inslrumenl display ol 6ngin lunclions and suppol systere and re@rd
ll lh 6ngin dedops any ot lhe io l@ing abnormal chacteristics during ru'in, shul ll
6. 7.
0.
Shutdow the eqine.
Idels and fllio capacliy betore @slannq rhe enqie. Ralerlo RebuI Egjne Bun-. Pr@drcs ao lnspeciions l bo su ol propr engine opeElion belore releasig the @hicle tor
Check the iud
oiscover and cofecl problns bloe @nlinuinq

Always ihvostiqal the lollowing condilions:
REBUILT ENGINE RUN-IN PROCEDURES

General
The duEblily and seryce lile ol a rebuill engin is dircty @lred lo its initial run n io towinq overhau . Aftor a compler owrhaul or any major repan job .volng inslallalion of pisron rjnqs, p slons, cylindei linefs or bea hgs, the ongine mu6l be run-in pior lo relese lor servic.
' . I . . t
Unusual.oiss, suchas knocklng, scpins,

A signilicat dop in e.gine oil pressure A slq nlica t ris6 in coolanl lem perature, exc@dins 116.C1240.F) A signlcarn rise in oilt6mpeElure thal exceds r16'c (240.F) An exhaust lempedture lhal exceds maximum a.ceplable limilslof lhe ongine involved, as msured by a pyromeler (il Any oil, eolant, fuel or air inl6l svstem laks
SPECIFICATIONS
MP8 EURO 3 ENGINE MECHANICAL SPECIFICATIONS
Mterial and Dimensional Dala
GENERAL DAIA, WEIGHTS AND DIIUENSIONS
r3i.rssn(51622i)
stgsow'tEdcam4[spe'c,1indef
wdds$;os.pimdepdms
Ermhnrc Mmaoe@
svr. GMs)
r8G2fuN(ie*1623 Ef)
COMPONENT FETURES AND MATEBIAIS
Dopfo'gdd1'ndudloh'6ngdffnna'nbdfigs
botm,h{FaflBinmounlinqplaldd.daiGaf
va
sydsm,
s
inJdo6r repraeabrg
casr
im Ee
ui r hisdor
a6!
'mqd
fr
pa*qs, ibqBl
SPECIFICATIONS
cylindsfHd_VlGuides
hdiduart progdnd unl
inFeE
(6): EMs modure
ceaflyp6punpiilagral*ilhpore.sledngpump;
refbB'lbypss
bt:
hrd *hB
'
. t
25 L
(26 qE.)
30 L (31 7 qls.)
nirun ffimum
m
SPECIFICATIONS
a for nq pa.ls andl lhe@loe, mdimum wer ust be slablishd by good judgmenl, expeden.e andeund shop
The specilicions
listed
va[ Lob Non nd Lm {EPc) Eh'usr vtu Lo Nir i (JRod4

E.husL
vk
Lobe Nom
Lin
{+Rocrs)
(rspedbi ody: ml
'd
dnq)
lrnsDsdim onrv: mr ro, mch.lnq)
cy rndd
sr*
Fans
tM
b Bld Dk
oop ' &ad
SPECIFICATIONS
/AcaurroN
NOf ahke he cylkdat head. fh6 w l clqqe the a<t@ ol hae njectotratves d
Do Do
NOf sind c.ppet kectot dee@g
vaGtrd.B.lghlocylhd.fH.adspdgF.@_
vae Guido Hsishr
atu
clindef
&d
spdns
tue
vd ssr ca,nreorc Dph 0nrer) vd srd d Dprh (Eru50
tujuslabie rdrf G.r ro cahaft Geaf
ea*
ash
Hsad Dane'er
rnrr
(E:u4 vd) Fd.!.r am creaEne (cdd
enqie)
SPECIFICATIONS
*hci
ue'
A'mcrtr(cdd Em)
Bl ckar e,* ditn cinq adiudiq *'d Brafe o.ref dl6n0 $R roGen@ cleBne dur (caftrrah b bEra rccbr rrm rdbn var Faca ro cyrindf Hd Dd 0n!1)
v
Fr b cyrds Had oe.r GihaGD
Nob:Fe9laci@l$ab@qnsrcpldnqus
SPECIFICATIONS
Eusl PrcsuE Govrnr
-'N,
l)
SPECIFICATIONS
Engine Component Torque Specitications (Critcal Fasteners)
AcavrtoN
ino of fastre and thta.ed hen Peift l ldim adequatety, fhe tatonq table debes th vais iEre arb the !nite ol theit @sabu Fltue lo @t1fot to lh$e llmils ay tsult severe @porern daage. Bepeate
NOfE
All@mponenrs a@ lo be clean and free lrom foign n1 l or rosion. Assmblis a to b mad usino sullabl lools and prcc6du6 s lhat n pemnent damage wll o@ur as a resull
Threds, wshe6, under head ol and washer taoe oi nul6 6hould be lubrlcaid with clean enqine oil unless olh6Niss specilied. The lollowing li.ld fsl6 rquire th use ol a calibfard mnual toue wench. lf an adaplef 5 requred n combialion wilh a loque w@cb, a coreclion J.lo mGt b applid t ih llque wnch radings in ordef lo oblain accuEle
cPE E@
lisht
er4
Fasrene6 nored by an dnsk C) ftorqu aft6r nsin fun'in.
quic
rEGm $ion {aepr adludabr
ldori@'d wirh or
p,Hpp
ied and
s@id
sws
(sp*
rh.F)
SPECIFICATIONS
andapplydiolhedppl
andapplysaailhenppe
Bolts and *rews lhal haw Imnd rusabilily spe.illed in lhe lable above mlst be afked wlih punch (A) ach lime rhy insla led in serce. Bolts and sc@s wilhlourpunch marks when moved have been lighlened liE llmes
rc Do no tffi
Da nat
lning geat mmting plate bolts, lning gear aatng bolls.
^cautrott
SENSORS AND WRll,G I{aRI{ESS
/AcaurtoN
Ownotquing a sen@r ot sens muhthg ew @n @st k ssar b@kag or th@d danage.
tusior (riiq qaf cMd c ha4 Atr Fsu4empErur ('nrd

camshan
mfo d)
coordremFd'e(f'o, nsh'sde.rrndf hd) cnG Ptr3ere (dod fodof '.omp'6o4 (rop

F[yheer Posirio"/sFed
Fu
ot
lrrher hsi@)
Fr*
(u6rf [r housinq)
snp) ofP'suc(bd o ddf .omp6on

LEm.mFor!re
(inside
SPECIFICATIONS
PA ENGINE COMPONENTS
varv (cyrinder Hd)
TOP OF ENGINE
covd
SPECIFICATIONS
CaDshft Beanng Caps and Feker Ar
fhe
is insrlled on lop (inb@d side) s ns lhe loq screws, numb6 aftrcugh 21. fhe rocker ar shaft and camshl bea ng @p relainng screws a ighlehed to sptrlicalion as rocker
ol lh camshan bearing @ps
arn shalt asebly
afunmftdandrcPla{lhnswsEs'
.fnda@dyroosloosn$rews
h31p2,lqhbnlhscl3$pfqr$
SPECIFICATIONS
"
D. :s"
a
L
ppt a
2 mm
lo.oru
hht
bad or sea
vihn20ind6otapptnqrh.*
SPECIFICATIONS
edb!lh6nunboinlho9hio'
SPECIFICATIONS
Additinl Top ol Enqne Conponenli
Lodu', var dludmnt (nrd d

Lo.kur. v
Adjdmed
(Erhaud wih EEin6 Bns)
RdaiGr
soa, shi {Edr Yos)
qs 8nb Pbb
spnns
(tu*e
eashh,
4Rd')
in
I rhs copper iiisdor sls@ is n4, iii6d rlks smes mud be lehrmed I
rhe copper idedor
ri6 deFs.
de@
is rcused. onv
*ps
d 5
bdfl aFly
uersr0
15 N.m
(7 11 b,ft).
. .
Wirh Ebad.bad &sisn
c@F s 8ee
(no
lnjsdor
wih ra.nom desrsn coppef shve d hjeclof
SPECIFICATIONS
PA ENGNE COMPONENTS
FFONT OF ENGNE
insaDi6andliohbn]nfuodefindiId'
SPECIFICATIONS
Chnkshft Front Sal Cdr
appry a 2 mm (5,64 imh)
bd
or
@P
n4njnftsola9glYimlfu$ahd
p*am
(a)
sh*n.
Flsuc165_rqEsgq$rcgscw
fighlenswsinlheodelindicaleda
SPECIFICATIONS
sbp2Wilyhha9mo'dl
Frent Ergn Support Mounlnq Bfackts
SPECIFICATIONS
Addilonl Frenl ol Enqn Componnls
Fhure
- codd
2, 5, 6,
PumP
Hruine
slep
rishbn
alr 6
srss
in
rs
rol
is squoi
AtehinqNub'nubbcvindsf!dardBlock
SPECIFICATIONS
MPA ENGINE COMPONES
AEAR OF ENGINE
! ,.
fig Gr TEn Plate
FguE4_kl'nlAppllc,donh
appry 2 m (0.o4 ind,i
bd
or
sabr b e
'imis mdd@k,0mind6of4plying'116sdml
q.ar prar nqr b rhs
23 4 N.n (2r 3
l'ft)
SPECIFICATIONS
l"q
bo*any$lemUedbplmecyl
r ) ckshrf Ge(2sffis) lBl rd'rd ab G8ar Hub (6 sdffi)

{c)
rnrmd al
adjBr,hb
er
Hb
lD) camshafi Gar and oampsr (6
SPECIFICATIONS
appry a 2 nm (o.oru
ind) bed d
*a
dh,omhsor4'r'tnerhesd'.
slag2'Tiohbnere$inlheo'ndiddad
SPECIFICATIONS
bE_Fltwh.cliocEn*.ha'l
sbFlqhbslesinlhodelindidd'
sla2'lnfuor&flndidsd:8mltichln'
SPECIFICATIONS
hm_F'y{heelHG'gloPld.
Bamovsanoldglmiedear.np appta2mm(564iich)bdd30o2sr0sear
r ro
e ry,h*r h@
nq lor
nrins ptare {fth 20 rtuIs or
apptirs
rh
sdd
Fture
1?6
ro4w sqren
- h4
.d
M1o
se$
(Hosin,
ro
M ,d
stock)
SPECIFICATIONS
o
s
sqwne cBs (Prft b HoGi4)
FsuE 4z
ro'que
M3
sbp4
M3
srs, 1+z
(rmd
or
hinq
q*r
Additonal B.r ol Enqn Componnl6

n
sHbhoF
| 30o 3s N,m {22r r3s
rfi)
SPECIFICATIONS
r,P EGINF COMPNENTS
Figuc4ru_roqugs.qkm DoNoTEusdfurefplddtrhhgsc8sALlly3us.n$Bsnsedice'
SPECIFICATIONS
Fiq[|30_ofElblsptsAsebly
25
+ei s
(r s +3
5/-
b.fi)
Additonal Bottom ol Engne Components
Hndsd! rbn'id{8n ro4313 Nn($,61ri).
SPECIFICATIONS
I!IP8 ENGINE COMPONENTS
RIGHf SIDE
rguld4l_T4u.s4ueneNUm
c.$ablingshadsFiem@poneds'
Ol C@ler
Cool.q Duct cover
SPECIFICATIONS
HqrceftqEsquncet{unb
00022 and
ch@k thar e dud
@, 0@'t
L5
ro6.t
indan
s@
B.
ere*
srep
in
eqreme r b rored
by
squffi
2 (indud ns a).
kt
$reG c
nd
Fg._To'qusqsnc
idd {s
m<.L. Mpod
ar
asmbu
SPECIFICATIONS
Turbocharger L(brcalon FiOs
rburcas
rqm squd..
ru
Ol
Presu Sery
Vatve
FiguE4s_oilPE*Urc*brtvdE
SPECIFICATIONS
SPECIFICATIONS
Addilionl Fghl-Sde Engire Conponents
MP8 ENGINE COMPONENTS
LEFT SIDE
iloldlocylndef*d
SPECIFICATIONS
SPECIFICATIONS
fgu1s_scfuNmbelddtf
SPECIFICATIONS
Na 5, No
{.5 Nn t3
Nn
+4
Lii)
(Nd !Eb)
3,25,r.5 N.h
fsal rFi)
No 6, 0 r1 s
{30 11 rb-f)
SPECIFICATIONS
Tandem Pump (Fuel and Porer
Srerinq)
ri6 N0 2, e !i2
No 1,3o
i12 Elr) N.n (44 is br)

N.m (se
No.3, rc
ri
0 N.m (s, +7
bf')
Addilonl Lfi-Side Engn Components
ar cmpreer, 3k.
t*n
2m
+50/ N.
(147
+s7l{
br)
arhchino
sc,e$
(ro
tuwef
sbro
Pmp)
SPECIFICATIONS
Slandard Bolt and Nut Torque Values
Th rorque vaiues in the rable
bd@ enJofm lo
SPECIFICATIONS
ENGINE GASKETS, LUBRICANTS AND SEALANTS
Gasket and Seal Reuse
Some gaskers and eals musl be discarded rm@d duing seryice, The lollwing table dsribs ih .ofnponnls and lherlimirs.
il
turq r'F (mrad
dud
dMi
nerremMd Dondappvoit
nm ns
G*
da .nd
qrinds
SPECIFICATIONS
Lubrcanls and Sealants
Us oly l lollNig @mmended sealing compornds and lubricants.
NOTE
Allqenuine MACK cylinder head s6kts a. precoald and do nol equire arry lype of ssling copoud. Bfor6 inslalling ns g$kets! degrcase bolh gaskei sealihg surlacs to wid
P
Eis'ne
p
Na s2s33io' o@cdnnqoe) Ldlp27?dfq!v&ndbolhtsds3l
Prr Nd
ds, rde is 6 (s dss and rheads) and @sh3
rrsF
DM cdnq6 334
oilrlrer
inq qasksrs
lturr-rm I hE)
qry
iNDH(
INDEX
INDEX
A
ABOUT THE MACK MP3 (EUBO 3) ENGINE
COPPEF SLEEVE REMOVAL... .., COUNTEFBORE INSPECTION AND CFANKCASE VENTILATION

CBANI<CASE VENf tLAltO (CCV)
aDVrsoRY LABELS. . . . . . . . . . . . . . . . . . . AIF COMPRESSOR INSTALLATION. .. . . . AIR COMPRESSOF FEMOVAL..,....... arR rN-raKE sYsTEM.... . . ,. . ... . ,.. . , ALf EBNATOF AND REFRIGEMNT COMPFESSOF INSTALTATON . . ... . ALf ERNATOF ANO FEFF]GERANT COMPFESSOR REMOVAL . .,,. . .. . .
. .. . ... . ... ASSET\BLY, , ,.. , AUTOMATICALLY TENSIONED SYSEM.
SEPARATOF FEMOVI................ CFANKCASE VENTILA ION (CCV) CFANKCASE VENTILATION SEPAFATOB. . . , CFANKCASEVENT]LATION SYSTEM,,,.,...
,..,
....
B
. .
CFANKC'.SEVENLAION,
CHECK.......,
CFANKSHAFT FRONT COVEF AND SEAL
BLOCKCLEANINGANOINSPECION,,.,,,..
BLOCK S'IFFENER PLATE
FEMOVAL.......
IlA
112 219
tNsT411TrON .... ... . . ... . .... . ... .. CMNKSHAFT FFONI COVEF FEMOVAL.... CRANKSHAFTFFONTSEALfiEMOVAL...... CRANKSHAFT FFONSEAL
BFACKE FEPLACEMENTPFOCEDUFE
...,
c
CAMSHAFTAENCHPROCEDURES,..,,,,.,, 146
NSALTATTON . . . . . . . . . . . . ... .134 CBANKSHAFI FEAF SEAL FEMOVAL..,.....103 CRANKSHAN FER SEAL
REMOVAI............................. 33 cat\sHAFTtNsPECTtON.,,..,,..,.... 146,219 CAMSHAFT INSALTATION . ...

CA]\'SHAFf
CFANKSHAFI REMOVAL . . ... . CRANKSHAFT VIBRATION DAMPEB AND FAN

PULLEY
FEMOVAL......,.
CAMSHAFT SENSOR DEPTH, CHECK, . . , . . . . . 49 CAMSHAFT NMING, CHEC( CCV SEPABATOF INSTALLATION. , . . , , . ..231
...
ccvSEPARATOF BACKT-ASH..
FEMOVL...............
PULLEY CYL NDER BLOCK RECONDIT ONIG , . . , . CYL NDER HEAD (VALVE) COVEH CYLINDER HEAD (VALVE) COVEF
INSTALLATION REMOVAL. . . . . . . . . . . _.......

.
2OT
231
tNsTA114TtON......................
CONNECTINGROD PISTON
ASSEMBLY
OVEBHAUL . . . . , . . . . .
otsssEMs1Y . . . . . . . . . . . . . . . . . . . _ .
CONNECTING FOD AND PISTON EENCH PFOCEDURES . . . . . . . . . . . - . . . . . . . .
.
BEI\OVAL_.............
PRESSUBE TEST . . , , .
..
coNVERStON CHABT. . . . . . . . . . . . . . . . . . COOLAN AND PUMP INLEf HOUSJNGS
oHECK . . . . . . . . . . . . . . . . . . . . . . . CYLINDEB LINEH FEMOVAL
FEMOVAI.........................
COOLANT DRAIN OUTLETS. . . . , . . . . . . . .
COOLAN FILER . COOLANTPIPE INSIALIATION...,.,..., COOLANTPUI\P INSTALI-ATION.,...,,.. COOLANTPUMF REMOV41........ COOLING DUC r COVEF AND OIL COOLE_F
D
DESCR|PT|ON. . . . . . . . . . . . . . . .
.....
....
DRIVE SELT BEPLACEMEN AND
TENS|ON|NG . . . . . .
.............
.
DBIVE BELTS AND FAN BUB AEMOVAL
coo1tNcsYsrEM...............,...,
COOLING SYSTEM COMPONENTS BENCH
E
EECU ANO COOLEF ., . EECU ANO COOLING'NSIALLATION PLAIE REMOVAL
. .
PROCEoURES . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM MAINTENANCE. . .,. .

COPPER SLEEVE NSTALLATION..
. . .
...,
INDEX
ENGLNE CHECKS
ANDTESTS......,,
FRONT ENGINE SUPPOFI FEMOVAL
FUELFILTERCHANGE..............,.,
FUEL FILTER REPLACEMENT . . . , . . . . . , FUEL LINESAND F LEF HOUSING
i,..
.
SPECIF CATIONS (CRITICAL
FASfENERS).
ENGINE ENGINE ENGINE ENGINE
.... . .. ........
. . .
COMPONENTS . . . . . . . . . , , . COMPRESSION, TEST. . . . . .
|NSTALLATON.............,...
DISASSEMBLY . . . . . , , . . , . . FINAL PBEPABAT ON AND
oPEFAf|ONALCHECK..........,
ENGINE GASKETS, LUBFICANTS AND
SEALANTS....._...............
INFORMATION PLAf E
G
G.SKET AND SEALREUSE
ENGINE ENGINE EGINE ENGINE ENGINE ENGINE
INSIALLATION.
.., .... . ..,
GENEML.. . ... .. . ...

.
..
.. . ..
,,...,
..
. . .
LUBRICATION SYSTEM...... MANAGEI\,IENT SYSTEM . . . . .
GENERAL INFOFMAT]ON . , . . , . .
GENEFAL INsIHUCTIONS , . . . . .
GLOSSARY OF TERMS . . . . . . . . .
OPESAIONAL CHECK . . . . . PFEHEAf EF/SPACEB
I
...153
IN-CHASSIS PAFI/COMPONENf
tNsT4114TtON..................
ENGTNE REMOVAL. . . . . . . . . . . . . . . . . . . ENG1NE SERIAL NUMSER
PROCEOUAES . . . . . . .
.....
INJECTOF SLEEVE AEPLACEMENI .

ENGINE SYMPTOI DIAGNOSIS . , . . . . . ENGINE WIFING HAFNESS FEMOVAL . EXHAUST MANIFOLD REI\OVAL. , , EXHAUST PFESSUBE GOVEFNOR
.
..
...
. .
REMOVAL
.. .. ... ....
INLE
AND EXHAUST VALVE FEMOVAL. .
INLET MANIFOI INSTALLATION . . . . . . .
INSTALLAT|ON......_........
EXHAUST PRESSURE GOVEFNOR
INLFI MANIFOT.D REMOVAI , . , , . . . . . . , .
FMOVA|. . . . . . . . . . . . . . . . . . .
iil
]NSPEC'ION............_..........
NSTATLATTON
. . . . .. . .. . . .. . .. . .. ._.
SYsTEM... .. .....
EXHAUST PRESSUBE GOVEFNOR, EXPLANATION OF NUI\EAEAL CODE. .
..
L
LINEF HEIGHT MEASUREMENf
LT]BFICANTS AND SEALANIS
LUBFTCAI|ONSYSTEM.................
LUBFICATION SYSIEM MAINTENANCE .
.. . ... ., . ..
.,
lt
MACX MP8 EURO 3 ENGINE DES GN
rNsT411TtON.....................
F LIEF ELEMEN INSTALLATION . , , . . . . F LTEFS ANO MISCELLANEOUS
FEATI]RES ..
COMPONENTS INSTALLATION . , , . . . . F NAL S-IEPS. . .. . . 220,243,
....
.. ..
MAIN BFRNG CAP INSIALLATION . , ,. ., MAIN BEABNG CAP BEMOVAL. . , .. ]\'ATEFJAL AND DIMENSIONAL DAA ... MOUNTINGfHE ENGINE ON A REPAR
..,
....,
. .
sfAND , . . . . . . . . . . _ . . . . . . . . . .
..
rNsT4114TtON.....................
FLYW-IEEL AND PILOf BEAR]NG
MP8 ENGTNE SERVTCE TOOLS. . . . _ . . . . . . . 303 MP8 EUFO 3 ENGINECOMPONENT LOCATION
BEMOVAL.......
vtEws
..........
........
FLYWHEEL BENCH PFOCFDURES FLYI'V}IEEL HOUSING INSTALLATIO . . .. FLYWHEEL HOUSING FEMOVAL...,..,. FLYWHEEL HOUSING FUNOUT, CHECX,, FLYWHEEL RING GEAR REPLACEMENT.. FRONT ENGINE SUPPOFT
....,,
MP3 EUFO 3 ENGINE MECHAICAL MP3 EUFO 3 ENGINE MODEL
SPECIFICAflONS..,..,.........
rDENfrFrcAf
oN................
MP8 EIJFO 3 ENGINESETUPAND
INDEX
N
NEOPRENE SEAL INSTALLATON NEOPRENE SEAL REMOVAL. , , , . . , , , , . , , . , 226
R
FEBUILT ENGINE RUN]N PROCEDURES],,..263
REMOV1........................
FEMOVING ENGINE FROM ENGINESTAND...212
o
OILAND FILTER CHANGE PROCEDUFE
,....
tNsTALLAftON.................
FOCKEF AFM SHAF ASSEMBLY..... ROCKEF AFM SHAFBENCH PROCEDURES ., ROCKER AFM SHAFT DISASSEMBLY . , ROCKEFARM SHAFTREMOVAL,...,,
OIL COOLEB AND COOLING DUCT COVER
orlcooLERRECONDI|ONjNG..-......... orLcooLEF,pFEssuFEfEsf ............

REMOVAL.
O L FILLEF PIPE AND DIPSTICK PIPE
|NSTALIATTON.,,.,,.,,,..,,,..,,,..,.
......,
ROCKERARM,CHECK..............
139 196
TNSfaLLATON_.......................
ISTALLATION
OILFILTEF HOUSING
..
s
SEAL INSIALLATION . . .
.
OIL F]LTEF VALVE HOUSING REMOVAL . . oTL LEVEL CHECK. OIL PAN orl PAN FEMOVAL. OIL PUMP AND SLOCKSTIFFENER PLATE
INSTALLATION.. -.........
-...... -...
.. .. 93
...
SEALREMOVAL..............
-...., , .,..10
.-
J37
SEFVICE PRECAUTIONS SUMMAFY. . SEFVICE PROCEOLJHES AND TOOL L-ISACE .
NST41ITpN........................
SPEC|ALTOOL...............
164
.3
SPECTALfOOLS........6,72,76,14.153,214,
223, 226,231,249,254 SPEC]AL TOOLS FOR ENGINE OVERHAUL. . . .3O3
STANDARD BOLf AND NUf TOFOUE
OILPI-IMP INSIALLATION....... OILPUMP PIPES AND STBAINEF
OILPUMP FEMOVAL. -...... -, O]LPUMP FEPLACEMENT (lN CHASSIS)..,., 231 vaLVEREPLACEMEN

O L THEBIIOSTAT VALVE
.................
vaLUES . . . . . . . . . . . . . . . _ . . . . . . . . . . . . . . 304 STARTER INSTALLATION...,,. STAFTEF FEMOVAL , ..., . ,..,
22r
222
EPLACMENI...................-...
P
T
TANDEM PUMP (FUELANO POWEF
STEEHTNG)rNSr4114TlON...,...,......202
TANOEM PUMP (FUELAND POWEB
PISfON AND CONNECTING FOD aSSEMBLY NSTALLAT]ON.............. 161 PISTON AND CONNECTING FOD
STEEF|NG)8EMOV41........
TEFLON@SFAL INSTATLATION . TEFLON@ SEAL FEMOVAL , . THERMOSTAT AND COVEF
.........100
assEMBLYFEMOVAL..................
113 117 123 124
PISTON COOLING SPFAY
FEMoVAL'.,''',''.'''.'''.,,'..,''''
BEP14CEMENT.......................
NOZLE
NSf4r14TtON,.......................193
GEAF COVEB REMOVAL
GEAH PLATE INSTALLATION....,....163 GEAF PLATE REMOVAL.., . GEAF TFAIN INSTALTATI
PISTONINSPECTIONANDCLEANING.......
PISTON RING INSPECT ON ANO POWER TAKE OFF (PTO) ASSEMBLY
THEBMOSIAf ANDCOVEF FEMOVAL..,,...106 THEFMOSTAf. CHECK . ... . ... TIMING GEAF COVER INSTALLATION..... ..19O
T]MING TIMING T]MING T]MING T]MING TOOLS
POWERTAKE.OFF INSfALIATION,...,...,. 139 POWERLEASI]I ENGINE BRAKE PFEL|M|NAFY STEPS. . _...... 213,236,244,250
..,
GEAF IFAIN FEMOVAL.

AND EOUIPMEN
...
TFOUBLESNOOTING TECHNIOU
rIFBOCHARGER.....,.......
TURAOCHARGEF INSTALLATION
INDEX
u
uNfT TNJECTOR CLEAN|NG,,,..............244 uNtf tNJEcToR tNsfA!TtoN ... _... _.... _176 UNITINJECTOR BEMOVAL..... vaLVE
VALVE SPFING INSPECTIO.. ... , VALVE STEM HEIGHT MEASUFEMENf
rNsralraoN.
......
.:
lt : i
!.
v
VAIVE AND UNT INJECOR 4DJUSTMENT .. .... VALVE GUIDE REPIACEMENT
PBOCEOUFE , ,. .... ... _ _.. .. . . _. VALVE SEM SEAL REPLACEMEI,T . . . . VALVE YOKE (BFIDGE] INSTALLATIOI
....,
VALVEYOKE(BF|DGE FEMOVA!
_.........
35
,..,.... . , .. . _... . .2s6 . valvE GUTDE WEAF_ CHCK...

vrvE NsPcTloN,
.,.,,,....
W
wJRtNG HABNESS NSTALLAON . . . . , . , , . .
m9
............142

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REPAIR INSTRUCTIONS, PART

2. Asemblelhe oi siher, ;udioni

pEs6u@ pipes inlo lhe pp as

Oil Pump Pipes and Striner

FEPAIR INSTBUCTIONS, PART

suppo mounring bfaokel

Pr6r. sp*ar stes

Crankshatt Front Cover and Seal lnstallatlon

inch) bead o'

REPAIR INSTBUCTIONS, PART

lnrall lhe font @wr

lnstallalon structios pply:

Usng a torque wn.h lighlen the capscrews i sequonc6@dinq lo

BEPAIB INSTRUCTIONS, PART

REPAIR INSTRUCTIONS, PART

Cylnder Head lnslallation

Rmore alignment guides, 9994267, Im

REPAIR INSTRUCTIONS, PABT

1cr n th liminq gar plate {as sh@n in lhe illuslalio).

(164 nch) lhck bead cil 10 e sudace at tho sde ol

ll in Place, de th cy indr claping lools, 9s96966, Iom

head gaskel on lhe enqne

REPAIB INSTRUCTIONS, PABT

th@-slep prcce$ is used tor inslallalion ol lhe

10. Check the ndilion

11, The cylinder head cap*rews ust ot b

REPAIR INSTRUCTIONS, PABT

respeclive beaing saddles. Use a soflaced mallet t sal th b6rig ps d$ th6

C ean and inspect the canshalt usinq

solwnl and comp@sed ar

REPAIR INSTRUCTIONS, PART

dnq on lhe chnkshafr

Chck lal lhe @mshatl is posilioned at

REPAIB INSTRUCTIONS, PART

Femde lhelhickness qauqe.

REPAIR INSTRUCTIONS, PABT

ll th backldh measurement is olt ol specif@lion, adjust th6 sr llank cleaBnce

shaft gar,liqhlen, but DO NOT lorque lh adjuslabl idler ged hub

in aoa nsl the thckne$ qauoe and

Fein6lall and tiqhien th6 J 44514-5 a$embly tool against the

REPAIR INSTRUCTIONS, PART

15, Tiqhten lhe inlemediale se6l (doutl

16. lnslalllheauxiliaryidlergearonlothtiino 17. Bemovelhobea

Unit lnjector lnstallation

FEPAIR INSTRUCTIONS, PART

Ren@ lhe boe

rndor Borc PErdion

O{ings on lhe unil injecloras

larS dlamelor, violl

tshwn snmd ror

BEPAIB INSTBUCTIONS, PABT

of corct l6oth olo lhe

lhe injcior hold d@n and n4 srew lnll nieolol

BEPAIR INSTRUCTIONS, PART

yokes on rheir rcspeclive d tke suf rhal lhey afe pbpery

Rocker Arm Shattand Engine Brake

Oillh vl yoks and lh camsha lobes

ll rBinstallinq an ineclor inlo lhe san ocatio, rcproomm nq is not quned.

Fepear rhe insrallarion sreps tor the

lro which they

REPAIR INSTRUCTIONS, PART

Lub.ical lh .kr arm

REPAIR INSTRUCTIONS, PART