Manual Servicio Motor MP8 Mack-2

REPAIR INSTRUCTIONS, PART
1.
Assmb e lhe slii'ener plale

wilh N lasl6nc. Do NOT
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
lnsrallthe oil pf$uB pip and lh6

cfo$o@r ppe bet) tofqu+lghtenlng the
2. Asemblelhe oi siher, ;udioni

8nd
ccsov
pEs6u@
pipes inlo lhe pp as
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
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
Using a lorque w rench, lighle lhe alaching

faslnB in squnc6 amording 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
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
o
o
o
o
FEPAIR INSTBUCTIONS, PART
Front Engne Support lnstalation

1299
Gvl
1- l m@d, dsenbte
loni enqi
ro rhe qlindef
lishle hsleneB lo specilillo.
the
suppo mounring bfaokel

block and
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
3.
Using a lolque wnch, tghle all lasteneA

i sequen@ ro sp6ilicarion.
l2
2.
Pr6r. sp*ar stes
170
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
1.
JBl
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
tolNirg
lnstallalon structios pply:
Ih e bois wiihoui 1ghGh g lh em

Using a stEighrdg ru e, make sure
the cder is flush wilh the leer da ol
lnsla ll
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
5.
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.
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
6/e
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
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.
7.
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.
lnslall the compressr slud wnh a new

sealing ring and n4lasleel
Fieure
2sr hj*br
cpFr srp{e
crnnq
NOTE
a.
Rmore alignment guides, 9994267, Im
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
REPAIR INSTRUCTIONS, PABT

2. lnsiall ful lnlector bo plqs, 9994251
6,
(164 nch) lhck bead cil

10 e sudace at tho sde ol
silimn6 s6lnl
Ensuro thal ths ngin block nd dtrk ar

clean and iree lom any dirt, qfeae or 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.
App y a 2 mm
1cr n th liminq gar plate {as

sh@n in lhe illuslalio).
th
NOTE
Tlre cylinder nead musl be
ue-liq hrened wilhin 20
sealanl hs be6n app id.
ioq
ffi*fl3fi
FiguB254_elnlApplldl.nhMHadb
5.
ll in Place, de th cy indr
claping lools, 9s96966, Iom
9996966
ns
head gaskel on lhe enqne
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
OTE
A
h@d botts a tightened.
th@-slep prcce$ is used tor inslallalion ol lhe
10. Check the ndilion
of lh cfinder head
anachig pscf4s and lublte the heads
(und6id) ad rhds with crean engine
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.
Oce lweed, screG iserled lhouqh

th adiustbl idlr qar hub nd plal
a used io draw lhe cylider afrard
lh6lnalslp,lhe head bot6 are

inserted and tighlgnd lo spcllicalion,
securinq lhe cy rdef head io ihe block.
ln
ffi
NOTE
D NoT o r rh rhreds in th hr6rr<
11, The cylinder head cap*rews ust ot b

used 016 lhan fi@ times. Mark the cylinder
head @pscBm by punchig lhem,
12.
lnsert lour cy indr had capscws lnto

l@alions 24, 26, 2a ad 30. Tighlen lhe
mpsc@ws to specilcation.
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,
Make sur lhe b a bing insrt on each

lowr berlng saddle. The beafng insefls ai
lhe No. 7 camshat jouhal haw lnlgEl
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
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.
NOTE
fhe lootis used when adlsting thtimtng gar
backlash when lhe ocker shafi assembly is
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.
ot

Timinq Gear Train lnstallatlon
3.
NOfE
Assembb rh adiusrbr ib; b@loem 3 in

Figurc 260), hub, bushins, lhrusl washer
and laslereG o the plate. Hand llohin lh
Apply liQhr coal ol clean engine oil lo all pats
Mlkg
^caurroN
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.
1. As*bl6 r4 o
2.
dnq on lhe chnkshafr
Apply a llm ol ol io lhe O ring and ssemble

lh chnksh gar on lh cnkshal hub.
FisuE
e - adlus*
t6
NOTE
Leaw two flne lo6e
luming lhe cEnkshatl wilh
3.adjGbbre
4,
Figu259_cEnk3hliGsrlaHubtrsbly
dsGs
rd!r
&r
rden Pur
I Gd,
| 7.Af
hec<f
Df
D,e
Chck lal lhe @mshatl is posilioned at
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.
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
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
9.
Femde lhelhickness qauqe.
t'oTE
a sllghl resislance on th6
F4u263_can.hfG.l'iniqlla*s^liqnmnl
10

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
$r4s slighlly. LoGening the hub
sc@s wllalih idlrqearlo be
movd slighlly irvoui nom lh m6ha
nsert a 0.1 mm (0.0er inch) thicknse
gauge on lhe prssue side ol the
adjusrable ld er qr toolh and
cashafl qear loolh by using ller
gauge hldr J 44935 ad J ,t4514,6
Wh ile holdino th adjuslable ld le r
gear
in aoa nsl the thckne$ qauoe and
shaft gar,liqhlen, but DO NOT

lorque lh adjuslabl idler ged hub
Fein6lall and tiqhien th6 J 44514-5
a$embly tool against the
c 5mp

I
g.
Remove th leeler guq from lh

adjustabe dler gear and camshn
15, Tiqhten lhe inlemediale se6l (doutl
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.
16. lnslalllheauxiliaryidlergearonlothtiino
ns
13. rnsiarlthe
inrermediare idle (double idLer)

gearsel (2) to lhe timing gear plare, us nq
id r) mounlng bols in
17. Bemovelhobea
seque.ce to
og cap
pre$ tools,
45109204.
Unit lnjector lnstallation

1221 GPI
NOfE
used, il musl be lited lo lhe
1. f
pr*
ously pericred, insla I prolclive

sleeve, J 42435-25, ad clean the unll
injeclor mppr d4 wilh lhe app@priale
FisuE
2t rnkrdr.
dr$
|6
(eude
rdre4
not
G'rd
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.
Ren@ lhe boe
proieolion
deM,
9S94251.
FsuE 21
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
uni lnlsdo'
Unft
Prcrdion
4. lnlall6w
.
.
rndor Borc PErdion
sre#
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
O{ings on lhe unil injecloras
Upper
nnS
larS dlamelor, violl
Lower
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

10.
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
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\.
The qaskel (llal washer) is passembled on new
7,
SLip
lhe injcior hold d@n and n4 srew

lnll nieolol
of corct l6oth olo lhe
o
Fioue274-Erd crconn*brbrunnh,dr
11.
Using lorqu wnch, lghlen lhe

hold dow scw in daqs to speflicarion.
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
Fiore2n-Unft nidorRdiner
1 nltuf
Nod
DM %k I 2 udrhFdr
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
Elv
lnf
:3
:E
injclor using hand pre$re lo seal lhe

O rings. Hand lighln lh
hold-down
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
yokes on rheir rcspeclive d

tke suf rhal lhey afe pbpery
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
dlM
ll rBinstallinq an ineclor inlo lhe san

ocatio, rcproomm nq is not quned.
13.
Rocker Arm Shattand Engine Brake
lnstallaton
[213 LPI
1.
Oillh vl yoks and lh camsha lobes
2.
Using lhe lilling toot, a5109250, and an

Gsislanr, plac lhe shall wilh fockef arms in
poslon on ihe inboard sido ol lhe camshaft
Fepear rhe insrallarion sreps tor the
NOTE
valve Yoke (Brdqe) lnstallalion
enqne bke, ihe exhaust

an inleg@ ulve and pisron.
t213 NVI
NOfE
Usd yokes have slablishd wear patterns.
Yokes belng retured 10 seflic musl b inslalled
in lhe same cylinder ocalion
2.
lro which they
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
t,
3.
a*bthdr'dr
Fdef shar a*mb y
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
l0- lnsn 6
1 1
12.
lpip lnlo lhe oi holeollhe

engine bke cofrtol valre.
o
NOTE
Mak6 su ihr lhe
Ojing
is s@ted lully i ihe
Postion lhe
@ntol vlvg on lh cylindr
Align lhe englne bke oil pipe and

wilh lh hol in rh r.ir sh.fr
Or nq

15. ll inslalled, eposition
NOTE
ak surerhe enqine bake oil pipe
13. lnsrllrh6 mnlrolvlve
EIE
ojing
is
'
rhe luel injecior

hmss ovr lh conlrol vdre and secure
qilh high lehperature tie strps (943472).
lully
bolts ad tighten lo
14. rrharnes isinsralledon

conlbl
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,
2.
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.
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.
Using a 3/4 16 UNF x 11.5 lap, lhroad

lhe hol indicled in Fig!re290,
b.
Apply lhad locling .mpound

(Loclrle@ 2z or qu len1l ro rh
reads ol lhe p uq,
c.
lnerr rhe plug wirh washef and tiqhren

ro spcilicalion.
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.
4. lnsrl
and hnd-t ghln the aching bolls.

quide pins d inslalt lh
Femow the
te
5.
Using a lolqu wrench, liqhten th atlahinq

bolls in sequnc ac@din g lo specif .a1lon.
Femove any
7.
lnsIalllhe limig gear plate to the iywheet
exs
sealanl.
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.
Lubricat lhe seallips wilh clean engie oil.
3.
lnsenlhe handle, 9992000, in lhe

f emover/inslaller
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
Mdn, ro
ndN
Fr!}hel
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
Ff Ma sar mratb.
5.
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
fackg,
anyy hel th
hol6 n t
rcbalans by
ctutd1 Bida
dtled
@]JJ6
\+
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.
8,
,--5'
Using a toquo wnch,

in sequence ac@rdino
BEPAIB INSTBUCTIONS, PART
,AcautoN
M
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
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.
11.
Ch ck to r p@pr
llywhel-lo-positi senso r
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,),
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.
FisuF 24
- @'
12. Crlully jnslalllhe
sNo. Galsa
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
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
2.
Applv a 2 mm (0.079inch) bead oi

MACK approled sealant lo lh seam
belwn lh lrol sel over nd the blo.k
lie mounnqfanq.
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
6.
f
l
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
3.
oildin
Ensur rhal ih 1 2 localinq pins on the seal

ar popery seabd inlh6l@alino holes in
NOTE
Use ca lo
pr*nl
NOTE
damagelolhe oil
The oil pan must bo istallod wilhin

20 minules of lhe sealanl being appled.
a sur lh oil pan seal is properly plced bslirr
Q)(
harnBs is inslalled, reconnect lhe ott

level/lepealure sensor mne.lor lo lhe
lf

Oil Fller Ppeand Dpstick Pipe
lnstallation
1
2.
nw
O r ng on lhs oil lill lube nd

inslalllhe tube to lhe sde oftheollpan.
lneallrh oilfi lrube lasrenerc and rlghrenlo
lnsla I a
lnstall a new O dng on lhe dlpsnck tube,

rhen nsrall rhe iube and secu fe wnh lhe
laslenr lnslll rhe dipslick.
Power Take-Off lnstallation
'
li equipped wilh a ptuer iakg'off (PTO), inslall

the asmbly lsing this pbcedure.
1
2.
Lubicale and Nemble a seal i lhe

ln the PfO ssmbly housing.
Gsmb
qrcM
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
2,
4.
I
cowr on lhe
fyvheel housig al the rear l th6 q/lindr
had. lnsiall rh fsreE mrkd 1 and 2
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.
AAI
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.
lnsrall rhe riminq qeaf
@Er sea s and
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.
2.
Check tor prcper enshai paito'n sensor

clance using lhe senerdeplh quq,
43400031,l dlBie it shims are
required lor ssn$r dplh.
8. Posilion lhe @r supporl brackel onto the

r fth ngin and inlalllhe supporl
brrck l l'srsnB i s.x.
9.
lnstallallti slp3. P-clampl and olher

6lainB Esd lo r6slrain lh ngin6
harnesses, ol lnes and c@lanl lubes lo lhe
a.
Fott6 lhe ngine unlil a loolh of lhe

@mshai i@thed whel is aliqned uilh
b,
lnse lhe depih
c.
qauqe inlo lhe sensor
bo unlil 6 oulr pn ol tre gauge is

lully seated aqahsi the nhhq gear
$r4
Looen lhe lhumb

ol lhe gauge
and Psh th inrpa oflhgaugin
until il colacfs a tooih d ln loolhod
Tigr'in rhe thumb

CAMSHAFT SENSOB DEPTH, CHECK
1. Be@
lhs plug lom lh6llyuheel holsing

and inslall lhe fywheel lurq lool.
.
.
-5r
io
*curc the
Calulry ro lh gauge fom the

camshaf sesor bor and obsetue lhe
localion ot steps belwen ihe inn6r d
outer pdionsol rhe gauge:
(d,---
$f4
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.
Coolanl Pump lnstallation
@
@
@
3,
[ 215
SW SG, SBI
l.
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.
2.
Prcss a
selinq dhQ inlo lhe grod ol
repla.emenl
the
@olanl pump.
3.
Posilion lh6 placmrl coolani pump

hpellerhousing on the base plalo and a ion
ns
l.slall lhe camshaft positlon sesor wlh lhe

apppnab shr(s) and n4 ong. secufe
lhe sersor with a boll and plug in lh
NOfE
rake sur6lh sealinq ng reains seaied h ihe
qbde of the PUnP imp6llrhous nq.
4,
lJse caE to hsre that ihe seal ng r ng

@mains pbpeny sealed and inslllrh6
mo ant pump bolts and lighle lo
5.
Poslion lh6 l6nsionr pulley on lhe f.ont of

lhe engine and nsialllhe tension$ bolts.
Tlghlen lhe bolls lo specication.
Thermostat and Cover lnstallation
Coolant Ppe lnstallation
[215 NU, NG & LD]
[215 SWI
UPPEB COOLAIII PIPE (BYPASS) HOUSING
1
l Ct,nderHd
Lubricato nd asmble a 4 seal in the

upper coolanl ppe housing llng.
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
4- Pcilio th lh6moslal
remins proD6 v
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
Oil Coolerand Cooling Duct cover
PUMP INLET HOUSING
1
2.
Lubndeand assemble nssealing ngs

on lhe pump inbr pipe ar
r-he
joinr wjlh rhe
Plae lh inlel housing in posilon belwen

th6 uppereolantpipo and the pump inlei.
Replac and lubficale I sea lno o finos.
[215 Dw' 2r9 EPI

The oll coolor msl be atached 1o the cooling
duct cover belo aftaohing the @r b lh
OIL COOLER INSTALLATION

1
2.
Using a shlp pick, carBlully remde lhe

rubber sear (norded qasket)
the grcove
n lheoilcooler c@er, il notalady
'fon done.
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
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
COOLING DUCT COVER NSTALIATON
1.
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.
lnslallrhe oi @derll@ plate over the oit

cooler Tqtfen ttnaB 1o spcilicalion
l4lener
NOTE
tl srock should be used b
fm deiormlng th slamped cwer that the
A small pe.e ol
kep
lool fool is pressig aqainsl.
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
lnslall lh fsl6nrs to rhe ear pipe n the olt

fller housng. Toque the bolls to
The uppr cenler mourninq location h6 liqhtr

ldee than olher mo1i0 locaiions.
5.
slart
a I
lolqle
lnstall the lont ppe wilh n4 seals bellee

lhoi fllerhousngandlheil@oercovei
realnlhg m@r lastene6 ahd
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.
lnsialllwo allgnenl pins to holdlho

in place ard 10 aid in lhe alignmenl oi
gskl
-),
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,
Clean lhe manilold mounling suriace on lhe
2.
Tmporily inslll n alignm6d slud at each

exhaust manfold fanqe bcalon on lhe
1.
NOfE
Mibrd s ds
4.
This is don lo hold lh manifold whil posilioning

the manifold gaskels lof nslallalon ol lhe bons
(ftbl)
2.
cv ndsr
Hd se
(wih
Apply nli-siz.ompoud to the threads

and under ths h6ds or contacl sula@s ol
ll lhe mnilold lasle6
NOTE
o
o'
ae\
,o
(_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.
NOTE
F'Urc3sAlgnmdPhh3blllio.
3.
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
Mk surelhe sp@ r seated p@pe y

in themdilold siep bore hole locxon.
lnsrall nw qakets olo lhe

wilhthe sa side lacing lre
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
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
speciielio.
5, 'aslene6
lnstaf nee
h gh temp1u gaskets
betwen the tulbo fange and qhausl
6, Psilion lhe lubocharqer and gaskels

aqainsl rh Bxhausr manilold.
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

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
2.
lnsrall a
ho usin g
9.
nM hiqhrepehtu o6kt EPc

and xhausl pipe.
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
2.
5.
Using a loque wrcnch, lighten repla@t

siuds a@ordhg lo spcicalion.
Asseble lh sner on the sruds in lhe
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
2,
1261 CKI
1-
Asemble lhe alr copr;ior on ine

moonring llange ollhetimiq gar plate.
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
2-
in the qrcove on the
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.
ns
lnslall a
rubbor s6l (moldd s6kt)
lnto the gl@e ol lhe iffake manhld.
NOTE
Torqle-righren the iniake manilold bolts in

s6q u nce lo sp ecifi@lio..
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
SeuBlh 6noin hamsslolhe inlake

nihld usi.g pdiously rmowd
lsill rh eLeclrical conecto. to the charge
ai lmpElur6 sn.or localed on the lop oi

the inlake and *curelhe hah* wlh li6
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.
NOfE
f4
use
scf6m wllh mounling spacefs when
nslallrg lhe lake mailold.
(Bocr) sen$'
Using torquo wench, I qhlen the sensor

io spec licaton.
aoding
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
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
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
the luel lrcm the lank inl lhs lu6lpump.
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
NOTE
lake sure the @olinq plar and EECU matng
1.
PGilionlhe EECU on the engine btok and

insiall ihe unling la6tee6.

4.
NOfE
ike su lhal rubber isolatoE re corectty
nsialled and thal lh grcund sl@p is gounded
10
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
F.r Firsf nd HoGnq
asbt
1,
Asemble lh tul finer housing onlh6 btock.
2,
Using lorquo wnch. tghten the taslnerc
acmding lo speciliEi on.
3.
Allach lhe ppe bellveen the sde ot the hd

al lhe raf ad the lilte.hous ng.
5.
Atach the line lo the bl@k with a P-clamp,

lnslalllh iul rlum lin beren rhe
h*d at lh lorn and lh lifter vlw
cylider
Lop.P,eure Fler
sppy Pump (Mounrd ro
Poref
Crankcase Ventilation Separator

1. Clean lhe cankse venlilallon sepato
malinq sulac o. lhe ngine btock. lnstalt a
rubber askel iffo {r s6pa6ror
n4
lnsrallrhe line ro rhe bock wrh P-clamps.
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.
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
clamp laslenerc ac@rding !o
6.
hc6
sp4l*on.
Assmbl 1e lnler hce on the separator

inlel and prpa fo re cov6r connslion
in a iulu@ slep,
7.
the
Fduress.FanDvePu'le'.ndc
lnsiattho* ctamps.
Using a lorque wench, tlghlen the
clamp taslnerc c@.ding lo
h66
sp4itilion.
Crankshaft Vibration Damper and

Fan Pulley lnslallatlon
[212 RB,2'16'tA]
AcaurroN
When handling a tbnton darpL b a6tul na
to daage ll fo6kg. Denls ln the auer
hsng sl rcndq the danpet inefecfive. rhe
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
t2
t3
viraion onpr
c,nrshaft Hub
Using aloquewcnch,tghlenlhe ataching

l6lneF in sequence in two stps
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.
BEPAIR INSTBUCTIONS, PART

6.
Fqure 3@
FDnt E qiru Po@
Tar.r
I
|
C8,264 DP1
Assemble lh allmalo. mourinq brackel

onlo lho cylind6r block. Ighlon ih6
Iastere6 a.cordang to spelicalion.
2,
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
ou
lf mNd, assemb e the bett tensio idter

Using a lorqe wrench, lighlen lhe
cordino to specf
A*emble the allernalor and reriqe;l

compGssoron lhei pads.
(FEProl
Alternator and Ref rgerant

Compressor lnstallation
1271
cr on.
lalene6
s.
m 6mp,sor
6. Mounrm
Bccb|
Fron'
Enan sppod
usinq alorque wrench, lghlenlhelasleefs

aoding lo specmcatun.
ll a hrnBss is installd. secuely connect
the eLectlical wi nqslaggddu ng
Assemble lhe be I pulleys on lh llnaror

and compressor hubs, r reved.
REPAIB INSTRUCTIONS, PABT
Wiring Harness lnstallaton
l3
wqHafss
1.
Roule ad pGition the harnss on fie

engine
noled durlng di6a6sembly,
2.
lnsn lh unil injclor ponion ol lhe h.me$

throqgh the hol l the tllnq gear housig.
3.
4,
Connecl ihe hamess lo each iiectf.
Conneclthehamessiotheengibk
mnlrcl valve t lnslalld.
Usinq hioh-lmplue wne es. 983472,
aliach ihe harness lo lhe cyLinder head.
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.
/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.
2.
cLrclva
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
Chck l\ lnsio. ol lhe lermanal on n6cto I

pns shq ihe tsl pins rol kit 999000a.
NOfE
ll lerminal pins are damaged or
2.
coroded, ep ace
Caelullyengagetheupperadlowerwiring
haiess conncroF lo lhe EEcu. vrify lhai
lhe connecloG are lalched and propedy
^caurroN
Ue aE to entute hat the EECU teminat pks

aE slaqft an.l undanaged,
Cylinder Head (Valve)
Cover
lnslallation
[211 JBI
3.
1.
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|.
lnslall lhe bolls lo secufe lh6 wiing hafness
FlguEscyn.&fH*dcovlG'3kt
3.
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
Appry a 2 mm i0.079 nch) bead of MAoK
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.
NOTE
The cylnder head cdr musl b in$aned
wilhin 20 miutes ol lhe slnl beinq
Fan Hub and Drive Beli lnstllation

[216 AAI
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.
The boll springs povde e@n tesion on lh
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
eiffi p*@I
gre
1.
shoLt
nury ot.l@th
tE
la d sr.rdly ahft out of
Atach engine lifung ioo s J 47033-1,

J 47033-6 and J 4703a4 as lottows:
a.
b
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
Placelhe lfing chan toihe gin tift

s*ure lhe chain lo th6
eys nd
c.
Slde th rr lifting plare inlo the @nter
d,
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
nl akady don e, asser; bl thd lottowjns

oompoenls onlh6 ngine using lhe
p ocedu fes cove red ea i6r in this 6eclion.
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.
.
I
.
Enginewkins harn*
cfakcase ventilt on lubing

EEC|Jandcoolinqplal6
lullines
Cra.kcase venlilalion sepalor
Fuel llter valve husing and
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
d6e
pos
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
fasleneBlrom the enqne stnd.
theenlhe hoisl,
pla@ lhe engine in a

suitable supporr ck or insiall rhe engine i
Using
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
NOfE
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
NOTE
Belore insiafing lhe enqin6, mak8 su
equipmet a@ inspecred lor sfety and
1.
Positlon the vehiclo 0n a
fat, lwel 6u.lace
Apply lhe parklng brako ad block ihe
wheels.Obse@allsatelypreautins.
R6rer to th SPECIFICATIONS section
lor
lnirfro boll lhe laslnB m.lioned
be
ou
Some groups ot
musl be tlqhtened in a
spcilc sequence,
Paflens
'aslene6 ol sequence are also
specied i the lorquo spcili@tion seclion,
lnsrallation
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
^caurroN
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.
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,
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 haual lE nsm iss io n. atlach lhe

uich linkage ad bfacker Giaing
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
Femo@lhe engine litl.o lool lrcm lh
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
OTE
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.'
To
'd
BEPAIB INSTBUCTIONS, PART

29. IttheBhicLs
is qupped
wlh;
@ndlio.9:
21- Co.necl E fan aclualor

22. Connecl lhe engine c@lanl lemp@lur
23. All5ch
the chafge air @oler oullel
24. Atach
the charge air cmlr inll
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.
30.
"
a.
Conct lh /C comprGso di$harge
conner
c.
Connel lhe
d.
con6ct ih6low prsu cutour
e,
Recharqe lhe NC syre wnh

grant rccd6ry
rfigErn usig
dd recycling equipenl for R134A.
rhe
Jc ln6
al tho
p@ssu@
sl6h
on lhe
cl
lnstall lhe nlei ar system componnls
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
Elwa
Connect all soso6 ad acluatoB,

oil and molant. lf aEilable, use @dal
qtEclornjeclorwhen addnq olnt.
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
.
.
.
!
.
.
.
CAMSHAFgEAFINGBFACKETS,
BEPLACEMENT
OIL fHEBMOSTAT ANO PFESSURE
SAFETY VALVE BEPLACEEN
CFANKSHAFT FBOT SEAL
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
Preliminary Steps
b.
bing
fh.
lllwing eFtunts md lo
'
t
CompEsion BEke Solenoid Valve
retuved a@ss to the @.haft

CRANKSHAFT BEARSEA!
CBANKCASE VENIIIAfION {CCV)
SEPAFATOF REPLACEI ENT
OIL PUMP REPLACE'ENT
INJECTORCOPPERSLEEVE
.
.
VALV STEM HEIGHT MEASUFEMENT
VALVE STEM SEAL REPLACEMENT
UNIfINJECfOFCLEANING
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
Camshaft Assembly
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
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
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.)
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
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,
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
2.
Clean lhe conlact sulacs of rhe oylinder

hd and lhe l@e ba ng brckets.
3.
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$
^caurtoN
dces@ lc@ la pnch lhe ba.ker

wh atkng rheit p6ilan on the
ctndet had. Daage lo rponenE ca, resu.
Do not
lrk th boaring caps lo lndile lhal

allermaiket being back6t and cap
ssmblies haE bn in$nd
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.
2.
5,
lnsrallrhe new lower bea ng brackels al
lhei spocliw marked positions
on
ihe
6. Chec* lhal lhe bearing bEckels can

siqhly on the localing pins.
Bckr Nos.
Braoket
m@
1 and 7 shoub rurn

sllghlly lodard ahd bad< at one side.
N6.
fiuSh
6 should
ove
Compbssion Brak Solnoid VaN

Va
and Unn lniclor Adiushnr
Cdr A$6mbly
lnsiall all prdiously rmowd bls to lh6
qbund (negatrve) bttery temrars.
Strl lhe noine, check lo lks d ppr
Va v
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
3.
ihe cder and cll ndt block s@ling
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.
'iguE3P-nemdngs.l.lyvawcdeldnng
4.
5.
lnsll a
n4
6.
Usig a lDrqu wnch, lighlen lhe valve

ac@dino to sDcilicalion.
valve n lhe
lnslal the new Elve and
cder
tur
inlo lh
BEPAIR INSTRUCTIONS, PART 2

Oil Thermostat Valve Replaceent
1. Femow rhe
Belo allempling lo rende the theftuslat

valve, apply the parking b6ke, shift nlo ne{n
and lhoouqhly clean aDUd rh vlve head.
2,
rhem6r1 e norith.i oir

tille. housing and diserd,
3, srall a
| 2.orPrc!&shtvE
nM rh.moslat vdw
wnh a
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
2.
Femove lhe fan b ade
lh6 lan clulch
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).
3.
Place a ew cnkshail flonl seal on the

cnkshatlfbnl seal rmowrnslall.
NOfE
The cankshaft lront sl
l 3 cEnk
hdfi
4,
fub
Posilion lhe cankshatl fronl seal
cEnkshalt hb nd cEnkshaf font cowr

Careiully dri@ the seal ilo lhe @rer unlil
lh lool bonoms aginsl th cankshaft hub
/AcaurroN
When handlkg a vbn danper be @@tut not
damg tha housing. Dals k lhe td
hoBg n rcndet the danpet ireect@. t
ro
dafuged, the viaion danper @nnat be

repaired and
6.
Bl
be rcPl@d.
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,
pr*nl
solhappig M5 screws ol
sulable lengt\ anch lhe dnkshan
l@nl 6ea removetislal er lo lhe seal.
Using rwo
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
7.
c'alshafi
Hub
ll equapped, nstalllhe
faslne6. Tighlen lhe
Fhu6
3e0
Dnw Bd rsn6roner ftor

CBANKSHAFT NEAR SEAL FEPLACEMENT
Special Tools
Handre *irh
vai
nopno tvpa
s usas {fib 25
si
horo)
(Esnrian
Neoprene Seal Removal
/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
wh@l
P*tut
1.
Elu ly rem@ lhe llywheel senso(
2.
lnslall lwo M10 screws to use as handl6s lo
3.
4.
Fmore lhe llyryheel.
U6inglhepuler,9990192, and the std

hamr, 9s96400. caE u0y rem@ the
REPA]R INSTRUCTIONS, PABT 2

Neoprene Seal lnstallation
L
2.
CIn lhe llywheel, housng nd
ckshaf
N}
Align proprly and 4semble lhe ew seal

on ihe sl hstl r, S998238
Freun
5.
@-
Fwh.t ttuhnad
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-
^caurtoN
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
Remwe lh6 clulch Gsnbly
2.
Ca@fuly rmoB lh llywheel
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
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
4.
ng is supplied wllh a
lalion g that shuld b eft
lnsralllhsalwlhourrcmovingrh
installato ring o@ lhe thrusl scw, sper
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.
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
7.
/
sl
ts in
Bem@ lhe c6kshall ar sal installation

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

CRANKCASE VENTILATION
(ccv) SEPARATOR
REPLACEMENT
CCV Separalor lnstallation
1,
Clean the mounlingsudaces on th6 cytinder

block and lhe CCV spaGloi
2.
gaskl, assmble the CCV

Using a
sepaElor on lhe cy inder block.
3.
Usinq alorque wrehch, tighten th screws

amording 10 6peclicalon.
4.
5.
Anach r,h CCV hoses.
6.
Slart the enline and chdk for leaks.
CCV Separalor Removal
1.
Dsennect th battries, or iurn of lh main
2-
Clean the cylider block afound lh
ccv
sepalo mounlig.
3_
Remow the
ccv sepator fo
the
re
Turn on lha main swit6h, or
OIL PUMP REPLACEMENT (IN CHASSIS)

t219 MUI
Special Tools
FrpheelTunie
roor (BsnaD
'
r@nnect th
'7'\'\''
o
311 O
i#btlionsyslm
2PUmpodlelP'pe
Oil Pump Removal

1
2.
3.
4.
5.
ll nol akeady done, remow tre oil pan.

Rmov the pump ilet pipe and straier
Bemde lhe php outlet plpe.

Reove lhe cbssder p pe.
Beow lhe blod( stllee plat.
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.
6.
ll necessary, rctal th cBnkshan oul oi t

wy usinq llywh61 turning lool, aBa0O014.
7.
Remove lhe oil pump lom lh brjna
p.
Oil Pump lnstallation

1. Clean a[ pans b be esed.
2.
Atlach the oil pup lo the No. 7 main
3.
Usinq a lorque wrenoh, liqhten the

amordino to specicalio.
sc6
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
ppes n
lhe pump housing ed instal ih molntng

scrcws ro secufe rhe plpe lranses lo lhe
12. Apply
a 2 mm t5/64 inch) bead
ol342sx33
rAcK-appoved seahn b lh wms

bel@ lhe llywheel housing and timrnq
geaf plale nd bhreen lhe mounina p at
and lhe cylider block.
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
strainei
Asmbllhe pipe and slEiner inlhe pump
housig and on lh block.
Usi.g loqu wrcnch, liqhln lhe

@ordlng to specil et on.
6c@s
rplae il jl
nessary Lubricale and assemble th sear
11. lnspecl th oll pan sal nd
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
rnjeb
copper
sre4 EnHior
unr hledo' P'ord'on
unr
ndd
Bo
unii rnidor BoE
r4 itu*dial)
sr*s (&d'D
cdb'y *anq Fqs
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
unir
hiftre.rc cre
ino
K[ (EssrhL)
offi

Preliminary Steps
fha lolowng
.@po@ts
need to be
to tl njEclot @PFt
Et'Gr'lE DrsassEMBLv or
ovrl f @s
sl@@s
(@
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
3.
Esue
2.
nqs are required lo coverlhe luel
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.
unr hFcbf Eo6 Pddi@ Pruq
lnsialltwosealnqrngs
n16 ng lhluigallry
Fsur 4o5
Fwheer tumrnq roor
REPAIR INSTBUCTIONS, PART 2

NOTE
NOTE
This is lo ensure lhat the @pper slede iappinq

lool does ot damag the pislo. due lo tool
Estheluming lool
is we lqreased
Applying gas6 willcaplure copper cuttlngs and

prryenl lhem l@m lal ing dMn inlo the oytinder
6- Thad lhe lap in small lhdemenls. Bemo@
belo
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
5. Llbrllo
the iip oi lhe
mm
ol
^caurtoN
tueads are no c conplelely thtough the tp

he cappet sleeve, lhe tp @n bak oll an t la
ot
nlolhe cylnd fhtd rcsu ndanqetothe

.ylindet p'ston. vatves ar turbochatueL
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
th ext.ror bo s tneaded
cplelely into the 6ppet ele* belae

atlenplhg lo rove l ar the np af the elee@
nay eak oft as
steM
Fsur .oa
adusrino copper
sl*rc Enccbr
tip
t s
ewed.
en siusty
Ths btatn
danage the pston,
Eoh
scrw of lhe exlEclor lml lo

secure the bolt- Makesu1atlhe set sc@
is seated against rhe llat pan ol lhe qt.tor
10. T ghlen lh sl
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
^cautoN
ue .n bds la Eo@ wet d@ws, ot

danaae to lhe nectot bore @ t*ult_
Do not
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.
Using lhe bfush, clean the cyllnder hd
iicld bo wll6 lor lhe @pper
deM.
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
inislor
lhe @pper
sle*
cleaing kil clean

seal of th -ylinder hd.
bo@
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
Copper Sleeve
opening n lhe cylind.
lnstallation . r
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.
:tr>.-
fr
Frqurc 4r4
crdnnq
\/
hl*r fp BoE
NOfE
Th injclor bor saling lml musl b usd lo
prdent debfis lfom enrering the luel p6sge.
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.
Flsu15_Fly}hsdruninlftol
NOfE
This is 1o sNuB lhl lh @pper slese
installation t@t does ot damaqe the piston du

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
n*
nN Oiig.
@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
rdt
taol s dentiled by a
bonM
sula@ lhal has a nachked crculat rcces. Use

of a @l wnh a penedu flal bonon ay esult n
dafuq to the pper seqe.
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
NOTE
Swdqinq bil ca bo ordrd
spar pad if
s.
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.
^caurroNn re
Failure to l@en the s@dgng bit

lhe bit bekg twEed ot bfaken.
a.
Lublcale the swedginq
in
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,
^caurtoN
spkdie an esuh
Falute ta hold he
in a twisld
Flnal Steps
nstal lhe folowlng copo@ts whch were
rcove.r fot @s Io the inlector copp
sl*v6 (@
1 1
Remove the s ewe inslallrion rml from lhe
NOTE
Itlhe inleclor is or being
ENGt|r'E EEASSEMBLV
Cy inder Head Corer
lot

UNIT INJECTOR CLEANING
Cleaning and Inspecton
NOTE
Prelminary Sleps
Rem@ lhe ioll@ing .omponents rom th
ngine (s ENGINE DISASSEBLY ior
.
.
Cy inder l@d Cove

Rocker
Arn ShanA$embly
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.
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,
1. Fen@
lhe two Ojigs

nd dscard th O{ings.
2.
Fis
r23
the njector
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
3. Cdrlh
4-
fo
6lotl@s:
opning lorll)e elect.il
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.
Srde a
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
Frsu6 425
Cr..nnq rl.0ror c,p Nor
s6r srac.
AcaurroN
rhe@onwi
be very had
dfi@ o
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.
Awd the
3,
lnsrall new
9.
Lubncale rhe injslor Ojings wilh clean
rings rhe gfooves o me
Fal Steps
lnslallth .llowhq 6pots on lh gine
{s@ ENGINE FEASSEMBLY lor pcedur6s):
.
.
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
2.
Femo@ conpornls as necessary 10 gain

@es to lhe cy inder had (lw) creL
Remove the cylinder head cover and r@ker
^caurtoN
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
3.
Femore
lheulre
yokes {bridses).
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.
a'
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
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

Plc lh dplh micromeler on lop ot lhe
lve siem helghl esurnt gaug and

nole i, Ihere is clence btuee lh end ol
and lhe lip ol lhe
fre micomeler spindle
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
lnslall lh components lhat were removed to

10 the cvlid had covr
qah access

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

Prelimnary Steps
@poent
nee.r b be
to th vIv sl $Is
EN6lt'lE DSASSEBLV l pro@.urcs):
fh fo owng
tvd f ae*s
(*
.
.
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,
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.
3.
4.
Beore and
dl*ad
lhe valve ste seals.
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
Use proredve goggls or ye inury could
Place th6 sa! qDid lml 8890001

posilion onlhe valve stm.
, in
n*
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.
le

5.
LcaurroN
g4
Us hty
taps wik the haet when
he sal o awid danage to the sea
as wdl as tl lop thbet potli at ,re
salkg
6kg
NOTE
use preict goggls or ey lnlury @ld
r@1, 851 12460, is deslgned ior

MPO and MP10 enqines,
lhe
apptopriat6 nd of ihe tol lr lh ngine b6ing
seal inrallarion
use
or MP7,
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
U*
6.
Mo lh6 wtu spring comp@$r to the

cylinder ol th cylinder pai and epeal
prc@doe.
lhe
Foiate ihe cEnkshaf so lhat
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
tl lllowing coponents vh.h werc

rffiove.! ot @ss to llB valve slen seals
(ee
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)
si
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.
sell-le
Special Tools

rnrno
Gd cM Aiqnmd tul

Valve and Unt lnjector Adjustmenl
NOTE
[213 NB,222 KGI
Focker
3 Fockr
4
GENERAL INFORMATON
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
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
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
Usingthellylvheeliuingiool,3a300o14,
bar lhe enqin over manuallylolhe
apprcpril camsh ma*ing fr
.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
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,
@-

3-
4.
d@6nce is nol wilhin specllcalion,

loose lll locknul and adiusl the 6leaance
lf lh
s.
lo pweni
luhing and lghlen the lockl to
Hold rhe adjusliq
EXHAT ST VALVE ATUUSTMNi
1.
n r@m
5.
Recheck lhe clearance aller tlqhtenlng th6
6,
Mark lhe @ker arm when adjusien ls
(Wlnlouf
POWERLEASHT)
Al lhe curenl camshalt soiing u6ed lor the
nlet vlws, adjut the exhalsl wEs
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-
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
e rccker arm whn adjushenl is
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,
Fecheok lhe clearance behreen th dhausl

and lhe valve yoke.
w v r@ker arm
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
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.
Adjusl ng Exhaust Fock. Arm CleaEnce
a.
Flemove lhe shim relaining screw
ad
@mow le 6him(s).
b,
oerermine rhe Ihickness ol the shh(s)

requircd ro p@ide lhe specitied
c,
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.
Fisure 446
Bhke R.cbr
adtBrod Inh
Diar
lBAdusrinqscrew
c.
S-
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
5.
Leave ih ller gauge
i pla@ belrveen the

exhaust rockor am pislon and lhe Elre
yoke shim and adjusl the bake rccker arm
Adjusling Bke Bocker
a.
Ah
clearnce
Loosen lhe iocknLn A on the bBke

fooker arm adiusiihq srew
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
a.
Mark rh respclivo .ocker
El@ adjuslmenl
am as each
complled.
OPEBATIONAL CHEC(
Ane lh vaLve and unil injeclor adjushenis have
been compleled, .heck ngln opeEtion as
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
Po@flashN egine brake, lighten the ptate

ng afiachnq screws b speci.arion after lhe
vlv nd unil injeclo adjustmenls hav been
sp
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,
Slaftlhe engie nd bring it utj to ofa

opeling lempeatuf.
3.
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-
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)
i@,-
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
lransmisso
_/_-'_=\
nol n ger
RemoElh16rrainingsc@sandsp nqs
@ef lom rhe cylinder
ad move the varve
Dsconn4l lhe wiring harness leads al lhe

unil inielors and camshalt sensor
coneclor Plllthe hame$ outlhfouqh lhe
3,
7.
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.
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
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.
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

10, Tighln lhe bolt6lo specijicalion. Wlh lhe
camshafi sl al fDc, lh doubl liming
malks on lhe qear should be allgned sith
Whil holdins th idler gear /n aqainst

lhe lhckn6s gauqe nd emshaft
qear, lighlen, bul DO NOf torqu6, rhe
lhe malking hole i the qearplale.
11. nstallthe ctamp
asebty
Tjghln r clamp $semby tool.
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
f.
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.
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).
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).
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
1.
Afler Engine Overhaul

Procedures
2.
Filter Element lnstallation
3.
4,
Al
ille6
1.
2.
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,
li ne@ssary, dd oil to 6ach lhe FUL! mafk
and @olanl condilioneE mus!mee!
lnslall
Usio
nd
airlihrin lh6 airfih$ housig.

trqu wrch,lighln lh tlchig
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
sSTM
NOTE

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
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
allowellenllo
run rroughrhehne b lurhany

debris lhn blw lh I'ne dtu wirh .l
comp@ssed alr
P*l
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.
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
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
.ew
But
Do ot work nsrrhetun wth rhe enqine
rorng. The engi. t car bcome active at

.nylmeethoutsai.g. Fa[rto hee.Ilhs
wrning ca rsu[ n sewr peFonat iiury,
Cooling System
1. Chck ihe @olig syslem. rake
su I
piugs ad coolnl dEin quick dis@neds
a nslalled and a light.
2.
Mak6 sure lhe lhermctat is insla ted.
3.
lnslallanqcoota
nfter
Fill the system wth lhe econended
NOTE
take su lhal all air is puEed fmm lhe cootinq
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.
2.
Slat the egin and tun il al idte irr

approximalely 5 minuleslo remwe a f
fapped in the tuelsyslem

5.
PRIMING THE FUEL SYSTEIIII
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.
Ch.* the luel syste
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
The ony ac@patle nethod af prmng the l@l
s the hand pet punp. apptykg at
to lE hEl ttnk using an aufiaty
sye@
p@t
punv
1.
Unlock tho hand
mr pump by pushing
lhe handle n and lunhg t
2.
Pump lho hand primr unlil lh force
whn lh luel 6yslem is completet epty, 200 or

ore strokes may be nedd lo p me lhe syslem
NOfE
There are NO bl6edippleslo be opened n oder
L@k lhe pump bV pushino lhe handle lnlo

lhe housing, lurning lt cockwiso and
Sbn lhe enqine and
ptle lhe fel system is PBOHIBI|ED.
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
ol
NOTE
3.
1,.
These
un it ata icreasod
idle lor aDp@xinalelv 5 miules lo remove
an tPpd in lh lul svslem.
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.

Engine Operational Check
1,
Remde alllools lro the engino
2.
Cone.l lhe batery b es (egative cable
3-
Cler lhe
rcrk area
ol
debls and p6onn1.
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.
Bunln Check
NOTE
b prop6r brk-i
inilial striup ol the enone.
is inponanl
4.
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,
5.
OpeElelhe engine wilhin lhe
NOTE
lnslll any addilional inslrumenlalion ndd lor
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.
120G-1600 pm Enq6 for 15 minuls.
NOTE
DO NOT alLow the enqlne to dfop io idle speed
15 minule break-in period al
1200-1600 rpm h6 bn compl16d.
ulillhe
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
The operator must be obsetoanl nrugho lhe

enlte run-in prooedure in order lo deleot ny
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
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,
ui r hisdor
inJdo6r repraeabrg
a6!
'mqd
fr
casr
im Ee
pa*qs, ibqBl
SPECIFICATIONS
cylindsfHd_VlGuides
hdiduart progdnd unl
inFeE
(6): EMs modure
ceaflyp6punpiilagral*ilhpore.sledngpump;
refbB'lbypss
bt:
.
t
25 L
(26 qE.)
30 L (31 7 qls.)
nirun
ffimum
m
hrd *hB
'
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
(rspedbi ody: ml
'd
Lin
{+Rocrs)
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
(E:u4 vd)
Fd.!.r am creaEne (cdd
ea*
Hsad Dane'er
rnrr
enqie)
ash
SPECIFICATIONS
*hci
ue'
A'mcrtr(cdd Em)
Bl ckar e,* ditn cinq adiudiq *'d

Brafe o.ref dl6n0 $R roGen@
cleBne dur (caftrrah b bEra rccbr rrm rdbn
var Faca ro cyrindf Hd Dd 0n!1)
Fr b cyrds Had oe.r GihaGD
Nob:Fe9laci@l$ab@qnsrcpldnqus
SPECIFICATIONS
Eusl PrcsuE Govrnr
-'N,
l)
SPECIFICATIONS
Engine Component Torque
Specitications (Critcal Fasteners)
NOfE
AcavrtoN
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
lisht
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
cPE E@
er4
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
Fasrene6 nored by an dnsk C)

ftorqu aft6r nsin fun'in.
quic
rEGm $ion {aepr adludabr
s@id
sws
(sp*
rh.F)
ldori@'d wirh or
p,Hpp
ied and
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
^cautrott
lning geat mmting plate bolts,

lning gear aatng bolls.
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
Fr*
ot
lrrher hsi@)
(u6rf [r housinq)
snp)
ofP'suc(bd o ddf .omp6on
LEm.mFor!re
(inside
SPECIFICATIONS
PA ENGINE COMPONENTS
varv (cyrinder Hd)
covd
TOP OF ENGINE
SPECIFICATIONS
CaDshft Beanng Caps and Feker Ar
fhe
arn shalt asebly
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
afunmftdandrcPla{lhnswsEs'
.fnda@dyroosloosn$rews
h31p2,lqhbnlhscl3$pfqr$
SPECIFICATIONS
D.
:s"
"
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
RdaiGr
Adjdmed
(Erhaud wih EEin6 Bns)
soa, shi {Edr Yos)
qs 8nb Pbb
spnns
(tu*e
eashh,
4Rd')
I rhs copper iiisdor sls@ is n4, iii6d rlks smes mud be lehrmed
I
rhe copper idedor
de@
is rcused. onv
*ps
uersr0
d 5
15 N.m
Wirh Ebad.bad &sisn
wih ra.nom desrsn coppef shve d hjeclof
c@F s 8ee
(no
lnjsdor
bdfl aFly
(7 11 b,ft).
in
ri6 deFs.
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$ahd
Flsuc165_rqEsgq$rcgscw
fighlenswsinlheodelindicaleda
p*am
(a)
sh*n.
SPECIFICATIONS
sbp2Wilyhha9mo'dl
Frent Ergn Support Mounlnq Bfackts
SPECIFICATIONS
Addilonl Frenl ol Enqn Componnls
Fhure
slep
rishbn
alr 6
srss
in
rs
rol
is squoi
AtehinqNub'nubbcvindsf!dardBlock
- codd
2, 5, 6,
PumP
Hruine
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
q.ar prar nqr b rhs
'imis
mdd@k,0mind6of4plying'116sdml
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
Fture
1?6
ro4w sqren
- h4
.d
M1o
apptirs
se$
rh
(Hosin,
sdd
ro
M ,d
stock)
SPECIFICATIONS
o
s
FsuE 4z
sbp4
M3
srs, 1+z
(rmd
or
hinq
ro'que
sqwne
M3
cBs (Prft b HoGi4)
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
ere*
srep
in
@, 0@'t
L5
eqreme r b rored
kt
$reG c
nd
by
squffi
2 (indud ns a).
Fg._To'qusqsnc
idd {s
m<.L. Mpod
ar
asmbu
ro6.t
indan
s@
B.
SPECIFICATIONS
Turbocharger L(brcalon FiOs
rburcas
Ol
Presu Sery
rqm squd..
ru
Vatve
FiguE4s_oilPE*Urc*brtvdE
SPECIFICATIONS
SPECIFICATIONS
Addilionl Fghl-Sde Engire Conponents
MP8 ENGINE COMPONENTS
LEFT SIDE
iloldlocylndef*d
SPECIFICATIONS
SPECIFICATIONS
fgu1s_scfuNmbelddtf
SPECIFICATIONS
Na 5,
No
3,25,r.5 N.h
fsal rFi)
{.5 Nn t3
No 6, 0 r1 s
Nn
+4
Lii)
(Nd !Eb)
{30 11 rb-f)
SPECIFICATIONS
Tandem Pump (Fuel and Porer
ri6
N0 2, e !i2
No 1,3o
Srerinq)
i12 Elr)
N.n (44 is br)
N.m (se
No.3, rc
ri
0 N.m (s, +7
bf')
Addilonl Lfi-Side Engn Components
ar cmpreer, 3k.
t*n
2m
arhchino
sc,e$
(ro
tuwef
sbro
Pmp)
+50/ N.
(147
+s7l{
br)
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
NOTE
Us oly l lollNig @mmended sealing

compornds and lubricants.
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
Na s2s33io' o@cdnnqoe)
Ldlp27?dfq!v&ndbolhtsds3l
Prr Nd
Eis'ne
oilrlrer
ds, rde is 6 (s dss and rheads) and @sh3
inq qasksrs
lturr-rm I hE)
rrsF
DM cdnq6 334
qry
iNDH(
INDEX
INDEX
COPPEF SLEEVE REMOVAL... ..,
COUNTEFBORE INSPECTION AND
A
ABOUT THE MACK MP3 (EUBO 3) ENGINE
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.
CFANKCASE VENTILATION
CBANI<CASE VENf tLAltO (CCV)
SEPARATOF FEMOVI................
CFANKCASE VENTILA ION (CCV)
CFANKCASE VENTILATION SEPAFATOB. . . ,
CFANKCASEVENT]LATION SYSTEM,,,.,...
CFANKC'.SEVENLAION,
B
BLOCKCLEANINGANOINSPECION,,.,,,..
IlA
BLOCK S'IFFENER PLATE
112
219
FEMOVAL.......
...,
c
CAMSHAFTAENCHPROCEDURES,..,,,,.,, 146
REMOVAI............................. 33
cat\sHAFTtNsPECTtON.,,..,,..,.... 146,219
CAMSHAFT INSALTATION . ...
CA]\'SHAFf
FEMOVAL......,.
CAMSHAFT SENSOR DEPTH, CHECK, . . , . . . . . 49

CAMSHAFT NMING, CHEC(
CCV SEPABATOF INSTALLATION. , . . , , .
..231
...
ccvSEPARATOF
CHECK.......,
CFANKSHAFT FRONT COVEF AND SEAL
BFACKE FEPLACEMENTPFOCEDUFE
FEMOVL...............
231
tNsT411TrON .... ... . . ... . .... . ... ..

CMNKSHAFT FFONI COVEF FEMOVAL....
CRANKSHAFTFFONTSEALfiEMOVAL......
CRANKSHAFT FFONSEAL
NSALTATTON . . . . . . . . . . . . ...
.134
CBANKSHAFI FEAF SEAL FEMOVAL..,.....103
CRANKSHAN FER SEAL
CFANKSHAFI REMOVAL . . ... .

CRANKSHAFT VIBRATION DAMPEB AND FAN
PULLEY
INSTALLATION
REMOVAL. . . . . . . . . . . _.......
PULLEY
CYL NDER BLOCK RECONDIT ONIG , . . , .
CYL NDER HEAD (VALVE) COVEH
tNsTA114TtON......................
CYLINDER HEAD (VALVE) COVEF
BACKT-ASH..
CONNECTINGROD PISTON
ASSEMBLY
OVEBHAUL . . . . , . . . . .
otsssEMs1Y . . . . . . . . . . . . . . . . . . . _ .
CONNECTING FOD AND PISTON EENCH
PFOCEDURES . . . . . . . . . . . - . . . . . . . .
coNVERStON CHABT. . . . . . . . . . . . . . . . . .
COOLAN AND PUMP INLEf HOUSJNGS
FEMOVAI.........................
BEI\OVAL_.............
PRESSUBE TEST . . , , .
oHECK . . . . . . . . . . . . . . . . . . . . . . .
CYLINDEB LINEH FEMOVAL
COOLANT DRAIN OUTLETS. . . . , . . . . . . . .
COOLAN FILER .
COOLANTPIPE INSIALIATION...,.,...,
COOLANTPUI\P INSTALI-ATION.,...,,..
COOLANTPUMF REMOV41........
COOLING DUC r COVEF AND OIL COOLE_F
....
coo1tNcsYsrEM...............,...,
COOLING SYSTEM COMPONENTS BENCH
PROCEoURES . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM MAINTENANCE. . .,. .
COPPER SLEEVE NSTALLATION..
...,
D
DESCR|PT|ON. . . . . . . . . . . . . . . .
.....
DRIVE SELT BEPLACEMEN AND
TENS|ON|NG . . . . . .
.............
DBIVE BELTS AND FAN BUB AEMOVAL
E
EECU ANO COOLEF
., .
EECU ANO COOLING'NSIALLATION
PLAIE REMOVAL
.
.
..
2OT
INDEX
ENGLNE CHECKS
ANDTESTS......,,
FUELFILTERCHANGE..............,.,
SPECIF CATIONS (CRITICAL
FASfENERS).
ENGINE
ENGINE
ENGINE
ENGINE
FUEL FILTER REPLACEMENT . . . , . . . . . ,

FUEL LINESAND F LEF HOUSING
.... . .. ........
COMPONENTS . . . . . . . . . , , .
COMPRESSION, TEST. . . . . .
DISASSEMBLY . . . . . , , . . , . .
FINAL PBEPABAT ON AND
|NSTALLATON.............,...
oPEFAf|ONALCHECK..........,
SEALANTS....._...............
G.SKET AND SEALREUSE
GENEML.. . ... .. . ...
INFORMATION PLAf E
INSIALLATION.
.., .... . ..,
LUBRICATION SYSTEM......
MANAGEI\,IENT SYSTEM . . . . .
OPESAIONAL CHECK . . . . .
PFEHEAf EF/SPACEB
..
,,...,
.. . ..
..
GENERAL INFOFMAT]ON . , . . , . .
GENEFAL INsIHUCTIONS , . . . . .
GLOSSARY OF TERMS . . . . . . . . .
tNsT4114TtON..................
...153
IN-CHASSIS PAFI/COMPONENf
PROCEOUAES . . . . . . .
ENGTNE REMOVAL. . . . . . . . . . . . . . . . . . .
ENG1NE SERIAL NUMSER
.....
INJECTOF SLEEVE AEPLACEMENI .

ENGINE SYMPTOI DIAGNOSIS . , . . . . .
ENGINE WIFING HAFNESS FEMOVAL .
REMOVAL
EXHAUST MANIFOLD REI\OVAL. , ,

EXHAUST PFESSUBE GOVEFNOR
...
.. .. ... ....
AND EXHAUST VALVE FEMOVAL. .
INLET MANIFOI INSTALLATION . . . . . . .
INLFI MANIFOT.D REMOVAI , . , , . . . . . . , .
INSTALLAT|ON......_........
FMOVA|. . . . . . . . . . . . . . . . . . .
..
INLE
EXHAUST PRESSURE GOVEFNOR
ENGINE GASKETS, LUBFICANTS AND

ENGINE
ENGINE
EGINE
ENGINE
ENGINE
ENGINE
i,..
FRONT ENGINE SUPPOFI FEMOVAL
iil
]NSPEC'ION............_..........
NSTATLATTON
. . . . .. . .. . . .. . .. . .. ._.
SYsTEM... .. .....
LINEF HEIGHT MEASUREMENf
EXHAUST PRESSUBE GOVEFNOR,
LT]BFICANTS AND SEALANIS
.. . ... ., . ..
LUBFTCAI|ONSYSTEM.................
EXPLANATION OF NUI\EAEAL CODE. .
LUBFICATION SYSIEM MAINTENANCE .

..
F
F LIEF ELEMEN INSTALLATION . , , . . . .
F LTEFS ANO MISCELLANEOUS
COMPONENTS INSTALLATION . , , . . . .
F NAL S-IEPS.
. .. . .
220,243,
.. ..
rNsT4114TtON.....................
FLYW-IEEL AND PILOf BEAR]NG
BEMOVAL.......
lt
MACX MP8 EURO 3 ENGINE DES GN
rNsT411TtON.....................
....
.,
FEATI]RES ..
....,
sfAND , . . . . . . . . . . _ . . . . . . . . . .
....,,
..
MP8 ENGTNE SERVTCE TOOLS. . . . _ . . . . . . . 303

MP8 EUFO 3 ENGINECOMPONENT LOCATION
vtEws
FLYWHEEL BENCH PFOCFDURES

FLYI'V}IEEL HOUSING INSTALLATIO . . ..
FLYWHEEL HOUSING FEMOVAL...,..,.
FLYWHEEL HOUSING FUNOUT, CHECX,,
FLYWHEEL RING GEAR REPLACEMENT..
FRONT ENGINE SUPPOFT
..,
MAIN BFRNG CAP INSIALLATION . , ,. .,

MAIN BEABNG CAP BEMOVAL. .
, ..
]\'ATEFJAL AND DIMENSIONAL DAA
...
MOUNTINGfHE ENGINE ON A REPAR
..........
........
MP3 EUFO 3 ENGINE MECHAICAL
SPECIFICAflONS..,..,.........
MP3 EUFO 3 ENGINE MODEL
rDENfrFrcAf
oN................
MP8 EIJFO 3 ENGINESETUPAND
INDEX
N
NEOPRENE SEAL INSTALLATON

NEOPRENE SEAL REMOVAL. , , , . . , , , , . , , . , 226
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
......,
|NSTALIATTON.,,.,,.,,,..,,,..,,,..,.
orlcooLERRECONDI|ONjNG..-.........
orLcooLEF,pFEssuFEfEsf ............
ROCKERARM,CHECK..............
REMOVAL.
O L FILLEF PIPE AND DIPSTICK PIPE
TNSfaLLATON_.......................
OILFILTEF HOUSING
ISTALLATION
..
OIL F]LTEF VALVE HOUSING REMOVAL . .

oTL LEVEL CHECK.
OIL PAN
orl PAN FEMOVAL.
OIL PUMP AND SLOCKSTIFFENER PLATE
-...... -...
INSTALLATION..
-.........
SEAL INSIALLATION . . .
...
SEFVICE PRECAUTIONS SUMMAFY. .

SEFVICE PROCEOLJHES AND TOOL L-ISACE .
J37
SEALREMOVAL..............
.-
.3
SPECTALfOOLS........6,72,76,14.153,214,
STANDARD BOLf AND NUf TOFOUE
vaLUES . . . . . . . . . . . . . . . _ . . . . . . . . . . . . . . 304
STARTER INSTALLATION...,,.
STAFTEF FEMOVAL , ..., . ,..,
22r
O L THEBIIOSTAT VALVE
EPLACMENI...................-...
, .,..10
223, 226,231,249,254
SPEC]AL TOOLS FOR ENGINE OVERHAUL. . . .3O3
OILPUMP FEMOVAL. -...... -,

O]LPUMP FEPLACEMENT (lN CHASSIS)..,., 231
.................
SPEC|ALTOOL...............
164
OILPI-IMP INSIALLATION.......
OILPUMP PIPES AND STBAINEF
222
TANDEM PUMP (FUELANO POWEF
STEEHTNG)rNSr4114TlON...,...,......202
TANOEM PUMP (FUELAND POWEB
PISfON AND CONNECTING FOD

aSSEMBLY NSTALLAT]ON.............. 161
PISTON AND CONNECTING FOD
assEMBLYFEMOVAL..................
PISTON COOLING SPFAY
-....,
.. .. 93
NST41ITpN........................
vaLVEREPLACEMEN
139
196
113
NOZLE
FEMoVAL'.,''',''.'''.'''.,,'..,''''
PISTONINSPECTIONANDCLEANING.......
.........100
NSf4r14TtON,.......................193
117
123
THEBMOSIAf ANDCOVEF FEMOVAL..,,...106

THEFMOSTAf. CHECK . ... . ...
TIMING GEAF COVER INSTALLATION..... ..19O
124
T]MING
TIMING
T]MING
T]MING
T]MING
TOOLS
PISTON RING INSPECT ON ANO
BEP14CEMENT.......................
STEEF|NG)8EMOV41........
TEFLON@SFAL INSTATLATION .
TEFLON@ SEAL FEMOVAL , .
THERMOSTAT AND COVEF
POWER TAKE OFF (PTO) ASSEMBLY
POWERTAKE.OFF INSfALIATION,...,...,. 139

POWERLEASI]I ENGINE BRAKE
PFEL|M|NAFY STEPS. . _...... 213,236,244,250
GEAF COVEB REMOVAL

GEAH PLATE INSTALLATION....,....163
GEAF PLATE REMOVAL.., .
GEAF TFAIN INSTALTATI
..,
GEAF IFAIN FEMOVAL.

AND EOUIPMEN
...
TFOUBLESNOOTING TECHNIOU
rIFBOCHARGER.....,.......
TURAOCHARGEF INSTALLATION
INDEX
u
vaLVE
uNfT TNJECTOR CLEAN|NG,,,..............244

uNtf tNJEcToR tNsfA!TtoN ... _... _.... _176
UNITINJECTOR BEMOVAL.....
v
,..,.... . , .. . _... . .2s6
.
valvE GUTDE WEAF_ CHCK...
.,.,,,....
......
.:
lt : i
............142
!.
....,
PBOCEOUFE
, ,. .... ... _ _.. .. . . _.
VALVE SEM SEAL REPLACEMEI,T . . . .
VALVE YOKE (BFIDGE] INSTALLATIOI
_.........
35
wJRtNG HABNESS NSTALLAON . . . . , . , , . .
m9
VALVEYOKE(BF|DGE FEMOVA!
VAIVE AND UNT INJECOR

4DJUSTMENT .. ....
VALVE GUIDE REPIACEMENT
vrvE NsPcTloN,
rNsralraoN.
VALVE SPFING INSPECTIO.. ... ,

VALVE STEM HEIGHT MEASUFEMENf

Manual Servicio Motor MP8 Mack-2

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual Servicio Motor MP8 Mack-2

Uploaded by

Copyright:

Available Formats

REPAIR INSTRUCTIONS, PART

Assmb e lhe slii'ener plale

lnsrallthe oil pf$uB pip and lh6

2. Asemblelhe oi siher, ;udioni

slide th oil pessure pipe inlo lhe oit

6smbl lh otl slrainr and oil pickup

Using a lorque w rench, lighle lhe alaching

Oil Pump Pipes and Striner

Bepacelheo tngsonlheol pressfe pip,

FEPAIR INSTBUCTIONS, PART

Front Engne Support lnstalation

suppo mounring bfaokel

Assemble lhe lon engine suppo.! onlo lhe

Using a lolque wnch, tghle all lasteneA

Pr6r. sp*ar stes

Apply 2 mm (5/g lnch) bead ot

Crankshatt Front Cover and Seal

Pla@ lhe cnkshaft lronl cowr wftn 6pacer.

inch) bead o'

REPAIR INSTBUCTIONS, PART

Within 20 minuls ol sealanl applcalion,

lnrall lhe font @wr

lnstallalon structios pply:

Ih e bois wiihoui 1ghGh g lh em

For lrr rype (B), the iolrowlng

Usng a torque wn.h lighlen the

RemoE the plaslic ring fom the crankshan

BEPAIB INSTRUCTIONS, PART

Timg Gear Plate lnstallation

cyrnder head is lnsralled atrer lhe riminq

Clean lhe limino qear plale on bolh sids.

inch) bead ol 342SX33

with 20 inutes ol ihe appliiion ot lhe

Wilhliming gear p ate i posilion @rguide

REPAIR INSTRUCTIONS, PART

Uslng a iorque wnch, tighin lh afia.hing

Cylnder Head lnslallation

The cylindr had b heavy. Do NOT allpl to

dd@. FsiluEto h*d thls warnlng may

lrncssary clean lhe unit injetorcopper

lnslall the compressr slud wnh a new

Rmore alignment guides, 9994267, Im

Wilh any cleaninc ol lh unit inictoB, uder no

REPAIR INSTRUCTIONS, PABT

(164 nch) lhck bead cil

Ensuro thal ths ngin block nd dtrk ar

Caelly l rhe cylindd head and indall

1cr n th liminq gar plate {as

head gaskel on lhe enqne

There are pohls embo$ed in lhe qasket

The hd gskl should be dlscaded ilthe

REPAIB INSTRUCTIONS, PABT

mouling plale unlilil makes colcl wilh

Teporry rnsrall rhe adjosrablo idrr qar

h@d botts a tightened.

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

10. Check the ndilion

ll is li6l l@e@d onro lhe bl@k dek

Oce lweed, screG iserled lhouqh

lh6lnalslp,lhe head bot6 are

11, The cylinder head cap*rews ust ot b

lnsert lour cy indr had capscws lnto

13. Remo lh cylinde r head llfr ing b racksl.

lnslal lhe laslee 6 secur g lh liminq gear