Mack MP8 (Euro4) Diesel Engine Service Repair Manual

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Covers: Mack MP8 (Euro 4 Emissions) Diesel Engine — service, repair and major overhaul procedures
Pages: 368
Format: PDF
Compatibility: Windows/Mac/Tablet

The MACK MP8 is a 13 liter (800 CID) engine with electronic unit injectors, a cooled Exhaust Gas Recirculation (EGR) system and the Holset Variable Geometry Turbocharger (VGT). The PowerLeash engine brake is optional. The engine conforms to Euro 4 emissions requirements.

Topics in the Mack MP8 (Euro4) Diesel Engine Service Repair Manual:

INTRODUCTION
VISUAL IDENTIFICATION
MP8 EURO 4 ENGINE MODEL IDENTIFICATION
Engine Information Plate
Engine Serial Number Identification
DESCRIPTION AND OPERATION
MACK MP8 EURO 4 ENGINE DESIGN FEATURES
Engine Components
Lubrication System
Crankcase Ventilation
Fuel System
PowerLeash Engine Brake
Exhaust Gas Recirculation System
Air Intake System
Variable Geometry Turbocharger (VGT)
Cooling System
Engine Management System
GLOSSARY OF TERMS
COMPONENT LOCATOR
MP8 EURO 4 ENGINE COMPONENT LOCATION VIEWS
TROUBLESHOOTING
ENGINE SYMPTOM DIAGNOSIS
Troubleshooting Technique
Noise and Vibration
ENGINE CHECKS AND TESTS
Special Tools
Camshaft Sensor Depth, Check
Camshaft Timing, Check
Crankcase Ventilation, Check
Cylinder Head, Pressure Test
Cylinder Liner and Piston Wear, Check
EGR Cooler, Pressure Test
Engine Compression, Test
Flywheel Housing Runout, Check
Oil Cooler, Pressure Test
Rocker Arm, Check
Thermostat, Check
Valve Guide Wear, Check
MAINTENANCE
LUBRICATION SYSTEM MAINTENANCE
Special Tool
Oil Level Check
Oil and Filter Change Procedure
Crankcase Ventilation System
FUEL FILTER REPLACEMENT
Fuel Filter Change
COOLING SYSTEM MAINTENANCE
Special Tool
Coolant Drain Outlets
Coolant Filter
DRIVE BELT REPLACEMENT AND TENSIONING
General Information
Automatically Tensioned System
REPAIR INSTRUCTIONS, PART 1
ENGINE REMOVAL
Special Tools
General Instructions
Removal
ENGINE DISASSEMBLY
Special Tools
General Instructions
Mounting the Engine on a Repair Stand
EGR Crossover Piping Removal
EGR Venturi Tube Removal
Cylinder Head (Valve) Cover Removal
Engine Wiring Harness Removal
Timing Gear Cover Removal
Camshaft Gear and Vibration Damper Removal
Rocker Arm Shaft Removal
Valve Yoke (Bridge) Removal
Camshaft Removal
Unit Injector Removal
Starter Removal
Turbocharger Removal
EGR Hot Pipe (Cooler Inlet) Removal
EGR Valve Removal
EGR Cooler Removal
Exhaust Manifold Removal
Oil Filter Housing Removal
Coolant and Pump Inlet Housings Removal
Cooling Duct Cover and Oil Cooler Removal
Drive Belts and Fan Hub Removal
EGR Mixer Removal
Crankcase Ventilation (CCV) Separator Removal
Fuel Lines and Filter Housing Removal
EECU and Cooling Plate Removal
Inlet Manifold Removal
Tandem Pump (Fuel and Power Steering) Removal
Air Compressor Removal
Flywheel and Pilot Bearing Removal
Power Take-Off (PTO) Assembly Removal
Flywheel Housing Removal
Crankshaft Rear Seal Removal
Timing Gear Train Removal
Timing Gear Plate Removal
Alternator and Refrigerant Compressor Removal
Thermostat and Cover Removal
Coolant Pump Removal
Cylinder Head Removal
Crankshaft Vibration Damper and Fan Pulley Removal
Crankshaft Front Cover Removal
Crankshaft Front Seal Removal
Oil Fill Pipe and Dipstick Retainer Removal
Oil Pan Removal
Front Engine Support Removal
Block Stiffener Plate Removal
Oil Pump Removal
Piston and Connecting Rod Assembly Removal
Main Bearing Cap Removal
Crankshaft Removal
CYLINDER BLOCK RECONDITIONING
Tools and Equipment
Piston Cooling Spray Nozzle Removal
Cylinder Liner Removal
Block Cleaning and Inspection
Liner Height Measurement
Cylinder Liner Installation
FLYWHEEL BENCH PROCEDURES
Flywheel Ring Gear Replacement
CONNECTING ROD AND PISTON BENCH PROCEDURES
Connecting Rod — Piston Disassembly
Piston Inspection and Cleaning
Piston Ring Inspection and Replacement
Connecting Rod — Piston Assembly
CYLINDER HEAD OVERHAUL
Tools and Equipment
Inlet and Exhaust Valve Removal
Cylinder Head Cleaning and Inspection
Valve Guide Replacement
Valve Spring Inspection
Injector Sleeve Replacement
Expansion Plug Replacement
Valve Inspection
Valve Installation
ROCKER ARM SHAFT BENCH PROCEDURES
Description
Rocker Arm Shaft Disassembly
Inspection
Rocker Arm Shaft Assembly
CAMSHAFT BENCH PROCEDURES
Camshaft Inspection
COOLING SYSTEM COMPONENTS BENCH PROCEDURES
Special Tools
Oil Cooler Reconditioning
EGR Cooler Cleaning
EGR Cooler Pressure Test
ENGINE REASSEMBLY
Special Tools
General Instructions
Crankshaft Installation
Main Bearing Cap Installation
Piston and Connecting Rod Assembly Installation
Oil Pump and Block Stiffener Plate Installation
Oil Pump Pipes and Strainer Installation
Front Engine Support Installation
Crankshaft Front Cover and Seal Installation
Timing Gear Plate Installation
Cylinder Head Installation
Camshaft Installation
Timing Gear Train Installation
Unit Injector Installation
Valve Yoke (Bridge) Installation
Rocker Arm Shaft and Engine Brake Installation
Flywheel Housing Installation
Crankshaft Rear Seal Installation
Flywheel and Pilot Bearing Installation
Oil Pan Installation
Oil Filler Pipe and Dipstick Pipe Installation
Power Take-Off Installation
Timing Gear Cover Installation
Coolant Pump Installation
Thermostat and Cover Installation
Coolant Pipe Installation
Oil Cooler and Cooling Duct Cover Installation
Oil Filter Housing Installation
Exhaust Manifold Installation
EGR Valve Installation
EGR Cooler Installation
EGR Hot Pipe (Cooler Inlet) Installation
Turbocharger Installation
Starter Installation
Air Compressor Installation
Tandem Pump (Fuel and Power Steering) Installation
Inlet Manifold Installation
EGR Mixer Installation
EECU and Cooler Installation
Fuel Lines and Filter Housing Installation
Crankcase Ventilation Separator
Crankshaft Vibration Damper and Fan Pulley Installation
Alternator and Refrigerant Compressor Installation
Wiring Harness Installation
Cylinder Head (Valve) Cover Installation
EGR Venturi Tube and Crossover Piping Installation
Fan Hub and Drive Belt Installation
Removing Engine from Engine Stand
Filters and Miscellaneous Components Installation
ENGINE INSTALLATION
Special Tools
General Instructions
Installation
REPAIR INSTRUCTIONS, PART 2
IN-CHASSIS PART/COMPONENT PROCEDURES
CAMSHAFT BEARING BRACKETS, REPLACEMENT
Preliminary Steps
General Information
Camshaft Inspection
Bracket Replacement Procedure
Final Steps
OIL THERMOSTAT AND PRESSURE SAFETY VALVE REPLACEMENT
Pressure Safety Valve Removal
Oil Thermostat Valve Replacement
CRANKSHAFT FRONT SEAL REPLACEMENT
Special Tools
Seal Removal
Seal Installation
CRANKSHAFT REAR SEAL REPLACEMENT
Special Tools
Neoprene Seal Removal
Neoprene Seal Installation
Teflon® Seal Removal
Teflon® Seal Installation
CRANKCASE VENTILATION (CCV) SEPARATOR REPLACEMENT
CCV Separator Removal
CCV Separator Installation
OIL PUMP REPLACEMENT (IN CHASSIS)
Special Tools
Oil Pump Removal
Oil Pump Installation
INJECTOR COPPER SLEEVE REPLACEMENT
Tools and Equipment
Preliminary Steps
Copper Sleeve Removal
Copper Sleeve Installation
Final Steps
TURBOCHARGER SMART REMOTE ACTUATOR (SRA) REPLACEMENT
Preliminary Steps
Turbocharger SRA Removal
Turbocharger SRA Inspection and Installation
Final Assembly
UNIT INJECTOR CLEANING
Preliminary Steps
Cleaning and Inspection
Final Steps
VALVE STEM HEIGHT MEASUREMENT PROCEDURE
VALVE STEM SEAL REPLACEMENT
Special Tools
Preliminary Steps
Seal Removal
Seal Installation
Final Steps
REPAIR INSTRUCTIONS, PART 3
MP8 ENGINE SETUP AND ADJUSTMENT
Special Tools
Valve and Unit Injector Adjustment
Checking and Adjusting Timing Gear Backlash
ENGINE FINAL PREPARATION AND OPERATIONAL CHECK
Filter Element Installation
Engine Lubrication System
Turbocharger
Cooling System
Fuel System
Engine Operational Check
REBUILT ENGINE RUN-IN PROCEDURES
General
Run-In Check
SPECIFICATIONS
MP8 ENGINE MECHANICAL SPECIFICATIONS
Material and Dimensional Data
Engine Component Torque Specifications (Critical Fasteners)
Standard Bolt and Nut Torque Values
ENGINE GASKETS, LUBRICANTS AND SEALANTS
Gasket and Seal Reuse
Lubricants and Sealants
SPECIAL TOOLS & EQUIPMENT
MP8 ENGINE SERVICE TOOLS
Special Tools for Engine Overhaul
INDEX

Contains Specifications, Illustrations and Procedures

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