Diesel Engine, Truck, Heavy Equipment Service Manuals

Mack MP7 EPA04 Diesel Engine Service Shop Manual

$19.99

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Product Description

 High definition, searchable, printable PDF  Instant download

Covers: Mack MP7 EPA04 Diesel Engine — service, repair and major overhaul procedures

  • MP7-325E
  • MP7-355E
  • MP7-405E
  • MP7-345C
  • MP7-365C
  • MP7-395C
  • MP7-325M
  • MP7-365M
  • MP7-405M

Pages: 379
Format:
PDF
Compatibility: Windows/Mac/Tablet

The MACK MP7 is a 700 CID (11 liter) engine with Delphi E3 unit injectors, a cooled Exhaust Gas Recirculation (EGR) system and the new Holset Variable Geometry Turbocharger (VGT). The design conforms to EPA04 emissions. This shop manual covers all maintenance, repair and overhaul procedures for the Mack MP7 EPA04 engine. View the shop manual on your computer/tablet or print off pages as needed.

Topics in the Mack MP7 EPA04 Diesel Engine Service Shop Manual:

INTRODUCTION
ABOUT THE MACK MP7 ENGINE
Service Precautions Summary
VISUAL IDENTIFICATION
MP7 ENGINE MODEL IDENTIFICATION
Engine Information Plate
Engine Serial Number Identification
DESCRIPTION AND OPERATION
MP7 ENGINE DESIGN FEATURES
Engine Variants
Engine Components
Lubrication System
Fuel System
PowerLeash™ Engine Brake
Exhaust Gas Recirculation System
Variable Geometry Turbocharger
Cooling System
Engine Management System
GLOSSARY OF TERMS
COMPONENT LOCATOR
MP7 ENGINE COMPONENT LOCATION VIEWS
TROUBLESHOOTING
ENGINE SYMPTOM DIAGNOSIS
Troubleshooting Technique
Start and Stop Problems
Abnormal Smoke Development
Low Power Output
High Fuel Consumption
Uneven Operation
Noise and Vibration
Engine Brake
Contaminated Fluid
ENGINE CHECKS AND INSPECTIONS
Compression Check
Carbon Monoxide in Coolant System Check
Carbon Monoxide in Fuel System Check
Valve and Rocker Arm Check
Cylinder Head Inspection
Cylinder Block Inspection
CAMSHAFT SENSOR AND HARNESS CHECKS
Special Tools
Camshaft Sensor Depth, Check
Harness and Connectors Check
Camshaft Timing Check
Road Test
COMPRESSION TEST
Special Tools
Compression Test on Vehicle
MAINTENANCE
LUBRICATION SYSTEM MAINTENANCE
Special Tool
Oil Level Check
Oil and Filter Change Procedure
FUEL FILTER REPLACEMENT
Fuel Filter Change
COOLING SYSTEM MAINTENANCE
Special Tool
Coolant Drain Outlets
Coolant Filter
DRIVE BELT REPLACEMENT AND TENSIONING
General Information
Automatically Tensioned System
REPAIR INSTRUCTIONS, PART 1
ENGINE REMOVAL
Special Tools
General Instructions
Removal
ENGINE DISASSEMBLY
Special Tools
General Instructions
Filters and Miscellaneous Components Removal
Mounting the Engine on a Repair Stand
Cylinder Head (Valve) Cover Removal
Engine Wiring Harness Removal — External
Engine Wiring Harness Removal — Internal
Timing Gear Cover Removal
Camshaft Gear and Vibration Damper Removal
Rocker Arm Shaft and Engine Brake Removal
Valve Yoke (Bridge) Removal
Camshaft Removal
Unit Injector Removal
Starter Removal
Turbocharger Removal
EGR Valve and Heat Shield Removal
EGR Hot Side Tube Removal
EGR Cool Side Elbow Removal
EGR Cooler Removal
Exhaust Manifold Removal
Oil Filter Valve Housing Removal
Coolant Pipe Removal
Oil Cooler and Cooling Duct Cover Removal
Fan Drive and Idler Removal
EGR Crossover Tube Removal
EGR MASS Flow Tube Removal
Intermediate Mixer Inlet Tubing Removal
EGR Mixer Removal
Fuel Lines and Fuel Filter Housing Removal
EMS Module and EMS Module Cooler Removal
Inlet Manifold Removal
Tandem Pump (Fuel and Power Steering) Removal
Air Compressor Removal
Flywheel and Pilot Bearing Removal
Power Take-Off (PTO) Assembly Removal
Flywheel Housing Removal
Crankshaft Rear Seal Removal
Timing Gear Train Removal
Timing Gear Mounting Plate Removal
Crankshaft Vibration Damper and Fan Pulley Removal
Alternator Removal
Thermostat and Housing Removal
Coolant Pump Removal
Cylinder Head Removal
Oil Fill Tube and Dipstick Retainer Removal
Crankshaft Front Cover Removal
Crankshaft Front Seal Removal
Front Engine Support Removal
Oil Pan Removal
Oil Pump and Valve Housing Removal
Block Stiffener Plate Removal
Piston and Connecting Rod Assembly Removal
Main Bearing Cap Removal
Crankshaft Removal
CYLINDER BLOCK RECONDITIONING
Tools and Equipment
Piston Cooling Spray Nozzle Removal
Cylinder Liner Removal
Cylinder Block Cleaning and Inspection
Counterbore Inspection and Cleaning
Liner Height Measurement
Cylinder Liner Installation
FLYWHEEL BENCH PROCEDURES
Flywheel Ring Gear Replacement
CONNECTING ROD AND PISTON BENCH PROCEDURES
Connecting Rod and Piston Disassembly
Piston Inspection and Cleaning
Piston Ring Inspection and Replacement
Connecting Rod and Piston Assembly
CYLINDER HEAD OVERHAUL
Tools and Equipment
Inlet and Exhaust Valve Removal
Cylinder Head Cleaning and Inspection
Valve Guide Replacement
Valve Spring Inspection
Injector Sleeve Replacement
Cup Plug Replacement
Valve Inspection
Valve Installation
ROCKER ARM SHAFT BENCH PROCEDURES
Description
Rocker Arm Shaft Disassembly
Inspection
Rocker Arm Shaft Assembly
CAMSHAFT BENCH PROCEDURES
Camshaft Inspection
COOLING SYSTEM COMPONENTS BENCH PROCEDURES
Special Tools
Oil Cooler Reconditioning
EGR Cooler Cleaning
EGR Cooler Pressure Test
ENGINE REASSEMBLY
Special Tools
General Instructions
Crankshaft Installation
Main Bearing Cap Installation
Piston and Connecting Rod Assembly Installation
Block Stiffener Plate Installation
Oil Pump and Valve Housing Installation
Front Engine Support Installation
Crankshaft Front Cover Installation
Crankshaft Front Seal Installation
Timing Gear Mounting Plate Installation
Cylinder Head Installation
Camshaft Installation
Unit Injector Installation
Valve Yoke (Bridge) Installation
Rocker Arm Shaft and Engine Brake Installation
Timing Gear Train Installation
Flywheel Housing Installation
Oil Pan Installation
Oil Filler Tube and Dipstick Tube Installation
Power Take-Off Installation
Timing Gear Cover Installation
Crankshaft Rear Seal Installation
Flywheel and Pilot Bearing Installation
EGR Crossover Tube Installation
Fan Bracket Installation
Coolant Pump Installation
Thermostat and Housing Installation
Oil Cooler and Cooling Duct Cover Installation
Coolant Pipe Installation
Oil Filter Valve Housing Installation
Exhaust Manifold Installation
EGR Valve and Heat Shield Installation
EGR Cooler Installation
EGR Hot Side Tube Installation
EGR Cool Side Elbow Installation
Turbocharger Installation
Starter Installation
Air Compressor Installation
Tandem Pump (Fuel and Power Steering) Installation
Inlet Manifold Installation
EGR Mixer Installation
EGR MASS Flow Tube Installation
Intermediate Mixer Inlet Tubing Installation
EMS Module and EMS Module Cooler Installation
Fuel Lines and Fuel Filter Housing Installation
Alternator and Refrigerant Compressor Bracket Installation
Crankshaft Vibration Damper and Fan Pulley Installation
Wiring Harness Installation
Cylinder Head (Valve) Cover Installation
Removing Engine from Engine Stand
Filters and Miscellaneous Components Installation
ENGINE INSTALLATION
Special Tools
General Instructions
Installation
REPAIR INSTRUCTIONS, PART 2
IN-CHASSIS PART/COMPONENT PROCEDURES
OIL PUMP REPLACEMENT (IN CHASSIS)
Oil Pump Removal
Oil Pump Installation
UNIT INJECTOR CLEANING
Preliminary Steps
Cleaning and Inspection
Final Steps
INJECTOR COPPER SLEEVE REPLACEMENT
Tools and Equipment
Preliminary Steps
Copper Sleeve Removal
Copper Sleeve Installation
Final Steps
TURBOCHARGER SMART REMOTE ACTUATOR (SRA) REPLACEMENT
Preliminary Steps
Turbocharger SRA Removal
Turbocharger SRA Inspection and Installation
Final Assembly
VALVE STEM HEIGHT MEASUREMENT PROCEDURE
VALVE STEM SEAL REPLACEMENT
Special Tools
Preliminary Steps
Seal Removal
Seal Installation
Final Steps
REPAIR INSTRUCTIONS, PART 3
MP7 ENGINE SETUP AND ADJUSTMENT
Special Tools
Valve and Unit Injector Adjustment
Checking and Adjusting Timing Gear Backlash
ENGINE FINAL PREPARATION AND OPERATIONAL CHECK
Filter Element Installation
Engine Lubrication System
Turbocharger
Cooling System
Fuel System
Engine Operational Check
REBUILT ENGINE RUN-IN PROCEDURES
General
Run-In Check
SPECIFICATIONS
MP7 ENGINE MECHANICAL SPECIFICATIONS
Material and Dimensional Data
Engine Component Torque Specifications (Critical Fasteners)
ENGINE GASKETS, LUBRICANTS AND SEALANTS
Gasket and Seal Reuse
Lubricants and Sealants
SCHEMATIC & ROUTING DIAGRAMS
MP7 ENGINE SYSTEM SCHEMATICS
Lubrication System Flow
Fuel System Flow
Cooling System Flow
Drive Belt Routing
Air Intake — Filtering, Cooling and Heating
MP7 Engine Wiring Diagram
SPECIAL TOOLS & EQUIPMENT
MP7 ENGINE SERVICE TOOLS
Special Tools for Engine Overhaul
DISASSEMBLED VIEWS
MP7 ENGINE DISASSEMBLED VIEWS
INDEX

Contains Specifications, Illustrations and Procedures

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