Diesel Engine, Truck, Heavy Equipment Service Manuals

Mack E7 Diesel Engine Overhaul Repair Manual

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Product Description

 High definition, searchable, printable PDF  Instant download

Covers: Mack E7 Diesel Engine with Bosch P7100/P8500 Mechanical Injection Pump
Pages: 303
Format: PDF
Compatibility: Windows/Mac/Tablet
File size: 30mb

Covers Mack E7 diesel engine disassembly, bench procedures, assembly, setup and adjustments, and basic mechanical troubleshooting.  V-Mac troubleshooting sold separately. This manual covers models with Bosch mechanical injection pumps only. See Mack E7 E-Tech overhaul repair manual for newer models.

Topics in the Mack E7 Diesel Engine Overhaul Repair Manual:

GENERAL INFORMATION
INTRODUCTION
ENGINE MODEL IDENTIFICATION
Engine Information Plate
LUBRICANTS AND SEALANTS
OVERHAUL PART REPLACEMENT
200 SPECIFICATIONS
SPECIFICATIONS
Improved Design
Engine General Specifications
Engine Features
Good Shop Practice — Fasteners
Performance Specifications (Oil Pressure and Intake Manifold Temperature)
FASTENER TORQUE
Fastener Selection and Installation
Fastener Sizes and Types
TORQUE SPECIFICATIONS
Torque Specifications for Critical Fasteners
Torque Specifications for Hose Clamps
Torque Specifications for Pipe Plugs
Torque Specifications for Non-Critical Fasteners
CONVERSION FACTORS
SPECIAL TOOLS
Special Tool List
V-MAC Tools
200 ENGINE REMOVAL
GENERAL
Vehicle Preparation
Engine Removal
200 ENGINE DISASSEMBLY
GENERAL
[219 EV] CENTRI-MAX™ AND SPIN-ON FILTER ELEMENTS
MOUNTING ENGINE IN STAND
Special Tools Required
[271 CB] ALTERNATOR
[215 HB] FAN ASSEMBLY
[231 PB] FUEL FILTER ADAPTER ASSEMBLY
[215 LD] COOLANT CONDITIONER ELEMENT
[215 NU] THERMOSTAT
[214 HD] AIR INLET MANIFOLD
[215 NK] COOLANT MANIFOLD
[215 DW & 219 EP] OIL COOLER AND OIL FILTER HOUSING ASSEMBLY
[215 SW] WATER PUMP
[214 SD] TURBOCHARGER
[222 KD] FUEL NOZZLE INLET TUBE ASSEMBLY
[214 EG] EXHAUST MANIFOLD
[213 JB] VALVE COVER AND RISER
[213 LP, NV & LH] ROCKER ARM, VALVE YOKE AND PUSH ROD
[222 KG] NOZZLE HOLDER
Special Tool Required
[213 EV] CYLINDER HEAD ASSEMBLY REMOVAL
[212 RB & RH] VIBRATION DAMPER AND CRANKSHAFT HUB
[261 CK] AIR COMPRESSOR
[221 GP] INJECTION PUMP
[221 CD] ECONOVANCE
V-MAC Equipped Engines
[211 NB] OIL PAN
[219 MU] OIL PUMP
[211 RP] TIMING GEAR COVER
[212 CV] AUXILIARY DRIVESHAFT
[213 CH] CAMSHAFT
[212 NP & LQ] PISTON AND CONNECTING ROD ASSEMBLY
[212 UC] FLYWHEEL
[211 HD] FLYWHEEL HOUSING
[211 JA] MAIN BEARING CAP
[212 HP] CRANKSHAFT
[219 RV] PISTON COOLING SPRAY NOZZLE
[212 NC] CYLINDER SLEEVE
Special Tool Required
200 BENCH PROCEDURES
[211 DB] CYLINDER BLOCK
Cylinder Sleeve Counterbore
[212 CV] AUXILIARY DRIVESHAFT
Description
Inspection
[212 LP] CONNECTING RODS
Description
Special Tools Required
Inspection
Wrist Pin Repair
[212 HP] CRANKSHAFT
Description
Inspection
[212 HA] Crankshaft Dowel Pin Replacement
[212 HV] Crankshaft Gear
[212 UB] FLYWHEEL
front
Page xiv
TABLE OF CONTENTS
[212 NP] PISTONS
Description
Special Tools Required
Disassembly
Inspection
[212 NV] PISTON RINGS
Keystone Ring Groove Check
Ring Installation
[212 LP & NP] CONNECTING ROD ASSEMBLY TO PISTON
[213 CH] CAMSHAFT
Description
Disassembly
Inspection
Assembly
[213 EV] CYLINDER HEADS
Description
Special Tools Required
[213 NB] Inlet and Exhaust Valve Removal
[213 EX] Cylinder Head Inspection
[213 EH] Fire Ring Groove
[213 EP] Valve Guides
[213 FB] Inlet and Exhaust Valve Seat Inserts
[213 MB] Valve Springs
[213 GB] Injection Nozzle Holder Insert
[213 FH] Valve Yoke Guide Pins
[213 FP] Cylinder Head Cup Plugs
Cylinder Head Pipe Plugs
[213 NB] INLET AND EXHAUST VALVES
Inspection
Valve Identification
Inlet and Exhaust Valve Installation
[213 LV] VALVE ROCKER ARM SHAFT
Inspection
Rocker Arms
Valve Rocker Arm Shaft Assembly (Except Jacobs Engine Brake)
Valve Rocker Arm Shaft Assembly (with Jacobs Engine Brake)
Dynatard Engine Brake Solenoid
[266 KD] DYNATARD ENGINE BRAKE
Dynatard Overload Protection (E7 Engines with Dynatard)
Dynatard Overload Protection System
[266] JACOBS ENGINE BRAKE
[266] ENGINE BRAKE SWITCH AND BRACKET ASSEMBLY
Description
Adjustment (E7 Mechanically Governed Engine with Engine Brake)
[215 DW] OIL COOLER ASSEMBLY
Description
Disassembly
Inspection
Assembly
[215 SW] WATER PUMP
[219 MU] OIL PUMP
Disassembly
Inspection
Improved “Fast Ratio” Auxiliary Driveshaft
Assembly
[221 CD] ECONOVANCE
Econovance Control Valve Assembly
Econovance Disassembly
Cleaning and Inspection
Econovance Assembly
[221 KU] INJECTION PUMP DRIVE HUB
Description
Special Tools Required
Cleaning
Installation of Drive Hub (Mechanically Governed Engines)
Installation of Drive Hub (V-MAC Engines)
[222 KG] INJECTOR NOZZLES
Nozzle Cleaning
200 ENGINE ASSEMBLY
GENERAL
[211 DB] CYLINDER BLOCK
Special Tools Required
Cleaning and Inspection
Cup Plug Replacement
Pipe Plug Replacement
[213 CC] Camshaft Bushings
[212 CB] Auxiliary Driveshaft Bushing Replacement
[212 NC] CYLINDER SLEEVE
Description
Special Tools Required
Installation
[219 RV] PISTON COOLING SPRAY NOZZLE
Description
Special Tools Required
Installation
Piston Cooling Nozzle Spray Positioning
[211 HA] CYLINDER BLOCK DOWEL PINS
Description
Special Tools Required
Removal
Installation
[212 HP] CRANKSHAFT
Installation
[212 HH] MAIN BEARING CAP
Special Tool Required
Installation
[212 NP & 212 LP] PISTONS AND CONNECTING RODS
Description
Special Tools Required
Installation
[211 HD] FLYWHEEL HOUSING
Description
Inspection
Dowel Pins
Capscrews (Flywheel Housing)
Installation
Runout
[212 JH] CRANKSHAFT WEAR RING
Special Tools Required
Removal
Installation
Wear Ring with Double-Lip Teflon Seal (Automatic Transmission)
[212 JH] CRANKSHAFT REAR OIL SEAL
Installation
[212 VC] FLYWHEEL (E7 ENGINE WITHOUT POINTER ON TIMING COVER)
Description
Installation
[213 CH] CAMSHAFT
Description
Special Tools Required
Inspection
Installation (Engine in Stand)
Installation (Engine in Chassis)
[212 CV] AUXILIARY DRIVESHAFT
Inspection
Installation
[219 MU] OIL PUMP
Description
Installation
[211 RP] TIMING GEAR COVER
[211 SB] TIMING GEAR COVER SEAL
Special Tool Required
Installation
[221 GP] FUEL INJECTION PUMP INSTALLATION
[212 RH] CRANKSHAFT HUB
Inspection
Installation
[212 RB] VIBRATION DAMPER
Description
Inspection
Installation
[211 NB] OIL PAN
Description (Isolating Oil Pan Gasket on E7 Engines)
Oil Pan Installation
[213 EV] CYLINDER HEADS
Description
Installation
[222 KG] NOZZLE HOLDER ASSEMBLY
Description
Special Tool Required
Installation
[213 LH] VALVE LIFTER PUSH RODS
Inspection
Identification
Installation
[213 NV] VALVE YOKES
Description
Installation
[213 LP] ROCKER ARMS
Description
Installation (Non-Brake and Dynatard Equipped Engines)
Installation (Jake Brake-Equipped Engines)
Brake Housing Installation
[213 JB] VALVE COVER
Description
Installation
[214 EG] EXHAUST MANIFOLD
Description
Installation
[215 NK] COOLANT MANIFOLD
Inspection
Installation
[261 CK] AIR COMPRESSOR
Installation
[221 CD] ECONOVANCE
Installation
[221 GP] FUEL INJECTION PUMP
Installation
[222 KD] FUEL NOZZLE INLET TUBE ASSEMBLY
Installation
[214 SC] TURBOCHARGER
Installation (Includes Pre-Lubing Procedures)
[215 NU, NG & LD] THERMOSTAT, THERMOSTAT HOUSING, THERMOSTAT SEAL
AND COOLANT CONDITIONER
[214 HD] AIR INLET MANIFOLD
[231 PB] FUEL FILTER ADAPTER ASSEMBLY
Installation
[215 SW] WATER PUMP
Installation
[215 DW & 219 EP] OIL COOLER AND OIL FILTER HEAD
Assembling a New Oil Filter Adapter
Installation
[271 CB] ALTERNATOR
Installation
Fan Belt(s)
200 SETUP AND ADJUSTMENTS
[213 NB] VALVE YOKE AND VALVE LASH ADJUSTMENTS
(NON-JAKE BRAKE ENGINE AND DYNATARD EQUIPPED)
Description
Special Tool Required
Locating and Marking Flywheel Valve Adjustment Markings
Valve Yoke Adjustment
Inlet Valve Adjustment
Exhaust Valve Adjustment
Continuation of Adjustments
[213 NB] VALVE YOKE, VALVE LASH AND SLAVE PISTON ADJUSTMENTS
(JACOBS BRAKE ENGINE)
Description
Housing Identification
Special Tools Required
Valve Yoke
Slave Piston, Inlet Valve and Exhaust Valve Lash Adjustments
Inlet Valve Adjustment
Exhaust Valve Adjustment
Slave Piston Adjustment
Continuation of Adjustments
[221 GP] INJECTION PUMP FIXED-TIMING PROCEDURES
Description
Special Tools Required
Setting Static Fuel Injection Pump Timing
Fuel Injection Pump Driven Gear Installation
Checking Pump-to-Engine Timing
Fuel Injection Pump Access Cover Installation
Fuel Injection Pump Pre-Lubrication
Timing Event Marker (TEM) Installation
[212 NP] LOCATING PISTON TOP DEAD CENTER (TDC)
E7 Series Engines with Front Timing Indicators
Special Tool Required
Locating Piston TDC
200 ENGINE INSTALLATION & TESTING
INSTALLATION
Description
Removing Engine from Engine Stand
Engine Installation into Vehicle
Filter Element Installation
FINAL PREPARATION
Lubrication
Engine Operational Check
REBUILT ENGINE RUN-IN PROCEDURES
Description
Run-In Check
[233 FA] CHASSIS-MOUNTED CHARGE AIR COOLING
Description
Special Tool Required
CMCAC Troubleshooting
CMCAC Pressure Test
Restriction Pressure Test
Core Repair
CMCAC Preventive Maintenance
200 TROUBLESHOOTING
CAMSHAFT TIMING CHECK
CAMSHAFT LOBE LIFT CHECK
PROPER FIRE RING/CYLINDER SLEEVE-TOP COMBINATIONS
General Information
Engines Built Prior to 1993
Engines Built from June 1993 to Present (3L Serial Number and Later)
Cylinder Head and Cylinder Block Leak Test Procedure
200 APPENDIX
E7 ENGINE SERIAL NUMBERS, JACOBS BRAKE APPLICATION
E7 LUBRICATION SYSTEM
E7 COOLING SYSTEM
INDEX

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