5-116 Final PDF

MACK MP8 ®
DIESEL ENGINE
SERVICE MANUAL JULY 2009
(EURO 3 EMISSIONS REGULATIONS)

(REVISED)
5-116
MACK® MP8 DIESEL ENGINE
SERVICE MANUAL (EURO 3
EMISSIONS REGULATIONS)
1
JULY 2009 © MACK TRUCKS, INC. 2009

(REVISED — SUPERSEDES ISSUE DATED JANUARY 2009) ENGINE 5-116
ATTENTION
The information in this manual is not all inclusive and cannot take into
account all unique situations. Note that some illustrations are typical and
may not reflect the exact arrangement of every component installed on a
specific chassis.
The information, specifications, and illustrations in this publication are

based on information that was current at the time of publication. Note that
illustrations and instructions are based on information that is subject to
change as new engine/chassis development continues.
No part of this publication may be reproduced, stored in a retrieval

system, or be transmitted in any form by any means including (but not
limited to) electronic, mechanical, photocopying, recording, or otherwise
without prior written permission of Mack Trucks, Inc.
Page ii
TABLE OF CONTENTS
TABLE OF CONTENTS
Page iii
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Advisory Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Service Procedures and Tool Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EXPLANATION OF NUMERICAL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ABOUT THE MACK MP8 (EURO 3) ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service Precautions Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
VISUAL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
MP8 EURO 3 ENGINE MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine Information Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine Serial Number Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MACK MP8 EURO 3 ENGINE DESIGN FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Exhaust Pressure Governor (EPG) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
PowerLeash™ Engine Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Engine Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
GLOSSARY OF TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
MP8 EURO 3 ENGINE COMPONENT LOCATION VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
ENGINE SYMPTOM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Troubleshooting Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Noise and Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
ENGINE CHECKS AND TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Camshaft Sensor Depth, Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Camshaft Timing, Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Crankcase Ventilation, Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cylinder Head, Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Cylinder Liner and Piston Wear, Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
EGR Cooler, Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Engine Compression, Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Flywheel Housing Runout, Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Oil Cooler, Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Rocker Arm, Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Thermostat, Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Valve Guide Wear, Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Page iv
TABLE OF CONTENTS
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
LUBRICATION SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Oil and Filter Change Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Crankcase Ventilation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
FUEL FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Fuel Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
COOLING SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Coolant Drain Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Coolant Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
DRIVE BELT REPLACEMENT AND TENSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Automatically Tensioned System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
REPAIR INSTRUCTIONS, PART 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
ENGINE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Mounting the Engine on a Repair Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Cylinder Head (Valve) Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Engine Wiring Harness Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Timing Gear Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Camshaft Gear and Vibration Damper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Rocker Arm Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Valve Yoke (Bridge) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Camshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Unit Injector Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Starter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Exhaust Pressure Governor (EPG) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Turbocharger Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Exhaust Manifold Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Oil Filter Valve Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Coolant and Pump Inlet Housings Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Cooling Duct Cover and Oil Cooler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Drive Belts and Fan Hub Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Inlet Air Preheater/Spacer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Crankcase Ventilation (CCV) Separator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Fuel Lines and Filter Valve Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
EECU and Cooling Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Inlet Manifold Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Tandem Pump (Fuel and Power Steering) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Air Compressor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Flywheel and Pilot Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Power Take-Off (PTO) Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Flywheel Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Crankshaft Rear Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Page v
TABLE OF CONTENTS
Timing Gear Train Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Timing Gear Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Alternator and Refrigerant Compressor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Thermostat and Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Coolant Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Crankshaft Vibration Damper and Fan Pulley Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Crankshaft Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Crankshaft Front Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Oil Fill Pipe and Dipstick Retainer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Oil Pan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Front Engine Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Block Stiffener Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Piston and Connecting Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Main Bearing Cap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Crankshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
CYLINDER BLOCK RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Piston Cooling Spray Nozzle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Cylinder Liner Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Block Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Counterbore Inspection and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Liner Height Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Cylinder Liner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
FLYWHEEL BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Flywheel Ring Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
CONNECTING ROD AND PISTON BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Connecting Rod — Piston Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Piston Inspection and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Piston Ring Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Connecting Rod — Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
CYLINDER HEAD OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Inlet and Exhaust Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Cylinder Head Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Valve Guide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Valve Spring Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Injector Sleeve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Expansion Plug Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
ROCKER ARM SHAFT BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Rocker Arm Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Rocker Arm Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
CAMSHAFT BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Camshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
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EXHAUST PRESSURE GOVERNOR, OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
COOLING SYSTEM COMPONENTS BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Oil Cooler Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Crankshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Main Bearing Cap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Piston and Connecting Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Oil Pump and Block Stiffener Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Oil Pump Pipes and Strainer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Front Engine Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Crankshaft Front Cover and Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Timing Gear Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Camshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Timing Gear Train Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Unit Injector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Valve Yoke (Bridge) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Rocker Arm Shaft and Engine Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Flywheel Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Crankshaft Rear Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Flywheel and Pilot Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Oil Pan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Oil Filler Pipe and Dipstick Pipe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Power Take-Off Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Timing Gear Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Coolant Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Thermostat and Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Coolant Pipe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Oil Cooler and Cooling Duct Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Oil Filter Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Exhaust Manifold Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Turbocharger Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Exhaust Pressure Governor (EPG) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Starter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Air Compressor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Tandem Pump (Fuel and Power Steering) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Inlet Manifold Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Engine Preheater/Spacer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
EECU and Cooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Fuel Lines and Filter Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Crankcase Ventilation Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Crankshaft Vibration Damper and Fan Pulley Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Alternator and Refrigerant Compressor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Wiring Harness Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Cylinder Head (Valve) Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Fan Hub and Drive Belt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
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Removing Engine from Engine Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Filters and Miscellaneous Components Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
REPAIR INSTRUCTIONS, PART 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
IN-CHASSIS PART/COMPONENT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
CAMSHAFT BEARING BRACKETS, REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Preliminary Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Camshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Bracket Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Final Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
OIL THERMOSTAT AND PRESSURE SAFETY VALVE REPLACEMENT . . . . . . . . . . . . . . . . . 221
Pressure Safety Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Oil Thermostat Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
CRANKSHAFT FRONT SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
CRANKSHAFT REAR SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Neoprene Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Neoprene Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Teflon® Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Teflon® Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
CRANKCASE VENTILATION (CCV) SEPARATOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 231
CCV Separator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
CCV Separator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
OIL PUMP REPLACEMENT (IN CHASSIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
INJECTOR COPPER SLEEVE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Copper Sleeve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Copper Sleeve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Final Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
UNIT INJECTOR CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Final Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
VALVE STEM HEIGHT MEASUREMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
VALVE STEM SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Final Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
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REPAIR INSTRUCTIONS, PART 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
MP8 EURO 3 ENGINE SETUP AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Valve and Unit Injector Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Checking and Adjusting Timing Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
ENGINE FINAL PREPARATION AND OPERATIONAL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . 265
Filter Element Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Engine Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
REBUILT ENGINE RUN-IN PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Run-In Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
MP8 EURO 3 ENGINE MECHANICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Material and Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Engine Component Torque Specifications (Critical Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . 276
Standard Bolt and Nut Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
ENGINE GASKETS, LUBRICANTS AND SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Gasket and Seal Reuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Lubricants and Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
SPECIAL TOOLS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
MP8 ENGINE SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Special Tools for Engine Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Page ix
NOTES
Page x
INTRODUCTION
INTRODUCTION
Page 1
INTRODUCTION
SAFETY INFORMATION
Advisory Labels
Cautionary signal words (Danger-Warning-Caution) may appear in various locations throughout this
manual. Information accented by one of these signal words must be observed to minimize the risk of
personal injury to service personnel, or the possibility of improper service methods which may damage
the vehicle or cause it to be unsafe. Additional Notes and Service Hints are used to emphasize areas of
procedural importance and provide suggestions for ease of repair. The following definitions indicate the
use of these advisory labels as they appear throughout the manual:
Danger indicates an unsafe practice that could result in death or serious

personal injury. Serious personal injury is considered to be permanent injury
from which full recovery is NOT expected, resulting in a change in life style.
Warning indicates an unsafe practice that could result in personal injury.

Personal injury means that the injury is of a temporary nature and that full
recovery is expected.
Caution indicates an unsafe practice that could result in damage to the product.
Note indicates a procedure, practice, or condition that must be followed in order for
the vehicle or component to function in the manner intended.
A helpful suggestion that will make it quicker and/or easier to perform a procedure,
while possibly reducing service cost.
Page 2
INTRODUCTION
Service Procedures and Tool Usage
Anyone using a service procedure or tool not recommended in this manual must first satisfy himself
thoroughly that neither his safety nor vehicle safety will be jeopardized by the service method he selects.
Individuals deviating in any manner from the instructions provided assume all risks of consequential
personal injury or damage to equipment involved.
Also note that particular service procedures may require the use of a special tool(s) designed for a
specific purpose. These special tools must be used in the manner described, whenever specified in the
instructions.
1. Before starting a vehicle, always be seated in the driver's seat, place the
transmission in neutral, apply the parking brakes, and push in the clutch
pedal. Failure to follow these instructions could produce unexpected
vehicle movement, which can result in serious personal injury or death.
2. Before working on a vehicle, place the transmission in neutral, set the
parking brakes, and block the wheels. Failure to follow these instructions
could produce unexpected vehicle movement, which can result in serious
personal injury or death.
Engine-driven components such as Power Take-Off (PTO) units, fans and fan
belts, driveshafts and other related rotating assemblies, can be very
dangerous. Do not work on or service engine-driven components unless the
engine is shut down. Always keep body parts and loose clothing out of range
of these powerful components to prevent serious personal injury. Be aware of
PTO engagement or nonengagement status. Always disengage the PTO when
not in use.
Do not work under a vehicle that is supported only by a hydraulic jack. The
hydraulic jack could fail suddenly and unexpectedly, resulting in severe
personal injury or death. Always use jackstands of adequate capacity to
support the weight of the vehicle.
Before towing the vehicle, place the transmission in neutral and lift the rear wheels
off the ground, or disconnect the driveline to avoid damage to the transmission
during towing.
REMEMBER,
SAFETY . . . IS NO ACCIDENT!
Page 3
INTRODUCTION
Mack Trucks, Inc. cannot anticipate every 앫 Use hoists or jacks to lift or move heavy
possible occurrence that may involve a potential objects.
hazard. Accidents can be avoided by recognizing
앫 NEVER run engine indoors unless exhaust
potentially hazardous situations and taking
fumes are adequately vented to the outside.
necessary precautions. Performing service
procedures correctly is critical to technician safety 앫 Be aware of hot surfaces. Allow engine to
and safe, reliable vehicle operation. cool sufficiently before performing any
service or tests in the vicinity of the engine.
The following list of general shop safety practices
앫 Keep work area clean and orderly. Clean up
can help technicians avoid potentially hazardous
any spilled oil, grease, fuel, hydraulic fluid,
situations and reduce the risk of personal injury.
etc.
DO NOT perform any services, maintenance
procedures or lubrications until this manual has 앫 Only use tools that are in good condition,
been read and understood. and always use accurately calibrated torque
wrenches to tighten all fasteners to specified
앫 Perform all service work on a flat, level
torques. In instances where procedures
surface. Block wheels to prevent vehicle
require the use of special tools which are
from rolling.
designed for a specific purpose, use only in
앫 DO NOT wear loose-fitting or torn clothing. the manner described in the instructions.
Remove any jewelry before servicing
앫 Do not store natural gas powered vehicles
vehicle.
indoors for an extended period of time
앫 ALWAYS wear safety glasses and protective (overnight) without first removing the fuel.
shoes. Avoid injury by being aware of sharp
앫 Never smoke around a natural gas powered
corners and jagged edges.
vehicle.
Page 4
INTRODUCTION
EXPLANATION OF NUMERICAL GROUP 400 — STEERING, AXLES, WHEELS
AND TIRES, DRIVELINE
CODE
GROUP 500 — BRAKES, AUXILIARY SYSTEMS
The organization of MACK service manuals has
been upgraded to standardize manual content GROUP 600 — CAB, TRUCK BODY
according to a reference system based on
component identification. The new reference GROUP 700 — ELECTRICAL
system will help link the information contained in
this publication with related information included The second two digits of the three-digit code are
in other MACK service/warranty publications, used to identify the system, assembly or
such as associated service bulletins, warranty subassembly, as appropriate, within each of the
manuals, and MACK Service Labor Time groupings. The codes applicable to this
Standards. publication are shown at the beginning of each
procedure, as necessary, to guide you to specific
The system is based on a numerical code, the component information.
first digit of which identifies the general
component grouping as listed here: Additionally, a two-character alpha code (i.e.,
[NV] RINGS, PISTON) may be referenced with
GROUP 000 — GENERAL DATA each procedure. This alpha code, in combination
with the three-digit Group number, identifies the
GROUP 100 — CHASSIS specific assembly, sub-assembly or part, and
directly relates to the first five positions of the
GROUP 200 — ENGINE operation code listed in MACK Service Labor
Time Standards.
GROUP 300 — CLUTCH, TRANSMISSION,
TRANSFER CASE AND PTO
Example:
Numerical Code
Page 5
INTRODUCTION
CONVERSION CHART
Conversion Units Multiply By:
Length Calculations
Inches (in) to Millimeters (mm) 25.40
Inches (in) to Centimeters (cm) 2.540
Feet (ft) to Centimeters (cm) 30.48
Feet (ft) to Meters (m) 0.3048
Yards (yd) to Centimeters (cm) 91.44
Yards (yd) to Meters (m) 0.9144
Miles to Kilometers (km) 1.609
Millimeters (mm) to Inches (in) 0.03937
Centimeters (cm) to Inches (in) 0.3937
Centimeters (cm) to Feet (ft) 0.0328
Centimeters (cm) to Yards (yd) 0.0109
Meters (m) to Feet (ft) 3.281
Meters (m) to Yards (yd) 1.094
Kilometers (km) to Miles 0.6214
Area Calculations
Square Inches (sq-in) to Square Millimeters (sq-mm) 645.2
Square Inches (sq-in) to Square Centimeters (sq-cm) 6.452
Square Feet (sq-ft) to Square Centimeters (sq-cm) 929.0
Square Feet (sq-ft) to Square Meters (sq-m) 0.0929
Square Yards (sq-yd) to Square Meters (sq-m) 0.8361
Square Miles (sq-miles) to Square Kilometers (sq-km) 2.590
Square Millimeters (sq-mm) to Square Inches (sq-in) 0.00155
Square Centimeters (sq-cm) to Square Inches (sq-in) 0.155
Square Centimeters (sq-cm) to Square Feet (sq-ft) 0.001076
Square Meters (sq-m) to Square Feet (sq-ft) 10.76
Square Meters (sq-m) to Square Yards (sq-yd) 1.196
Square Kilometers (sq-km) to Square Miles (sq-miles) 0.3861
Volume Calculations
Cubic Inches (cu-in) to Cubic Centimeters (cu-cm) 16.387
Cubic Inches (cu-in) to Liters (L) 0.01639
Quarts (qt) to Liters (L) 0.9464
Gallons (gal) to Liters (L) 3.7854
Cubic Yards (cu-yd) to Cubic Meters (cu-m) 0.7646
Cubic Centimeters (cu-cm) to Cubic Inches (cu-in) 0.06102
Liters (L) to Cubic Inches (cu-in) 61.024
Liters (L) to Quarts (qt) 1.0567
Liters (L) to Gallons (gal) 0.2642
Cubic Meters (cu-m) to Cubic Yards (cu-yd) 1.308
Page 6
INTRODUCTION
Weight Calculations
Ounces (oz) to Grams (g) 28.5714
Pounds (lb) to Kilograms (kg) 0.4536
Pounds (lb) to Short Tons (US tons) 0.0005
Pounds (lb) to Metric Tons (t) 0.00045
Short Tons (US tons) to Pounds (lb) 2000
Short Tons (US tons) to Kilograms (kg) 907.18486
Short Tons (US tons) to Metric Tons (t) 0.90718
Grams (g) to Ounces (oz) 0.035
Kilograms (kg) to Pounds (lb) 2.205
Kilograms (kg) to Short Tons (US tons) 0.001102
Kilograms (kg) to Metric Tons (t) 0.001
Metric Tons (t) to Pounds (lb) 2205
Metric Tons (t) to Short Tons (US tons) 1.1023
Metric Tons (t) to Kilograms (kg) 1000
Force Calculations
Ounces Force (ozf) to Newtons (N) 0.2780
Pounds Force (lbf) to Newtons (N) 4.448
Pounds Force (lbf) to Kilograms Force (kgf) 0.456
Kilograms Force (kgf) to Pounds Force (lbf) 2.2046
Kilograms Force (kgf) to Newtons (N) 9.807
Newtons (N) to Kilograms Force (kgf) 0.10196
Newtons (N) to Ounces Force (ozf) 3.597
Newtons (N) to Pounds Force (lbf) 0.2248
Torque Calculations
Pound Inches (lb-in) to Newton Meters (N•m) 0.11298
Pound Feet (lb-ft) to Newton Meters (N•m) 1.3558
Pound Feet (lb-ft) to Kilograms Force per Meter (kgfm) 0.13825
Newton Meters (N•m) to Pound Inches (lb-in) 8.851
Newton Meters (N•m) to Pound Feet (lb-ft) 0.7376
Newton Meters (N•m) to Kilograms Force per Meter (kgfm) 0.10197
Kilograms Force per Meter (kgfm) to Pound Feet (lb-ft) 7.233
Kilograms Force per Meter (kgfm) to Newton Meters (N•m) 9.807
Radiator Specific Heat Dissipation Calculations
British Thermal Unit per Hour (BTU/hr) to Kilowatt per Degree Celsius (kW/°C) 0.000293
Kilowatt per Degree Celsius (kW/°C) to British Thermal Unit per Hour (BTU/hr) 3414.43
Temperature Calculations
Degrees Fahrenheit (°F) to Degrees Celsius (°C) (°F − 32) x 0.556
Degrees Celsius (°C) to Degrees Fahrenheit (°F) (1.8 x °C) + 32
Page 7
INTRODUCTION
Pressure Calculations
Atmospheres (atm) to Bars (bar) 1.01325
Atmospheres (atm) to Kilopascals (kPa) 101.325
Bars (bar) to Atmospheres (atm) 0.98692
Bars (bar) to Kilopascals (kPa) 100
Bar (bar) to Pounds per Square Inch (psi) 14.5037
Inches of Mercury (in Hg) to Kilopascals (kPa) 3.377
Inches of Water (in H2O) to Kilopascals (kPa) 0.2491
Pounds per Square Inch (psi) to Kilopascals (kPa) 6.895
Pounds per Square Inch (psi) to Bar (bar) 0.06895
Kilopascals (kPa) to Atmospheres (atm) 0.00987
Kilopascals (kPa) to Inches of Mercury (in Hg) 0.29612
Kilopascals (kPa) to Inches of Water (in H2O) 4.01445
Kilopascals (kPa) to Pounds per Square Inch (psi) 0.145
Power Calculations
Horsepower (hp) to Kilowatts (kW) 0.74627
Kilowatts (kW) to Horsepower (hp) 1.34
Fuel Performance Calculations
Miles per Gallon (mile/gal) to Kilometers per Liter (km/L) 0.4251
Kilometers per Liter (km/L) to Miles per Gallon (mile/gal) 2.352
Velocity Calculations
Miles per Hour (mile/hr) to Kilometers per Hour (km/hr) 1.609
Kilometers per Hour (km/hr) to Miles per Hour (mile/hr) 0.6214
Volume Flow Calculations
Cubic Feet per Minute (cu-ft/min) to Liters per Minute (L/min) 28.32
Liters per Minute (L/min) to Cubic Feet per Minute (cu-ft/min) 0.03531
Page 8
INTRODUCTION
ABOUT THE MACK MP8
(EURO 3) ENGINE
[200 EA] Do NOT use starting fluid (ether) on engines
1 equipped with an inlet manifold air heater
element. An explosion could occur. Failure to
heed this danger may result in severe
Two optional fan drives are available: On/Off and

electronically actuated. The electronically
actuated viscous fan drive is precisely controlled
by the Engine Electronic Control Unit (EECU).
Timing gears mount on the rear of the MP8

improving the flow of cooling air around the front.
Special service instructions apply to the camshaft
position sensor. The mounting plate, idler and
camshaft gears are marked to facilitate proper
installation. The air compressor drive gear
meshes with the double idler instead of the
auxiliary idler as on the MP7 engine.
Another feature of the MP8 is the rear engine

power take-off (REPTO-ready) that is gear driven
Figure 1 — MACK MP8 Euro 3 Engine through the timing gear train. An optional PTO
with drive gear, bearing and housing can be
The MACK MP8 (Euro 3) is a 13 liter (800 CID) added at the factory.
engine with electronic unit injectors and an
exhaust pressure governor (EPG) for engine The rocker arm shaft is held in place by camshaft
braking. The optional PowerLeash™ engine bearing capscrews. There are special instructions
compression brake is available in combination for installing the camshaft bearing caps and the
with the EPG for increased engine braking rocker arm shaft during service.
performance. The engine conforms to Euro 3
emission requirements. A stiffener plate fastens to the bottom of the
cylinder block to ensure block strength and
A wide range of the current transmission rigidity. The engine can be used with axle forward
offerings, including manual, automated manual or axle back vehicles by virtue of optional oil
and automatic, can be teamed with the MP8. pans. The engine fan is mounted high or low
depending on vehicle configuration.
Diagnostic help can be found in the Premium
Tech Tool (PTT). To obtain PTT, contact your local The MP8 uses unit injectors. The unit injector
MACK dealer. incorporates the pump, valve and injector. Its
internal solenoids permit fast, precise control of
The engine weighs approximately 1145 kg fuel delivery into the cylinder. The unit injectors
(2524 lb.) dry (with air compressor, without oil, are encased by the valve cover and not exposed
coolant, starter, fan, alternator and clutch). Its to the heat of exhaust system components.
design includes a one-piece cylinder head, a
single overhead camshaft, three or four rocker Fuel passes through two filters, one of which
arms per cylinder, unit injectors and no pushrods. separates water from the fuel. High-pressure fuel
Monosteel™ steel pistons are made in one piece. in the unit injectors is created via the rocker arms
with roller followers in constant, direct contact
with the cams.
Page 9
INTRODUCTION
Replacing injectors requires a specific procedure, 2. DO NOT grind the injector copper sleeves.
and installation requires that the EECU be
3. Install the crankshaft main bearing caps
programmed to recognize replacement injectors.
according to marked assembly number.
Cleaning injector bores requires a special tool.
4. Connecting rod caps MUST BE mated to
Standard equipment on the engine includes the their respective connecting rods due to the
exhaust pressure governor (EPG) which utilizes a “fractured manufacturing” process used.
shutter in the exhaust pipe after the turbocharger Also, the rod caps can be installed only one
for engine braking. The EPG can be combined way because of the difference in spacing
with the optional PowerLeash™ engine between screw holes at each side of the
compression brake for additional assist in cap.
deceleration and braking.
5. DO NOT use the lifting eye on the flywheel
housing when tilting the engine/transmission
There are multiple design variations of the
assembly to an angle greater than
PowerLeash™ engine brake utilizing a 3-rocker
15 degrees.
valve train or a 4-rocker valve train. The variations
require a different camshaft, special exhaust 6. Cylinder head installation requires lowering
valve rocker arms and yokes (bridges), an oil the head onto the gasket using the
control valve and wiring harness. Exhaust valve alignment screws and washers at the sides
clearance for PowerLeash™ equipped engines is of the head and block. The head must be
adjusted with shims. pulled back to the mounting plate using
screws inserted through the plate. Pressed
Unique colors and the appearance of the valve bosses in the gasket keep the head from
cover, filters and logo labels distinguish the MP8 making full contact with the gasket surface
from other engines in the MACK line. and prevent damage to the elastomer
sealing rings as the head slides into
Preventive maintenance is important to get the position.
most from the MACK MP8 engine and to ensure
7. Do NOT use starting fluid (ether) on engines
many years of reliable, trouble-free operation.
equipped with an inlet manifold air heater
Refer to the current TS494 Maintenance and
element.
Lubrication manual for schedules and
specifications.
Repair instructions in this manual deal with

removal, installation, disassembly, assembly, The use of starting fluid (ether) on engines
setup and adjustments of MP8 components. equipped with an inlet manifold air heater
element is prohibited. An explosion could
There are restrictions concerning the reuse of occur. Failure to heed this danger may result
certain fasteners. Refer to current specifications in severe personal injury or death.
bulletins and the SPECIFICATIONS section of
this manual for detailed information. 8. The MP8 engine uses a number of O-rings
for sealing various fluid joints and tubes. It is
essential that new O-rings of the correct
Service Precautions Summary material be used whenever joints are
disassembled and reassembled.
Following is a summary list of the DO and DON’T
issues applying to MP8 engine service.
1. DO NOT machine the cylinder head for
clean-up since this will change injector
depth, thereby affecting emissions. It will
also upset the ability to correctly adjust
timing gear backlash.
Page 10
VISUAL IDENTIFICATION
Page 11
MP8 EURO 3 ENGINE MODEL 앫 Maximum torque
IDENTIFICATION 앫 Rated power
앫 Rated power speed
Engine Information Plate 앫 Displacement
앫 Low idle speed
The engine information plate is located on the top
of the cylinder head (valve) cover. This plate 앫 Exhaust brake
includes information concerning the following
items. In addition to the information plate, there is
another label on the cylinder head (valve) cover.
앫 Engine model and emissions level This additional label lists the chassis number,
앫 Prop. version engine serial number and respective barcodes.
2
Figure 2 — Engine Information Plate
Engine Serial Number Identification

In addition to the engine information plate on the
cylinder head cover, the engine is also identified
by the engine serial number stamped into the
cylinder block. This serial number is located on
the block left side at the front just below the inlet
manifold.
Page 12
DESCRIPTION AND OPERATION
Page 13
MACK MP8 EURO 3 ENGINE Main features of the cylinder head are:
DESIGN FEATURES 앫 One-piece cast iron
[200 EA] 앫 Integral thermostat housing
3
Separate chambers for exhaust and inlet at each

cylinder make this a “crossflow” design. The fuel
channel, drilled from front to rear, connects with
grooves machined around each injector opening.
A plug at the rear of the cylinder head seals this
channel.
CAMSHAFT AND VALVE TRAIN

The engine has an overhead camshaft and rocker
arm shaft in support of four valves per cylinder.
The camshaft rides on seven journals with a
bearing cap and support block (saddle) at each
point. The bearing inserts (shells), bearing caps
and support blocks are replaceable.
If the engine is equipped with EPG exhaust brake

only, there are three cams for each cylinder,
including inlet, injection and exhaust. Each valve
rocker arm drives two valves via a pinless yoke
Figure 3 — MACK MP8 Euro 3 Engine (or bridge).
To accommodate the low cab forward design, the On some engines, the EPG exhaust brake is
inlet manifold is configured differently for the used in combination with the PowerLeash™
conventional versus the low cab forward chassis. engine brake. With this configuration, the engine
The air inlet from the charge air cooler is at the can have three or four cams for each cylinder
front of the inlet manifold on the conventional depending on the PowerLeash™ variant
chassis, but near the rear of the manifold on the (3-rocker or 4-rocker).
low cab forward design. 5
Engine Components
CYLINDER HEAD
4
Figure 5 — PowerLeash™ 3-Rocker Valve Train
1. Inlet Valve Yoke (Bridge) 3. Adjustment Shim

Figure 4 — Cylinder Head with Valves and Camshaft 2. PowerLeash™ Exhaust 4. Shim Retaining Screw
Supports Valve Yoke (Bridge)
Page 14
Exhaust valve yokes include a shim for
6
adjustment. Replaceable valve guides and seats

are made of alloyed cast iron and steel
respectively. All valve guides have oil seals.
Exhaust valves have double valve springs.
Rollers in the ends of the rocker arms contact the

cam shaft. The contacts with the yokes have ball
sockets for flexibility.
The camshaft is induction-hardened. Timing

marks for valve and injector adjustment are
located on the flange forward of the No. 1
camshaft journal. These marks are for adjusting
valve clearance. They do not apply to camshaft
timing.
Camshaft thrust washers are integral on the No. 7

journal bearing. Smooth rotation is ensured by
means of a vibration damper on the camshaft
gear. Teeth on the damper interact with the
Figure 6 — PowerLeash™ 4-Rocker Valve Train camshaft position sensor for input to the EECU.
7
1. Inlet Valve Yoke (Bridge) 5. PowerLeash™ Brake
2. Inlet Valve Rocker Arm Rocker Arm
3. Injector Rocker Arm 6. Exhaust Valve Yoke
4. PowerLeash™ Exhaust (Bridge)
Valve Rocker Arm 7. Shim Retaining Screw
Figure 7 — Camshaft Assembly Components
1. Spacer 5. Upper Bearing Cap

2. Vibration Damper 6. Bearing Inserts
3. Camshaft Gear 7. Thrust Bearing Inserts
4. Camshaft 8. Lower Bearing Cap (Support)
Page 15
Timing marks on the camshaft provide for valve
9
and injector adjustment. PowerLeash™ includes

its own electronic control governed by driver's
choice through a switch near the steering wheel.
This control mounts on the cylinder head
between the No. 3 and No. 4 cylinder rocker
arms. The wiring harness includes additional wire
leads for PowerLeash™.
8
Figure 9 — Cylinder Block and Stiffener Plate
Figure 8 — MP8 Euro 3 Engine Timing Marks — 1. Cylinder Block 2. Block Stiffener Plate
Camshaft Front End
Main bearing caps are made of nodular cast iron
CYLINDER BLOCK machined together with the cylinder block. Cast
alignment slots in the block and tabs on the caps
The cylinder block is made of cast iron. For
ensure proper alignment at installation. Each cap
increased cylinder block rigidity and noise and
is marked with its location beginning with No. 1 at
vibration reduction, a steel stiffener plate attaches
the front. Cap Nos. 4 and 7 are unique and are
to the bottom.
not numbered.
The main and piston lubricating channels are
The block includes cylinder liners that contact the
drilled longitudinally through the block. These are
coolant directly (wet liners). The casting shape
plugged at the front of the block. The main
follows the contours of the cylinders to increase
channel opens into a cast-in channel that
rigidity and reduce noise.
supplies oil to the timing gears. The piston
cooling channel is covered by the timing gear
cover.
Page 16
Head to Block Alignment CYLINDER HEAD GASKET
10
The cylinder head gasket is made of one piece of
sheet steel with vulcanized elastomer seals on oil
and coolant conduits. The design of the engine
and head gasket requires a unique procedure for
installation of the cylinder head.
The screws and washers at the side guide the

head into side-to-side alignment as it is laid on
the gasket and block. Screws passed through the
timing gear mounting plate into the head pull the
head into alignment fore and aft. Small, stamped
bosses on the gasket hold the head clear of the
seals and allow it to glide accurately into position
against the mounting plate during installation.
Tightening the head bolts flattens the bosses on
the gasket. For this reason, a new head gasket
must be installed whenever the head is removed.
11
Figure 10 — Head to Block Alignment Screws and

Washers
1. Cylinder Head 3. Cylinder Block

2. Alignment Screws and
Washers
Three screws and washers installed at the side

(two in the block and one in the head) align the Figure 11 — Cylinder Head Gasket
head from side to side at assembly. Fore and aft,
the head is aligned by contact with the timing
gear mounting plate.
The head is aligned with the timing gear plate by

screws passed through the mounting plate into
the head and tightened securely. It is extremely
important to remove these screws before
attempting to remove the cylinder head from the
block. Failure to heed this caution may result in
severe damage to the timing gear plate and other
engine components.
Page 17
CYLINDER LINERS OIL PAN
The cylinder block uses replaceable wet cylinder The oil pan is plastic or steel with a threaded plug
sleeves. The lower end of each sleeve is sealed for draining. The plastic pan has a groove in the
against the block with three elastomer rings. The mounting flange which accepts a molded
upper end is sealed with a ring of EPDM elastomer gasket for a seal. The steel pan is
elastomer situated directly under the sleeve sealed with a gasket on the oil pan flange.
collar. This design cools the upper section of the Twenty-two spring-loaded screws clamp the pan
sleeve better because the area of coolant to the block.
circulation is larger. 13
The lower seals are fitted in grooves in the

cylinder block. The bottom seal is of a different
material and fluorescent violet in color to
distinguish it from the intermediate seals.
12
Figure 13 — Oil Pan and Stiffener Plate
1. Block Stiffener Plate 2. Oil Pan with Gasket
The oil pan includes an oil level/temperature

sensor with connector. The filler tube and dipstick
Figure 12 — Cylinder Liner and Seals mounting ports are also components of the oil
pan.
1. Upper O-Ring — EPDM 3. Lower Sealing Ring —
(Black) Viton (Purple)
2. Middle Sealing Rings —
EPDM (Black)
Oil pans with the sump at the front or at the rear
are available to accommodate axle forward or
axle back chassis.
Page 18
CRANKSHAFT The rear main cap (No. 7) includes an attaching
point for the lube pump. Thrust washers to control
The crankshaft is drop forged steel and induction
axial movement straddle the central journal (cap
hardened. It has seven journals with replaceable
No. 4). The remaining caps (Nos. 1–3, 5 and 6)
bearings. Five oversized replacement bearing
are numbered to facilitate correct assembly.
options are available to accommodate crankshaft 14
regrinding.
Figure 14 — Crankshaft, Bearings, Thrust Washers and Cap Alignment Tabs
1. Alignment Tab, Block 3. Thrust Washers

2. Alignment Tab, Cap 4. Upper and Lower Bearings
A Teflon® seal bearing directly on the crankshaft

flange is used at the front of the crankshaft. The
front seal has an outer felt ring which serves as a
dust cover. At the rear of the crankshaft is another
seal that bears directly on the machined surface
of the crankshaft gear. Additionally at the rear,
there is a groove in the rear crankshaft flange for
an O-ring which forms a seal between the flange
and the gear.
Whenever the lower main bearing caps are

installed in the engine block, ensure the lower
main bearing cap is installed in the same location
of the engine block as removed. Also, ensure that
the aligning mark (boss) on the bearing cap
aligns with the mark (boss) on the engine block.
Page 19
PISTONS AND CONNECTING RODS
15
Figure 15 — Piston and Connecting Rod
1. Piston Ring Set 6. Connecting Rod Bolts

2. Wrist Pin Snap Ring 7. Connecting Rod Bearing Cap
3. Piston 8. Upper and Lower Connecting Rod Bearings
4. Piston Cooling Nozzle 9. Connecting Rod
5. Assembly Matching Marks 10. Wrist Pin
Connecting rods are forged steel and are used in

16
combination with one-piece Monosteel™ steel

pistons. The bearing caps are attached with four
M12 capscrews spaced to prevent misalignment.
The rods and caps are made by a “fracture”
process that requires a cap be assembled with its
original rod. Never attempt to use mismatched
rods and caps.
The piston is fitted with three rings. In the top

groove is a compression ring with a “keystone”
cross section. In the second groove, the
compression ring has a rectangular cross
section. In the third groove is a spring-loaded oil
scraper ring.
Figure 16 — Piston Cooling
1. Piston Cooling Nozzle 3. Opening Valve

2. Control Valve
Page 20
Oil flow for the piston cooling system is controlled TIMING GEARS
by two valves. The opening valve supplies oil and
The timing gears are located at the rear of the
the control valve balances the oil flow to the
engine. Backing up the gears is a plate: a 6 mm
piston cooling channel. The piston cooling nozzle
(1/4 inch) thick steel sheet attached to the
is aligned so that the oil jet hits the underside of
cylinder block.
the piston crown.
The advantages of this configuration are more
precise timing, fewer components and lower
noise levels.
17
Figure 17 — Timing Gears and Plate
1. Crankshaft Gear 6. Power Steering/Fuel Pump Gear

2. Double Idler Gear 7. Air Compressor Gear
3. Adjustable Idler Gear 8. Oil Pump Gear
4. Camshaft Gear and Damper 9. Power Take-Off Gear (optional)
5. Auxiliary Idler Gear 10. Timing Gear Plate
The power steering/fuel pump gear, the air The camshaft gear fastens to the hub on the end
compressor gear and the PTO gear are not timing of the shaft. A vibration damper also attaches to
gears. The pump and compressor gears fasten to the hub outboard of the gear. Teeth on the
their respective components. The pump gear is damper actuate the camshaft position sensor.
driven by the auxiliary idler gear. The compressor The gear is driven via the adjustable idler.
gear is driven by the double idler gear.
The double idler drives the adjustable idler and

the gear used to drive the power take-off, if so
equipped. This is part of the “REPTO-Ready”
feature. A PTO unit with drive gear is substituted
for a cover on the flywheel housing.
Page 21
DRIVE BELTS Each belt uses an automatic tensioner. In the
high position, view 1 in Figure 18, there are two
This engine can be configured to accommodate
idler pulleys in the primary loop: one between the
either the conventional chassis or the low cab
coolant pump pulley and the tension idler; the
forward (LCF) design. Depending on the vehicle,
other between the crankshaft pulley and the fan
the fan location may be high or low on the fan
hub.
bracket.
In the low position, view 2 in Figure 18, the idler
Two poly-V belts drive the front engine
between the damper and fan pulleys is omitted.
accessories. The outer, primary belt (10 or
12 ribs) drives the coolant pump and fan hub from
a pulley on the crankshaft flange nested in the Lubrication System
vibration damper. The inner, secondary belt (six
ribs), driven by the crankshaft vibration damper, A gear-type pump at the rear of the engine,
drives the alternator and refrigerant compressor. driven by the crankshaft gear, draws lubricant
18
from the oil pan and supplies the system. Oil
flows from the pump through the distribution
housing to the filters, to a gallery at the right side
of the engine serving the crankshaft journals, to a
gallery at the left side serving piston lubrication
and cooling, to the cylinder head and rocker shaft
duct (valve rocker and camshaft) and back to the
oil pan. The system includes crankcase
ventilation.
Two full-flow filters and a by-pass filter maintain

clean lubricant. A sensor in the oil pan monitors
fluid level. There is an oil cooler immersed in
engine coolant inside the coolant duct cover.
Figure 18 — Drive Belt Routings — Conventional and

LCF Chassis
1. Conventional Chassis 2. LCF Chassis
Page 22
OIL PUMP
19
Figure 19 — Lubrication System Diagram
A strainer and pickup tube lead the lubricant into

the pump. For the axle forward oil pan, the
strainer is mounted on a short tube held in place
by a bracket attached to the distribution housing.
For the axle back model, a long tube without the
bracket is supplied.
Page 23
OIL FLOW CONTROL AND FILTRATION
20
Figure 20 — Lubrication System Flow Diagram
1. Strainer 11. Air Compressor

2. Pickup Tube 12. Turbocharger
3. Oil Pump 13. By-Pass Filter
4. Pressure Pipe 14. Piston Cooling Nozzles
5. Oil Cooler A. Reducing Valve
6. Filter Housing B. Safety Valve
7. Full-Flow Filters C. Oil Cooler Thermostat Valve
8. Main Lubrication Gallery D. Overflow Valve, Full-Flow Filter
9. CCV Separator E. Opening Valve, Piston Cooling
10. Exhaust Brake Oil Control Valve F. Control Valve, Piston Cooling
There are three filters, one by-pass and two The reducing valve maintains constant system oil
full-flow, attached to a housing mounted at the pressure. The safety valve prevents excessive
lower right side of the engine. Oil flow through the pressure during periods of high viscosity. The oil
filters and the lubrication system is controlled by cooler thermostat valve prevents oil from entering
six valves, including: the cooler until it warms to the set point. The
overflow valve allows oil to by-pass the filter if it
앫 Reducing Valve
becomes clogged. The opening valve prevents oil
앫 Safety Valve from moving to the piston cooling outlets until the
system reaches the set pressure. The control
앫 Oil Cooler Thermostat Valve
valve regulates the oil flow to the piston cooling
앫 Overflow Valve, Full-Flow Filter channels.
앫 Opening Valve, Piston Cooling
앫 Control Valve, Piston Cooling
Page 24
Crankcase Ventilation open spaces are ducted through a pipe that
opens to the atmosphere near the bottom of the
Lubricant becomes a mist in many areas of the engine.
engine as the result of the motion of the parts
(e.g., rocker arms, pistons, crankshaft, camshaft The crankcase ventilation (CCV) system
and rocker shaft). The mist rides the drafts of air separates the oily mist from the gases by
and other gases that circulate in the open spaces centrifugal force. The oil returns to the oil pan.
in the engine. To prevent pressure buildup, the The remainder escapes to the atmosphere.
21
Figure 21 — Crankcase Ventilation System Separator
1. Seal Ring 5. Separator Housing

2. Separator Inlet Hose 6. Housing Seal
3. Separator Vent Tube 7. Pressure Regulator
4. Vent Tube Bracket
A turbine in the CCV separator, driven by a small The open port connects to a tube leading to the
stream of oil striking its fins, spins at high speed. bottom of the engine where road draft draws the
The mixture of gases and oily mist trapped in the gases into the atmosphere.
valve cover and the timing gear cover drains onto
the top of the center of the turbine and runs down
onto several discs rotating with the turbine.
Separation occurs as the mixture, flung outward
by the turbine, strikes the walls of the CCV. The
droplets of mist coalesce into a liquid and drain
back into the oil pan along with the oil that drives
the turbine. The gases are free to leave via an
open port.
Page 25
Fuel System
22
Figure 22 — Fuel System Diagram
1. Fuel Pump 13. Hand Pump Handle

2. Fuel Tank and Inlet Tube 14. Water Level Sensor
3. EECU Cooler 15. Water Discharge Control Switch (Instrument Panel)
4. Fuel Filter Housing 16. Electrical Water Drain Valve
5. Fuel Pre-Filter 17. Automatic Air Bleed Valve (closes when filter removed)
6. Water Cup 18. Service Port (Pressure Gauge)
7. Secondary (Main) Filter 19. Supply Pressure Sensor
8. Fuel Gallery 20. Fuel Heater (Optional)
9. Unit Injector 21. Service Shutoff Valve (closes when filter removed)
10. Pressure Regulator Valve 22. One-Way Valve (Hand Priming)
11. Pump Safety Valve (Pressure Regulator) 23. Automatic Air Bleed Valve
12. One-Way Valve 24. Fuel Tank Breather
The fuel pump attaches with the power steering

pump to the flywheel housing at the rear left side.
It turns on the same shaft as the power steering
pump. The common drive gear meshes with the
auxiliary idler driven by the crankshaft gear. At
600 rpm, the pump delivers a minimum 100 kPa
(14.5 psi), and at 1200 rpm, 300 kPa (43.5 psi).
At 400–550 kPa (58–80 psi), the gallery regulator
valve opens to control fuel gallery pressure.
Page 26
Fuel is drawn by the suction side of the fuel pump FUEL FILTRATION
from the fuel tank into the ECU cooling plate and
Primary and secondary filter elements attach to
enters the fuel filter housing. Fuel passes by the
the underside of the filter valve housing. The
one-way check valve which prevents the bleeding
housing, located at the front lower left side of the
of fuel back to the fuel tank and into the primary
cylinder block, has an integral hand-priming
fuel filter. The fuel becomes filtered by passing
pump for bleeding the system. The 30 micron
through the filter media from the outside to the
pre-filter (primary filter) also separates water from
center of the primary fuel filter. The fuel leaves
the fuel. Water collects in a cup on the bottom of
the primary filter and passes by a one-way valve
the pre-filter. There is a sensor to keep track of
located in the threaded nipple of the primary filter.
the water and signal the EECU.
The fuel flows from the filter housing to the
suction side of the fuel pump through an external
A one-way check valve located in the filter
fuel line. Fuel becomes pressurized after leaving
housing prevents fuel from draining back to the
the fuel pump and flows back to the filter housing
fuel tank when the engine is shut down. Also
to enter the secondary filter. The fuel becomes
included in the fuel filter housing is the fuel
filtered by passing through the filter media from
pressure sensor just above the secondary filter.
the outside to the center of the secondary filter.
The fuel leaves the secondary filter and passes
by an automatic air bleed valve which is located in
the threaded nipple for the secondary filter. Fuel
passes by the fuel pressure sensor and then exits 앫 The collected water can be dumped only
the filter housing to enter the rear of the cylinder while the engine is not running, the key is in
head through an external fuel line. After fuel the ON position and the parking brake is set.
enters the cylinder head, it passes through the 앫 Some trucks are built with a remote mounted
fuel gallery of the cylinder head to continuously fuel water separator. In this case, the fuel is
deliver fuel to all six unit injectors. Fuel leaves the drawn through the remote mounted filter
cylinder head after passing by the fuel pressure before it reaches the ECU cooler plate. On
regulator located at the left front corner of the the filter base, the mounting location for the
cylinder head. Fuel is routed back from the standard primary filter is blocked off with a
cylinder head to the filter housing through an plate.
external fuel line to deliver some return fuel back
into the suction side which goes to the fuel pump.
Any excessive fuel not consumed is bled off
through the de-aeration valve and then, directed
back to the fuel tank.
Page 27
UNIT INJECTORS
23
Figure 23 — Unit Injector Diagram
1. Injector Yoke 7. Pressure Relief Valve

2. Copper Sleeve (with bead) 8. Solenoid Coil
3. O-Ring 9. Solenoid Coil
4. Fuel Gallery 10. Injector Valve
5. O-Ring 11. Injector Piston
6. O-Ring 12. Injector Nozzle
Page 28
This engine uses double solenoid unit injectors. The fuel pump pressurizes the gallery so that fuel
Unlike systems that require separate components rushes into each injector when it opens. Gallery
for delivering, pressurizing and injecting, this unit pressure is regulated by a valve that delivers
injector combines these functions. These excess fuel back to the tank.
injectors precisely control the fuel delivery
because of the two solenoids. The solenoids, Copper sleeves, acting as coolant jackets, line
pump and nozzle are in a single body in close the bottoms of the injector bores. Engine coolant
proximity to each other. circulates around these sleeves aiding the
process of controlling injection temperature.
The injector is set in a pressurized fuel gallery
where the fuel temperature is constant. Uniform There are four phases to the injector cycle of
fuel temperature means uniform quantity in each operation. These include:
injection which means uniform power output from
앫 Fill phase
each cylinder.
앫 Spill phase
앫 Injection phase
앫 Pressure drop phase
24
Figure 24 — Unit Injector — Fill and Spill Phases
1. Pump Plunger 3. Injector Nozzle

2. Fuel Gallery
Fill phase (A): During the filling phase, the pump Spill phase (B): The spill phase begins when the
plunger is on its way up, the camshaft lobe is camshaft lobe forces the rocker arm to push the
passing its highest point and the rocker arm is on pump plunger down. The fuel can now flow
its way toward the camshaft base circle. The fuel through the fuel valve, through the holes in the
valve is open, allowing fuel to flow into the unit unit injector and out through the fuel gallery. The
injector from the lower fuel gallery. Fuel flows into spill phase continues as long as the fuel valve is
the cylinder head and the unit injector pump open.
cylinder. Filling continues until the pump plunger
reaches its upper position.
Page 29
25
Figure 25 — Unit Injector — Injection and Pressure Drop Phases
1. Pump Plunger 3. Injector Nozzle

2. Fuel Gallery
Injection phase (C): The injection phase begins

when the fuel valve closes. The camshaft lobe
and rocker arm continue to press down on the
pump plunger and injection occurs as the path The dimension by which the injector nozzle
through the fuel valve closes. The injection phase extends from the head is critical. This means that
continues as long as the fuel valve is closed. machining the head in any way that changes this
nozzle extension is not permitted.
Pressure drop phase (D): The injection phase 26
ends when the fuel valve opens and pressure in
the unit injector drops below the nozzle opening
pressure. The fuel flows through the open fuel
valve, through the unit injector holes and out
through the fuel gallery. Note that the fuel valve
position (closed or open) determines when the
injection phase begins and ends. The time during
which the fuel valve is closed determines the
amount of fuel injected at each pump stroke.
Unit injectors are categorized and coded with

regard to tolerances. Whenever a unit injector is
replaced, the replacement injector MUST be
programmed for the cylinder in which it is
installed. This is done by programming EECU
parameters using the VCADS pro or the Premium
Tech Tool (PTT) to set Injector Trim parameters
with the trim codes marked on the injectors.
Figure 26 — Injector Coding
1. Serial No. 2. Unit Calibration No.
Page 30
Exhaust Pressure Governor (EPG) System
27
Figure 27 — Exhaust Pressure Governor (EPG) System
1. EPG Shutter Housing 3. Air Cylinder

2. Shutter 4. Air Valve Unit
The exhaust pressure regulator (EPG) is placed To meet the varying control air needs of the
in direct connection with the turbine housing of exhaust brake, the engine electronic control unit
the turbocharger, and has two tasks: sends a Pulse Width Modulated (PWM) signal to
the AVU valve, where the signal pulse width (as a
앫 When idling, the engine is kept warm by
percentage) determines the output air pressure to
creating a back pressure in the exhaust
the pressure cylinder.
manifold.
앫 When the accelerator pedal is released, it Figure 27 shows the situation during normal
acts as an exhaust brake. driving. When the AVU valve is not receiving
electric current, the shutter (2) is completely open
The exhaust pressure regulator consists of a and the exhaust is free to pass.
shutter housing (1), a shutter (2) and a pneumatic
cylinder (3) as shown in Figure 27. Compressed
air is taken from the vehicle air system and
controlled by an air valve unit (AVU), which is
available in two variants — for turbochargers with
or without waste gates (actuators) respectively.
The AVU valve consists basically of a solenoid
valve, an air valve and a printed circuit board. It
regulates the pressure steplessly within the 0.5 to
7.5 bar range. The valve has a built-in reducing
valve, which releases different pressures for the
respective amounts of braking.
Page 31
PowerLeash™ Engine Brake
28
The engine can be equipped with a

PowerLeash™ engine brake system to assist in
slowing the vehicle when necessary. The system
includes:
앫 Wiring harness
앫 Camshaft
앫 Oil control valve
앫 Exhaust rocker arm or exhaust and brake
rocker arms
앫 Exhaust valve yokes (bridges)
There are multiple design variations of the

PowerLeash™ engine brake utilizing a 3-rocker
valve train or a 4-rocker valve train.
POWERLEASH™ (3-ROCKER)
With the 3-rocker PowerLeash™ design, the
exhaust rocker arms contain a power piston and
non-return valve to actuate the exhaust valves for
engine braking. The three rocker arms are
positioned on the shaft (front to back) in the order
of inlet, injector and exhaust. Both the inlet and Figure 28 — PowerLeash™ (3-Rocker) Components
exhaust rocker arms each drive the valve pairs
via a pinless yoke (bridge). 1. Camshaft 7. Non-Return Valve
2. Exhaust Lobe 8. Power Piston
3. Charging Lobe 9. Adjustment Shim
4. Decompression Lobe 10. Pressure Relief Valve
5. Exhaust Rocker Arm 11. Yoke, Exhaust Valve
6. Blade Spring
There are two small lobes on each of the exhaust

cams in addition to the regular lobe. Their
locations are timed to open the exhaust valves at
the end of the induction stroke and immediately
before TDC on the compression stroke when
engine braking is activated.
The exhaust rocker arms are sturdier than

standard and are equipped with blade springs to
maintain clearance between the roller and the two
small extra lobes when PowerLeash™ is not
activated. Valve clearance adjustment is
accomplished through the use of shims attached
to the top of the valve yoke.
Page 32
POWERLEASH™ (4-ROCKER) OPERATION (3-ROCKER AND 4-ROCKER)
With the 4-rocker design, the exhaust rocker arms PowerLeash™ operation depends on all of the
contain a pump piston in addition to the power following conditions which must exist
piston and non-return valve. An additional “brake” simultaneously.
rocker arm, working in combination with the
앫 Accelerator pedal released
exhaust rocker arm, drives the pump piston for
engine braking. 앫 Engine speed above 1000 rpm
29
앫 Clutch pedal released
앫 Road speed above 5 km/h (3.1 mph)
앫 ABS inactive
앫 Transmission in gear
앫 Oil temperature above 60°C (140°F)
앫 Charge air pressure below 50 kPa (7.25 psi)
On the cylinder head, the oil control valve

connects the oil passages in the head and rocker
shaft. The control valve reduces the oil pressure
in the rocker shaft to 100 kPa (14.5 psi) when
PowerLeash™ is not activated.
30
Figure 29 — PowerLeash™ (3-Rocker) Components
1. Camshaft 7. Non-Return Valve

2. Charging Lobe 8. Piston
3. Decompression Lobe 9. Spring
4. Exhaust Rocker Arm 10. Brake Rocker Arm
5. Pump Piston 11. Exhaust Lobe
6. Power Piston
At each cylinder, there is a fourth cam to drive the Figure 30 — PowerLeash™ Oil Control Valve — Location
brake rocker arm. This cam contains the charging
and decompression lobes which are timed to 1. Tie Wraps 4. Control Valve
open the exhaust valves at the end of the 2. Electrical Connector 5. Tube — Valve to Shaft
3. Attaching Screws
induction stroke and immediately before TDC on
the compression stroke when engine braking is
activated.
With the 4-rocker design, it is the engine brake

rocker arm that is equipped with a blade spring.
Here, the purpose is to keep the roller in contact
with the fourth “brake” cam.
Page 33
When the accelerator pedal is released (and the
System Oil Pressure
PowerLeash™ switch is ON), the solenoid opens
allowing some oil to escape through a small port. Engine
Speed/RPM Temperature Pressure
Reduced spring pressure moves the piston,
opens the passage to the rocker shaft and 600 90–110°C >250 kPa
increases the oil pressure. The system opens the (195–230°F) (>36 psi)
exhaust valve during induction and again >1100 90–110°C 300–550 kPa
immediately before TDC on the compression (195–230°F) (44–80 psi)
stroke.
>1100 Cold Engine 650 kPa
The engine slows because the extra volume (95 psi)
under compression takes more power to
compress, and escaping pressure in the
combustion stroke reduces the power output. A Rocker Shaft Oil Pressure
switch on the instrument panel allows the driver Engine
to engage or disengage PowerLeash™. Engine Brake Speed/RPM Pressure
Active 1000–2300 >220 kPa
If the ABS system becomes active, it (>32 psi)
automatically disables PowerLeash™. If the oil
Inactive — 80–120 kPa
temperature goes below 55°C (131°F),
PowerLeash™ cannot be activated. A warning (12–17 psi)
lamp on the instrument panel flashes if the driver
attempts to activate it under this condition. Air Intake System
A port in the cylinder head allows access to the Fresh air enters the intake above the back of the
oil passageway. The plug can be removed and a cab. Plastic duct work leads the air to the filter
gauge and hose assembly inserted for use during assembly mounted on the bulkhead under the
diagnostic procedures. hood. An impregnated paper filter prevents
31
foreign particles from passing through. The
assembly design permits the addition of a second
filter if needed in extreme environments.
A combination pressure/temperature sensor

mounted on the pipe between the filter housing
and the turbocharger alerts the driver if the filters
need replacement before the scheduled service.
The brake system air compressor also draws
fresh, clean air from this same pipe.
Figure 31 — Cylinder Head Oil Pressure Access Port
Page 34
Turbocharger A housing containing an impeller, shaft seals,
bearing and pulley attaches to the mounting
The turbocharger is of Map Width Enhancement plate. The bearing is a permanently lubricated
design, which means that the air intake is divided combination roller and ball bearing. Between the
into two areas (an inner and an outer area) shaft seals and the bearing, there is a ventilated
connected by a ring-shaped gap. This space which leads into a duct behind the pulley.
turbocharger design ensures efficiency at both This allows internal leaks to be detected.
33
low and high rotation speeds.
32
Figure 33 — Coolant (Water) System Components

Figure 32 — Turbocharger
1. Impeller Housing 3. Coolant Pump Mounting
2. Coolant Pump Seal Plate
1. Exhaust Manifold 3. Exhaust Pressure
2. Turbocharger Governor (EPG)
THERMOSTAT
Cooling System This is a piston-type, full-flow thermostat with
piston, bulb, seal and housing in a single
The cooling system incorporates a belt-driven assembly. Coolant flows continuously, either back
coolant pump mounted on the front of the engine to the pump, or to the radiator and back to the
on the right. It also uses a piston-type thermostat pump. It has lower pressure drop compared to
housed in the front of the cylinder head and a fan other types. The thermostat is mounted on the
with viscous or air-operated drive mounted above front of the cylinder head.
the crankshaft pulley. A coolant conditioner (filter)
attached to the pump housing filters impurities
from the coolant and releases supplemental
coolant additives for system protection.
COOLANT PUMP
The back of the coolant (water) pump, with its
ducts for distributing coolant, is a separate
casting attached to the cylinder block.
Page 35
ENGINE COOLING FAN Engine Management System
The cooling fan (Figure 34) runs via a viscous or
air-operated drive through which fan speed is ENGINE ELECTRONIC CONTROL UNIT
electronically controlled by the EECU. With (EECU)
precise EECU control, fan speed is continuously
35
adjusted in response to several interrelated
influences. This makes for efficient cooling with
low fuel consumption.
34
Figure 35 — EECU and Cooler
The engine management system module, also

known as the Engine Electronic Control Unit
(EECU), is located on the left side of the engine
just below the inlet manifold. The EECU is cooled
by fuel circulating through a plate attached to the
cover of the unit. The fuel comes from the tank on
its way to the fuel pump.
Figure 34 — Viscous Drive Engine Cooling Fan Algorithms, called maps, are programmed in the
EECU so that it can translate sensor data into
1. Solenoid Valve and 2. Connector (to EECU) action. These maps enable the EECU to receive
Speed Sensor status information from the sensors and send
functional data to the actuators so they can
Other fan drive options include On/Off Fan simultaneously assume the proper posture for the
Clutches and Electronically Modulated Fan safest, most efficient operation of the engine in
Drives. Refer to Engine Cooling Service Manual, any given instant.
7-002, for a complete description of all available
fan drive systems. Due to the EECU self-learning capability, it is
necessary to reset the learned EECU parameters
after servicing some engine-related components.
This allows the EECU to learn the new
component's behavior. After servicing is
complete, perform the “Learned Data Reset”
located in the Function Group 1 menu on the PC
tool.
Page 36
SENSORS AND ACTUATORS 36
Sensors on the engine provide for electronic

control. The figures that follow show the locations
of the devices on the left and right sides of the
engine, respectively.
Figure 36 — MP8 Euro 3 Engine Sensors
1. Water Level (in fuel/water separator) 7. Charge Air Pressure/Temperature

2. Oil Level/Temperature 8. Camshaft Position
3. Fuel Pressure 9. Inlet Air Pressure
4. Fan Speed (only if equipped with viscous fan) 10. Engine Position/Speed
5. Coolant Level Sensor (in expansion tank) 11. Oil Pressure
6. Coolant Temperature (at front edge of cylinder head) 12. Crankcase Pressure
Page 37
GLOSSARY OF TERMS Idler Tensioner
A belt tensioning device designed to maintain
Carbon Monoxide (CO) optimum tension under varying engine speeds
An odorless, colorless gas resulting from and load.
incomplete combustion of hydrocarbons; found in
diesel truck exhaust; poisonous to humans and Intake Air Temperature and Humidity Sensor
animals. Mounted in the air intake between the air cleaner
and the turbo compressor housing, detects
Electronic Unit Injector (EUI) outside air temperature and humidity and relays
Controlled electronically by the EECU, there is these values to the EECU.
one electronic unit injector for each cylinder of an
engine. A unit injector incorporates the pump, the Oxides of Nitrogen (NOx)
injector nozzle and two solenoids in a single body. High temperatures and pressures of combustion
Actuated by the camshaft via rocker arms with produce oxides of nitrogen (NOx). When
roller followers, electronic unit injectors offer combustion temperature exceeds 1372°C
precise fuel metering using a process called “rate (2,500°F), oxygen and nitrogen combine in large
shaping.” quantities to form NOx. By themselves, NOx
emissions are no great hazard; however, when
Engine Electronic Control Unit (EECU) mixed with the right amount of HC in the air, NOx
A microprocessor-based controller usually will combine in the presence of sunlight to form
mounted on the engine block. On the MP8 smog.
engine, a cooling plate mounts on the surface of
the module. A tube on the plate conducts fuel Poly-V Belt
drawn from the tank on its way to the pump A multi-ribbed belt design incorporated into the
before being pressurized. The fuel acts as the accessory drive belt and pulley arrangement at
coolant. With the MACK V-MAC® IV system, the the front of the engine.
EECU controls fuel timing and delivery, fan
operation, engine protection functions and engine Roller Follower
brake operation.
A type of rocker arm with an axle-mounted roller
Hydrocarbons (HC) that rides on (or follows) a camshaft lobe. The
rolling motion of this design provides increased
Chemical compounds composed only of carbon load capacity with less friction than the flat-faced
and hydrogen. Gasoline, diesel fuel and motor oil rocker arm design. Roller followers provide the
are all examples of a very large group of rocker arm lifting action for the electronic unit
hydrocarbons. The largest source of injector, intake and exhaust valves and exhaust
hydrocarbons is petroleum. brake.
Idler Gear Vehicle Electronic Control Unit (VECU)

A gear running between a driving and a driven A microprocessor-based controller, sometimes
gear to make the driven gear rotate in the same referred to as a module, mounted in the cab,
direction as the driving gear. inside the passenger-side dash panel. With the
MACK V-MAC IV system, the VECU controls
engine speed, cruise control, accessory relay
controls, idle shutdown and trip recorder
functions.
Page 38
COMPONENT LOCATOR
COMPONENT LOCATOR
Page 39
COMPONENT LOCATOR
MP8 EURO 3 ENGINE 37
COMPONENT LOCATION
VIEWS
[200 EA]
The locations of primary component assemblies
of the MP8 engine are identified in the
illustrations contained in this section.
Figure 37 — MACK MP8 Euro 3 Engine, Right-Side View (Front >)
1. Exhaust Manifold 7. Coolant Pump

2. Exhaust Pressure Governor (EPG) 8. Coolant Conditioner
3. Turbocharger 9. Full Flow Oil Filters
4. Thermostat 10. Bypass Oil Filter
5. Alternator 11. Starter
6. Fan Hub
Page 40
COMPONENT LOCATOR
38
Figure 38 — MACK MP8 Euro 3 Engine, Left-Side View (< Front), Conventional Chassis Configuration Shown
1. Air Compressor 5. Refrigerant Compressor (Pad Mount)

2. Power Steering Pump 6. Alternator (Pad Mount)
3. Low Pressure Fuel Pump 7. CCV Separator
4. Fuel Filters
For the conventional chassis, the air inlet is at the

front of the inlet manifold which is the
configuration shown in Figure 38. For the low cab
forward (LCF) chassis, the air inlet is located near
the rear of the manifold.
Page 41
NOTES
Page 42
TROUBLESHOOTING
TROUBLESHOOTING
Page 43
TROUBLESHOOTING
ENGINE SYMPTOM DIAGNOSIS Before Troubleshooting Begins
[200 EA] Before troubleshooting begins, observe all shop

safety procedures.
The Vehicle Management and Control
(V-MAC IV) system monitors engine function and
displays a code when a fault is detected. The Noise and Vibration
code can be observed on the instrument panel or
through an electronic diagnostic tool. An
NORMAL VERSUS ABNORMAL
explanation of the fault codes can be found in
VCADS, Guided Diagnostics or the Fault Code Noise is the name we give to vibration that
Manual, 8-218. Guided Diagnostics also includes irritates us through our ears. Vibration can be felt
symptom-based troubleshooting. To obtain Tech without being heard. Engine operation can cause
Tool, contact your local MACK dealer. vibration and noise throughout a vehicle that we
regard as “normal.”
The Tech Tool provides complete system
diagnostics. For more information, see manual Abnormal noises and vibrations suggest that
8-371 or the Tech Tool web site. Repair something is not working properly or is not
information is available in the respective engine assembled properly. A damaged driveshaft can
service manuals and from the MACK Electronic cause abnormal vibration. A loose fastener allows
Information System (EIS). EIS is easily accessed two surfaces to rub or slap together causing
with Tech Tool. unusual noise in response to the vibration.
Be sure to discuss noise and vibration issues with

Troubleshooting Technique the driver. It is important to discover under what
conditions these occur. Maybe a test drive will be
Talk to the vehicle operator. Learn how the engine necessary to familiarize yourself with the details
operated before it failed. Ask about the of the driver's story. Even so, it will probably be
maintenance schedule and the fuel, coolant and necessary to start the diagnostic process with a
lubricant used. Begin by attempting to determine guess as to the nature of the difficulty.
whether anything has happened recently that
could point to the electrical system, but which is
not related to the electronic control system.
Depending on the vehicle configuration, a

problem may be caused, or influenced, by
malfunctions in other vehicle components. Be
sure to inspect for unusual conditions among the
batteries, tires, axles, trailer, bodybuilder
adaptations and other possibilities. Consult
specific service information resources according
to the conditions observed. Fuel waxing, for
example, can cause symptoms easily mistaken
for other engine problems.
If possible, recreate the problem in an

environment similar to that described by the
vehicle operator. Run the engine at the
temperature at which the symptom occurred.
Engine problems can be electrical, mechanical or

a combination of the two. Electrical and electronic
problems will, for the most part, cause fault codes
to be set in the V-MAC system.
Page 44
TROUBLESHOOTING
The table below affords an opportunity to make
note of various influences discovered while
investigating the problem and organize thoughts.
It is made for you to use as you see fit.
The noise or vibration occurs: Yes No Remarks

When the vehicle is stationary
At idle Engine Speed =
When power take-off is engaged Engine Speed =
Other items of interest
When the vehicle is in motion

With a particular superstructure
At a particular weight
At a particular speed
On a particular type of road
Driving without cruise control
Driving with cruise control
Driving using the speed governor
At full load
In a particular gear
When freewheeling (clutch
disengaged)
Vehicle information
Type of chassis suspension (air?)
Type of cab suspension (air?)
Type of driver's seat (make and
model)
Other items of interest
Notes:
If the solution does not become evident in the

course of completing the check list above, use
Tech Tool to investigate further.
Page 45
TROUBLESHOOTING
ENGINE CHECKS AND TESTS 앫 Cylinder Liner and Piston Wear, Check
앫 EGR Cooler, Pressure Test
Included in this section are the following engine
checks and tests: 앫 Engine Compression, Test
앫 Camshaft Sensor Depth, Check 앫 Flywheel Housing Runout, Check
앫 Camshaft Timing, Check 앫 Oil Cooler, Pressure Test
앫 Crankcase Ventilation, Check 앫 Rocker Arm, Check
앫 Cylinder Head, Pressure Test 앫 Thermostat, Check

앫 Valve Guide Wear, Check
Special Tools
Tool No. Description Image

9989876 Dial Indicator (Available)
9990105 Sealing Plate for MP7 Cylinder Head
9990106 Sealing Plate for MP7, MP8 and MP10

Cylinder Heads
9990107 Connection Disc for MP7, MP8 and MP10

Cylinder Heads
Page 46
TROUBLESHOOTING
9996662 Pressure Gauge and Hoses (Available)
9996956 Flywheel Turning Tool for MP7 Engine

(Essential)
9999683 Sweep Dial Indicator (Essential)
9999696 Magnetic Stand (Available)
85109036 Cylinder Head Lifting Tool (Essential)
Page 47
TROUBLESHOOTING
88800014 Flywheel Turning Tool for MP8 and MP10
Engines (Essential)
88800031 Camshaft Sensor Depth Gauge (Available)
88800215 Sealing Plate
88800216 EGR Cooler Test Kit
J 5347-B Dial Bore Gauge
J 42753 Fuel Line Kit
J 47364 Cylinder Head Adapter Plate
Page 48
TROUBLESHOOTING
Camshaft Sensor Depth, Check d. Tighten the thumb screw to secure the
inner part of the gauge.
The signal from the camshaft sensor must e. Carefully remove the gauge from the
exceed 0.5 volt in order to start the engine. If the camshaft sensor bore and observe the
signal is low, check the depth setting of the location of steps between the inner and
sensor following this procedure. outer portions of the gauge (Figure 40):
1. Remove the plug from the flywheel housing 앫 Both steps below the surface of
and install the appropriate flywheel turning the gauge = no shims required.
tool, 9996956 (MP7) or 88800014 (MP8 and
MP10). 앫 One step below the surface of the
gauge = one shim required.
2. Check for proper camshaft position sensor
clearance using the sensor depth gauge, 앫 Both steps above the surface of
88800031, to determine if shims are the gauge = two shims required.
40
required for sensor depth.
39
Figure 40 — Depth Gauge

Figure 39 — Using Gauge at Camshaft Sensor Location
3. Install the camshaft position sensor with the
a. Rotate the engine until a tooth of the appropriate shim(s) and new O-ring. Secure
camshaft toothed wheel is aligned with the sensor with a bolt and plug in the
the sensor bore. harness connector.
b. Insert the depth gauge into the sensor

bore until the outer part of the gauge is
fully seated against the timing gear
cover.
c. Loosen the thumb screw of the gauge
and push the inner part of the gauge in
until it contacts a tooth of the toothed
wheel.
Page 49
TROUBLESHOOTING
Camshaft Timing, Check Crankcase Ventilation, Check
1. Remove the cylinder head (valve) cover. 1. Check the inlet pipe to the CCV separator for
oil film, oil residue and particles. Remove
2. Check the camshaft vibration damper for
any accumulated oil and dirt particles from
damage to the pulse wheel pins.
the pipe.
3. Check the pulse wheel mounting for secure, 41
square attachment.
4. Turn the engine crankshaft so that the TDC
mark on the camshaft corresponds to the
marks on the camshaft bearing cap No. 7
(MP7) or camshaft bearing cap No. 1 (MP8
and MP10) and the flywheel TDC mark “0” is
opposite the pointer on the flywheel housing.
5. To ensure that the camshaft is correctly
installed, complete a valve lift check on the
intake valves of cylinder No. 1.
앫 Temporarily adjust the No. 1 inlet rocker
arm, at the valve yoke, to zero lash.
앫 Position a dial indicator at the inlet Figure 41 — CCV Inlet Pipe Connection
valve yoke for the No. 1 cylinder.
2. Remove the CCV separator from the engine.
앫 Preload the dial indicator and reset the
dial to align with zero. 3. With the separator removed, rotate the
turbine by hand. It should rotate easily. If it
앫 Turn the engine in the normal direction does not rotate easily, replace the separator
of engine rotation one full rotation to “0” unit.
and past to the mark 6 degrees (after 42
TDC) on the flywheel.

앫 The dial indicator travel reading should
be approximately 1.6 ±0.03 mm
(0.06 ±0.01 inch) for MP7 and MP8 or
1.4 ±0.03 mm (0.05 ±0.01 inch) for
MP10. This reading indicates a
correctly timed camshaft.
앫 Readjust the cylinder No. 1 inlet valves
and yoke.
If the camshaft is one tooth out of time, the dial

Figure 42 — CCV Separator Turbine Wheel
indicator reading will be approximately 0.762 mm
(0.030 inch) out of specification and should
experience a fault code for the camshaft sensor.
6. Install the cylinder head (valve) cover.
Page 50
TROUBLESHOOTING
4. Check the oil nozzle in the CCV base for dirt
44
and any accumulated oily deposits. Clean

the nozzle as required. If unable to clean the
nozzle sufficiently, replace the complete
CCV separator assembly.
43
Figure 43 — Oil Nozzle (Separator Base)

Figure 44 — Sealing Plates Installed (Typical)
1. Sealing Plates (Cooling 3. Connection Disc

If the oil nozzle becomes clogged, the oil Ports) (Thermostat Housing)
2. Sealing Plate (By-Pass
pressure is reduced and the turbine does not Port)
rotate as it should.
2. Connect the pressure gauge, 9996662, to a
suitable air supply. Connect the pressure
Cylinder Head, Pressure Test gauge hose to the connection disc on the
cylinder head. Adjust the pressure to
(Cylinder Head Removed) 100 kPa (14.5 psi) using the control valve.
Close the stop valve for two minutes. The
The following procedure applies for MACK MP7, pressure should not fall.
MP8 and MP10 engine cylinder heads. While the
3. Lower the pressure in the cylinder head by
procedure is typical, the sealing tools required will
adjusting the knob on the pressure gauge
be different for each MP engine series.
control valve.
1. Clean the contact surfaces on the cylinder 45
head. Install the:

앫 Sealing plates, 9990105 (MP7),
9809696 and 9998266 (MP8) or
9990164 (MP10), onto the cylinder
head coolant ports using cylinder head
bolts and M16 nuts
앫 Connection disc, 9990107, in position
on the thermostat housing bore
앫 Plug, M12x1.5, in the temperature
sensor hole
앫 Sealing plate, 88800215, on the side of
the cylinder head
Figure 45 — Pressure Gauge Adjustment Knob
Page 51
TROUBLESHOOTING
4. Attach the cylinder head lifting tool, 9. Lower the pressure in the cylinder head by
85109036, to the cylinder head. adjusting the knob on the pressure gauge
control valve.
5. Using a hoist, lower the cylinder head into a
container suitable for the pressure test. Fill 10. Using a hoist, remove the cylinder head from
the container with 70°C (158°F) water. the water container.
46
11. Remove the sealing plates and connection
disc from the cylinder head. Using
compressed air, blow the water off the
cylinder head and out of all threaded holes.
Use care with the fuel passages to make sure

that no dirt enters the fuel channels. Dirt can
cause the unit injectors to be damaged.
Cylinder Liner and Piston Wear,

Check
Thoroughly clean the cylinder liners and pistons
before inspecting and measuring. To thoroughly
check for cracks, remove the cylinder liner from
the cylinder block. Mark the position of the
Figure 46 — Testing for Air Leaks cylinder liner in the cylinder block before
removing it so it can be installed in the same
6. With the pressure gauge connected to an air position during assembly.
supply and the connection disc on the
cylinder head, carefully open the gauge
control valve.
7. Set the pressure to 50 kPa (7.25 psi) and
hold the pressure for one minute.
8. Raise the pressure to 150 kPa (21.8 psi) and
close the stop valve. After two minutes,
check for a drop in pressure and for any air
bubbles forming around the cylinder head.
A drop in pressure and the appearance of air

bubbles indicates a leak(s) in the coolant, fuel or
oil passages. The source of the leak(s) must be
found and the cylinder head repaired or replaced
as required.
Page 52
TROUBLESHOOTING
CYLINDER LINER
48
1. Check the cylinder liner for cracks, paying

special attention to the liner flange. The
standard dye penetrant or Magnaflux®
method can be used for checking.
2. Measure the cylinder liner wear with a
cylinder bore gauge. The original bore size
of the cylinder liner can be used as a
reference measurement.
47
Figure 48 — Measurement Locations
4. If wear is greater than 0.05–0.10 mm

(0.002–0.004 inch), use a complete liner kit
(cylinder liner, piston, piston rings, piston pin
and cylinder liner seals). Also consider
engine oil consumption to determine when
to replace the cylinder liner.
Pistons and cylinder liners are available from

stock only as matched pairs and should not be
mixed.
PISTON
Figure 47 — Measuring Cylinder Liner Wear
Inspect the piston ring grooves, lands, skirt and
3. Measure the cylinder liner at Top Dead combustion bowl for wear, scuff marks, deep
Center (TDC), at Bottom Dead Center scratches, cracks and blow-by. Pistons are NOT
(BDC) and at a couple of positions in repairable. Discard worn or damaged pistons.
between. At each point, measure in two
directions — engine crosswise and engine
lengthwise.
Do not stamp or engrave on the TOP of the
piston. Failure to heed this caution may result in
severe engine damage.
To ensure that pistons are reinstalled into the

same cylinders, the pistons must be tagged with
the corresponding cylinder number when
removed during disassembly.
Page 53
TROUBLESHOOTING
EGR Cooler, Pressure Test
50
(Not Applicable for MP8 Euro 3

Engine)
1. Check inside the gas inlet port. If build-up of
soot is seen, perform the EGR cooler
cleaning procedure before checking for
leaks.
2. Lubricate the O-rings on the coolant inlet
and outlet port plugs with a suitable O-ring
lubricant. Install the plugs and cap on the
EGR cooler. Install the plugs on the EGR
cooler coolant inlet and outlet ports. Install Figure 50 — Conducting Pressure Test
the coupler on the plug and connect the
gauge to the coupler.
If a large enough container cannot be obtained,

Do NOT over-tighten the fasteners on the plugs the EGR cooler can be tested without being
and cap. immersed in water by using the test plugs
included with the kit, 88800216-5, to seal the gas
49 outlet port. The EGR cooler core can then be
filled with water and tested by applying air
pressure to the coolant outlet port as shown in
Figure 51. When using this technique, the cooler
must be tested in the upright position.
To ease the installation of the test plug, coat

the inside of the hose with a suitable O-ring
lubricant.
51
Figure 49 — Installation of Leak Test Kit on Cooler
1. 88800216-1 5. U-Bolt
2. 88800216-2 6. 9996662
3. Flange Capscrew 7. 9998333
4. Flange Nut
3. Fill a container with enough water to cover

the EGR cooler.
4. Lower the EGR cooler into the container of
water at room temperature (or fill the cooler
core with water — see NOTE).
Figure 51 — Test with EGR Gas Outlet Port Plugged
1. Test Plug, 88800216-5 2. EGR Cooler
Page 54
TROUBLESHOOTING
5. Apply air pressure (240 kPa [35 psi]) to the
EGR cooler. Maintain the pressure for
15 minutes. If the EGR cooler is leaking
internally, there will be a steady stream of On engines fitted with PowerLeash™, secure the
bubbles coming from the gas inlet or outlet pistons in the rocker arms with rubber bands or
openings. If a steady stream of bubbles tie straps so the pistons do not drop out when the
appears, replace the EGR cooler. rocker assembly is lifted. Pistons and rockers are
matched together. Failure to heed this caution
may result in severe component damage.
52
If the cooler is being tested without being

immersed in water, look inside the gas inlet port.
If bubbles are seen, the cooler is leaking
internally and must be replaced.
A stream of bubbles seen coming from around

the plugs in either of the coolant ports indicates
that the O-rings may be damaged. If this is the
case, remove the plugs, inspect the O-rings and
replace as required.
6. Lift the EGR cooler out of the container and

remove the pressure testing equipment.
7. Dump the water from inside the EGR cooler
and then use compressed air to remove any
remaining water from the cooler core and
outer cover.
Engine Compression, Test

(on Vehicle)
Verify suspected leaks in the cylinder head or Figure 52 — Tie Strap Holding Engine Brake Piston
block by pressure testing before replacing these. (MP7 Shown)
Do not use Magnaflux® inspections alone as
replacement criteria. 2. Remove the PowerLeash™ (engine brake)
control valve if so equipped.
Before proceeding with the tests, look for coolant
stains around the sealing plugs on the cylinder
head. Check that the plugs are installed properly
and in good condition.
It is very important to loosen the rocker arm shaft
1. Remove the cylinder head (valve) cover. assembly uniformly across the complete shaft.
Loosening the rocker shaft assembly unevenly
can cause damage.
Page 55
TROUBLESHOOTING
3. Install the appropriate lifting tool, 85109050 8. Connect a remote starter switch to the
(MP7), 85109250 (MP8) or 85109035 starter.
(MP10), on the rocker arm assembly.
Loosen the rocker arm shaft uniformly
across the complete shaft. Remove the
rocker arm assembly. Do not run the starter motor for longer than
4. Remove the unit injectors and clean the 15 seconds at a time. Wait 60 seconds before
copper sleeves if necessary. trying again.
5. Install an adapter, J 47363, in each of the
9. Connect the compression gauge, J 6692-B,
unit injector ports.
to the adapter on the first cylinder. Crank the
6. Refit the rocker arm assembly to the engine. engine with the remote starter switch until
the needle on the compression gauge stops
7. Install the PowerLeash™ control valve and
moving (maximum compression). Record
oil tube between the valve and the rocker
and repeat for all remaining cylinders.
arm shaft as follows:
10. Remove the screws for the PowerLeash™
앫 Lubricate and assemble the seals on
control valve.
each end of the oil tube.
11. Remove the control valve and the oil tube
앫 Insert the larger end of the oil tube in
between the valve and the rocker arm shaft.
the rocker shaft.
12. Install the lifting tool, 85109050 (MP7),
앫 Make sure the oil seal is in place at the
85109250 (MP8) or 85109035 (MP10), on
bottom of the valve assembly.
the rocker arm assembly. Loosen the rocker
앫 Position the valve assembly on the arm shaft uniformly across the complete
mounting plate and insert the free end shaft. Remove the rocker arm shaft
of the oil tube. assembly.
앫 Using a torque wrench, tighten the 13. Remove the J 47363 adapters from all of the
attaching screws according to cylinders.
specification.
53 14. Install the unit injectors using new O-rings
and new sealing washers.
15. Connect the wiring harness to the unit
injectors.
16. Carefully lower the rocker arm shaft
assembly onto the head.
17. Remove the lifting tool from the rocker arm
shaft.
It is very important to tighten the rocker arm shaft

assembly uniformly across the complete shaft.
Tightening unevenly can cause damage to the
rocker arm shaft assembly.
18. Tighten the rocker arm shaft screws in the

sequence specified.
19. Install the PowerLeash™ control valve and
Figure 53 — Engine Brake Control Valve Oil Tube
Orientation (MP7 Only) oil tube between the valve and the rocker
arm shaft making sure the sealing rings are
1. Control Valve 3. Rocker Arm Shaft correctly positioned before tightening the
2. Oil Tube screws.
Page 56
TROUBLESHOOTING
3. To check axial runout, attach the dial gauge
to the flywheel using the magnetic base and
position its tip against the outer flange
If the oil tube is installed incorrectly with the large (transmission mounting surface) of the
end in the control valve and the small end in the flywheel housing. Set the dial gauge to zero.
rocker arm shaft, oil leaks will occur. This may
cause oil starvation in the rocker arms which can 4. Rotate the flywheel and note the indicated
result in engine failure. runout at a minimum of four locations around
the outer flange of the housing. Compare the
noted runout with the specified axial runout
20. Tighten the control valve screws according
tolerance.
to specification and then connect the wiring 55
harness to the valve assembly.
21. Adjust the valve and the unit injector rockers.
22. Install the cylinder head cover.
23. Bleed the fuel system.
Flywheel Housing Runout, Check

(Clutch Removed)
CHECKING AXIAL AND RADIAL RUNOUT

1. Clean the flywheel and flywheel housing.
2. Remove the plug from the flywheel housing
and install the appropriate flywheel turning
tool, 9996956 (MP7) or 88800014 (MP8,
MP10).
54
Figure 55 — Checking Axial Runout
1. Magnetic Stand, 2. Sweep Dial Indicator,

9999696 9999683
Figure 54 — Turning Flywheel (MP8 Shown, Typical)
Page 57
TROUBLESHOOTING
5. To check radial runout, position the tip of
57
the dial gauge against the inner flange of the

flywheel housing. Rotate the flywheel and
note the indicated runout, again at a
minimum of four locations around the inner
flange of the housing. Compare the noted
runout with the specified radial runout
tolerance.
56
Figure 57 — Clamp Tools, Installed
3. Adjust the pressure gauge reduction valve

knob until the pressure gauge needle is at
zero.
4. Connect the pressure gauge assembly to
the fitting on the clamp. Lower the oil cooler
into a bath of water. The water temperature
should be at approximately 70°C (160°F).
58
Figure 56 — Checking Radial Runout
1. Dial Gauge, 9989876 2. Magnetic Stand,

9999696
6. If the runout values are out of specification,

check the mating surface for the flywheel
housing against the engine block and the
mating surface for the flywheel on the
crankshaft. Do this before replacing the Figure 58 — Testing Oil Cooler
flywheel housing.
7. Remove the flywheel turning tool and 5. Increase the pressure to 250 kPa (35 psi)
reinstall the plug in the flywheel housing. using the reduction valve knob and check for
air bubbles emerging from the oil cooler. The
test period should last for at least one
Oil Cooler, Pressure Test minute.
1. Clean the coolant side of the oil cooler with a
water-soluble degreasing fluid. Flush the oil
side of the cooler with degreasing solvent. Air bubbles emerging from the oil cooler indicate
2. Install the clamp tools, 9996845, making a leak. The oil cooler should be replaced.
sure they are properly seated.
Page 58
TROUBLESHOOTING
Rocker Arm, Check 3. Push down on the rocker arm so that any oil
film is forced out of the upper side of the
rocker arm shaft.
4. Set the dial indicator to zero.
Make sure there is clearance between the rocker 5. Position a pry bar directly under the rocker
arm rollers and the camshaft when performing arm in the shaft area. Pry the rocker arm up
the following rocker arm bushing and roller and note the reading on the dial indicator.
bushing checks. The maximum clearance allowed between
the rocker arm and shaft is 0.1 mm
(0.0039 inch). If the clearance is greater,
ROCKER ARM BUSHINGS replace the rocker arm and check the shaft
1. Install the appropriate flywheel turning tool, for wear.
60
9996956 (MP7) or 88800014 (MP8 and
MP10), and turn the engine until the
camshaft is in a position where the rocker
arm roller being checked is on the base
circle of the camshaft lobe. Make sure that
there is clearance between the roller and
camshaft.
To check the injector, the rocker arm roller must

be on the base circle of the camshaft lobe and
the injector adjusting screw backed off (preload
must be readjusted).
2. Position the magnetic stand, 9999696, and

dial indicator, 9989876, so that the tip of the
indicator is on top of the rocker arm above
the middle of the rocker arm shaft bushing Figure 60 — Prying Rocker Arm Up
area.
59
6. Repeat the check on all other rocker arm
bushings.
ROCKER ARM ROLLER BUSHINGS

1. Using the flywheel turning tool, 9996956
(MP7) or 88800014 (MP8 and MP10), turn
the engine until the camshaft is in a position
where the rocker arm roller being checked is
on the base circle of the camshaft lobe.
2. Make sure there is clearance between the
rocker arm roller and the camshaft lobe.
To check the injector, the rocker arm roller must

be on the base circle of the camshaft lobe and
the injector adjusting screw backed off (preload
must be readjusted).
Figure 59 — Dial Indicator Positioning
Page 59
TROUBLESHOOTING
3. Rotate the roller a few turns so that the oil 5. Adjust the tip of the dial indicator so that it is
film between the roller bushing and shaft is horizontal to the center of the roller. Zero the
forced out. If the roller jams, is sticky or dial indicator.
rough, the rocker arm should be replaced.
61
Check that the tip of the dial indicator is

pre-tensioned and can move in both directions.
6. Place a screwdriver between the rocker arm

and the roller. Carefully pry the roller out as
far as possible and note the value on the dial
indicator.
Use care when prying or pressing on the roller to

avoid damage to the surface of the roller.
Figure 61 — Forcing Oil from Roller
63
4. Place the dial indicator, 9989876, into the

magnetic stand, 9999696, and position the
magnetic stand as level as possible on the
rocker arm.
62
Figure 63 — Prying Roller Out
Figure 62 — Dial Indicator Positioning
Page 60
TROUBLESHOOTING
7. Using a blunt object, press the roller in as far 9. Repeat the check on all other rocker arm
as possible. Note the reading on the dial roller bushings as necessary.
indicator. The maximum clearance allowed
between the roller bushing and shaft is
0.1 mm (0.0039 inch). If the clearance is Thermostat, Check
greater than this, replace the rocker arm.
64 With the thermostat removed from the engine,
check its operation as follows:
1. Check to be sure that the thermostat closes
fully. This can be done by holding it up to the
light to verify that there is no visible gap at
the opening point. If the thermostat does not
close properly, replace it.
2. Add water to a suitable container and warm
the water to 75°C (167°F). With the water
warmed, immerse the thermostat in the
water. Use a piece of wire attached to the
thermostat.
66
Figure 64 — Pressing Roller In
8. When replacing a rocker arm, lubricate the

new rocker arm roller bushing with clean
engine oil. Use an oil can and insert the
nozzle into the oil channel passage. Rotate
the roller while lubricating and check that oil
comes out on both sides of the roller.
65
Figure 66 — Thermostat Closed
3. After at least 30 seconds, check that the

thermostat is still closed.
Figure 65 — Lubricating Rocker
Page 61
TROUBLESHOOTING
4. Now warm the water to 100°C (212°F). After 4. Using the dial indicator 9989876 and holder
at least 30 seconds at the boiling point, 9999696, place the tip of the dial indicator
check that the thermostat has opened against the edge of the valve disc. Move the
approximately 16 mm (0.63 inch). If the valve back and forth laterally in the direction
thermostat has not opened, it must be of the intake/exhaust ports. Note the
replaced. A good thermostat starts to close measured value and compare it with the
at approximately 92°C (198°F) and is fully acceptable wear limit specified for the
closed at approximately 82°C (180°F). engine.
67 68
Figure 67 — Thermostat Open Figure 68 — Measuring Valve Guide Wear
1. Dial Indicator, 9989876 2. Magnetic Stand,

Valve Guide Wear, Check 9999696
WEAR CHECK 5. Repeat Step 4 to check all valve guides.

Replace the valve guides if the measured
1. Remove the oil seals from the valve guides. values exceed the acceptable wear limit.
2. Mount the cylinder head on a suitable
engine stand using the cylinder head
adapter plate J 47364.
3. Install a new valve into the guide so that the
end of the valve stem is even with the valve
guide edge.
Page 62
MAINTENANCE
MAINTENANCE
Page 63
MAINTENANCE
LUBRICATION SYSTEM MAINTENANCE
Special Tool

9998487 Oil Filter Wrench (Available)
Oil Level Check

69
When checking oil levels, the vehicle must be

parked on level ground. Components must be
filled to the correct level. DO NOT OVERFILL.
The best time to check oil level is while the engine

is COLD (prior to starting at the beginning of the
work day, or after the vehicle has sat
approximately 2 hours). At normal operating
temperature (engine oil temperature above 80°C
[175°F]), oil level can be checked 15 minutes
after shut down.
Figure 69 — Oil Level Check
Failure to wait a sufficient amount of time (2 hours

if engine oil temperature is below 80°C [175°F])
or 15 minutes if oil temperature is above 80°C
[175°F]) will result in an inaccurate dipstick
reading.
For accurate oil level readings, the dipstick must

be inserted fully into the dipstick tube. The level
must be close to the FULL line (at least between
the LOW and FULL lines) on the dipstick, but
must NOT exceed the FULL line.
Page 64
MAINTENANCE
Oil and Filter Change Procedure Crankcase Ventilation System
[219 EV] The crankcase ventilation (CCV) system
separator is not repairable. If there is apparently
This engine is equipped with improved spin-on faulty operation, perform these inspections before
type oil filters. replacing the separator.
1. Inspect the separator inlet hose and
DISPOSABLE SPIN-ON OIL FILTER connectors at the valve cover and at the
REPLACEMENT separator. Remove any obstruction, oil film,
Change oil and replace oil filters using the residue and particles.
following procedure: 2. Inspect the separator outlet hose and
1. Run the engine until normal operating connector. Remove any obstruction, oil film,
temperature is reached. Then, shut off the residue and particles.
engine and drain the oil before the engine 3. Remove the separator and attempt to turn
cools. the turbine manually. If it does not turn
2. Thoroughly clean the area around the filters easily, replace the separator.
before removing. 4. If the turbine turns easily, inspect and clean
3. Using filter wrench 9998487 or equivalent, the oil jet nozzle.
remove the spin-on filters and wipe the filter 5. Reassemble the separator and the hoses.
mounting base clean.
6. If faulty operation continues, continue fault
4. Fill each filter with 1.9 liters (2 quarts) of the tracing with Guided Diagnostics.
specified engine oil. DO NOT allow any
contaminants to enter the filters while filling.
5. Apply a film of clean engine oil to the sealing
gasket on each new filter.
6. Install the filters and tighten 3/4 to 1 turn
after the gasket contacts the base.
7. Fill the crankcase with the recommended
engine oil. If the engine is equipped with a
REPTO unit, add one additional quart.
8. Start the engine and check for leaks. Run
the engine for approximately five minutes,
then shut it off and recheck the oil level. Add
oil if necessary.
Use of anything other than genuine MACK filters

may cause damage and void the engine warranty.
Change filters according to the recommended
maintenance schedule.
Page 65
MAINTENANCE
FUEL FILTER REPLACEMENT FUEL FILTER REPLACEMENT
Fuel Filter Change

Because of ice buildup or fuel waxing which can
[231 BA] clog fuel filters, it may be necessary during
extremely cold weather to reduce the time or
FILTER DESCRIPTION mileage interval between fuel filter changes.
Two filters ensure that clean, waterless fuel Be careful to prevent foreign matter of any kind
reaches the electronic unit injectors. One is a from entering the filters during service.
full-flow filter, the other is a water separating Install new fuel filters dry.
pre-filter with a transparent cup to collect and
drain the water. A water-in-fuel sensor informs the
driver of excessive accumulation in the cup. The Water Separating Pre-Filter Replacement
water separating pre-filter is in the “suction side”
of the fuel circuit. It is a spin-on type with one end To replace the water separating pre-filter:
of its casing threaded to receive the cup. 1. Disconnect the electrical cable.
The full-flow main filter is on the “pressure side” 2. Make sure the filter casing is thoroughly
of the circuit. It is also an easily replaced spin-on cleaned. If not already done, wash the area
filter. The casing completely encloses the filter around the filter mounting adapter with a
element. This filter is rated at 3–5 microns. suitable solvent and blow dry with
70 compressed air.
3. With a suitable container in place to collect
spillage, open the fitting and drain the filter.
4. Unscrew and remove the water cup.
5. Using a filter wrench, remove the filter from
the mounting bracket and discard it safely.
6. Apply a thin film of clean engine oil to the
sealing gasket of the new filter.
7. Screw the new dry filter in place and tighten
an additional 3/4 to 1 turn by hand after the
gasket contacts the base.
After filter installation, operate the hand primer to

fill the fuel filters before attempting to start the
engine.
Figure 70 — Fuel Filters 8. Screw the water cup into the filter casing.
1. Water Separating 4. Drain Assembly

Pre-Filter 5. Full-Flow Main Filter
2. Water Separator Bowl
3. Water-in-Fuel Sensor
Harness
Page 66
MAINTENANCE
Full-Flow Main Filter Replacement
To replace the full-flow main filter:

There is a new-style pre-filter with a
stepped-down diameter at the bottom of the filter. 1. Make sure the filter casing is thoroughly
The earlier-style filter has straight sides with a cleaned. If not already done, wash the area
larger bottom diameter which requires an adapter around the filter mounting adapter with a
to attach the fuel/water separator bowl to the suitable solvent and blow dry with
filter. When replacing the previous straight-sided compressed air.
filter with the current stepped-down version, the 2. Put a suitable container in place to collect
adapter is not used. However, do not discard the spillage.
adapter as it can be used should inventory of the
earlier-style filter still be available. 3. Using a filter wrench, remove the filter
casing from the mounting bracket and
discard it.
9. If necessary, replace the full-flow main filter.
See the following instructions. 4. Apply a thin film of clean engine oil to the
sealing gasket of the new filter.
10. Connect the electrical cable.
5. Screw the new dry filter in place and tighten
11. Start the engine and run at idle for five
an additional 3/4 to 1 turn by hand after the
minutes to fill the filter with fuel.
gasket contacts the base.
12. Check for leaks.
6. If necessary, replace the water separating
pre-filter. See the preceding instructions.
7. Start the engine and run at idle for five
minutes to fill the filter with fuel.
8. Check for leaks.
Severe engine damage may be caused by

attempting to prime the fuel system using an
auxiliary pump or by applying air pressure in the
fuel tank. These techniques may destroy seals
that prevent fuel from leaking into the crankcase.
Page 67
MAINTENANCE
COOLING SYSTEM MAINTENANCE
Special Tool

J 48061 Coolant Filter Wrench (Available)
Coolant Drain Outlets

Extra outlets provide convenient drain sites for For Australia, engines are not equipped with the
use during maintenance and other procedures coolant filter. VCS coolant is used to protect the
involving coolant. cooling system.
Coolant Filter
REMOVE AND REPLACE
The coolant filter attaches to the back of the 1. Close the shut-off valve on the coolant pump
coolant pump housing. It resembles a spin-on oil housing.
filter. The filter element and casing are replaced
as a unit.
71
In the closed position, the pin on the shut-off

valve should be horizontal.
2. Place a suitable container below the filter to

collect spilled coolant.
3. Using filter wrench J 48061 or equivalent,
unscrew the filter and discard it safely.
4. Apply a light film of coolant on the face of the
new filter gasket.
5. Screw the new filter on the threaded nipple
extending from the mounting flange.
6. Using the filter wrench, tighten the filter one
full turn after the gasket contacts the base.
7. Open the shut-off valve on the coolant pump
housing.
8. Check for any coolant leaks.
Figure 71 — Coolant Filter
1. Shut-Off Valve 2. Coolant Filter
Page 68
MAINTENANCE
DRIVE BELT REPLACEMENT The lower tensioner for the fan and coolant pump
is mounted on the coolant pump housing. This
AND TENSIONING tensioner applies its load counterclockwise. The
[216 AA] upper tensioner for the alternator (and refrigerant
compressor if so equipped) is mounted on the
alternator bracket. The tensioner applies its load
General Information in a counterclockwise direction.
The service life of the multi-groove belts is

considerably improved over other systems and
Automatically Tensioned System
allows the use of higher horsepower cooling fans.
All MP8 engines are equipped with multi-groove INSTALLATION
belt systems.
Swing the tensioner to the fully sprung position
and without force, using belt tensioner tool,
MP8 Engine J 44392, place the belt over the pulleys. Do not
In the dual multi-groove drive belt arrangement, allow the tensioner to snap against its stops. Do
the fan drive and coolant pump are driven directly not pry the belt over a pulley.
from the crankshaft pulley by a 10- or 12-rib
multi-groove belt. The alternator and the air TENSIONING
conditioning compressor (if equipped) are driven
off the crankshaft pulley by a six-rib multi-groove No tensioning adjustment is required. Once the
belt (Figure 72). Two automatic tensioners are tensioner is released against the belt, the belt is
used, one for the fan drive and one for the tightened to optimum tension automatically at all
accessory drive. speeds and loads.
72
MAINTENANCE
The condition of the belt and tensioner should be
checked when performing preventive
maintenance inspections. Belt tension levels
need not be checked as long as the tensioner is
in good condition and there is no evidence of a
loose belt.
Figure 72 — Belt-Drive Arrangement
1. Conventional 2. LCF (N/A Australia)
Page 69
NOTES
Page 70
REPAIR INSTRUCTIONS, PART 1
Page 71
ENGINE REMOVAL
Special Tools

DBT2V700 Coolant Extractor/Injector
J 47038-3 Engine Lifting Tool Set

J 47038-4
J 47038-6
J 47038-8
J 48061 Coolant Conditioner Filter Wrench
Page 72
General Instructions 3. Using the oil filter wrench, 9998487 or
equivalent, remove the oil filters.
4. Using a suitable filter wrench, remove the
fuel filters.
Before removing the engine, make sure tools and 5. Using the coolant filter wrench, J 48061 or
equipment are inspected for safety and available equivalent, remove the coolant filter.
for use.
6. Disconnect the inlet air heater if present.
7. If the vehicle is equipped with air
conditioning:
앫 It is good practice to steam clean the engine a. Using A/C refrigerant recovery and
to remove road grime, grease and oil before recycling equipment, recover the
starting work. Steam cleaning the engine refrigerant.
and engine area allows more detailed b. Disconnect the A/C compressor
inspection and improved workmanship. discharge hose at the connection near
앫 Prevent moisture from entering the air intake the radiator support.
system. If moisture enters the system, make c. Disconnect the A/C line at the
sure it is removed (dried) before the engine receiver/dryer.
is reinstalled.
d. Locate and disengage the electrical
앫 Prevent the steam cleaning nozzle from connector from the binary pressure
spraying directly on any electronic switch on the receiver/dryer.
components and connections.
e. Locate and disengage the electrical
앫 Avoid the use of any caustic or corrosive connector from the low-pressure cutout
cleaning detergents. switch in the A/C refrigerant line.
1. Position the vehicle on a flat, level surface 8. Disconnect and remove the upper radiator
with ample work space around the vehicle. tube from the engine.
2. Apply the parking brake and block the 9. Disconnect the cab heater and fuel heater
wheels to prevent the vehicle from moving. coolant return lines from the radiator lower
Observe all safety precautions. tube (if applicable).
3. Disconnect the battery negative (ground) 10. Disconnect and remove the lower radiator
cable. tube.
4. Drain the air tanks. 11. Remove the charge air cooler inlet tube and
hoses.
12. Remove the charge air cooler outlet tube
Removal and hoses.
1. Remove the hood. On cab over engine 13. Disconnect the radiator fan if electronically
models, tilt the cab. controlled.
2. Place suitable containers beneath the
engine and drain the oil and coolant. Open
the coolant drain valves in the block and the
radiator. The radiator and intercooler assembly is heavy
and difficult to handle. Provide a suitable lifting
device and a helper to support it safely during
removal.
If available, use the coolant extractor, DBT2V700,
to remove coolant from the engine.
Page 73
14. Remove the radiator and charge air cooler 16. If equipped, remove the exhaust bracket
assembly. from the flywheel housing.
The fan assembly is heavy and difficult to handle. Provide a container to collect power steering
Obtain assistance to support it safely during fluid.
removal.
17. Remove the power steering hoses.
15. Remove the fan assembly.
18. Disconnect the exhaust system from the
turbocharger.
19. Disconnect electrical cables or wires
To prevent fluid leaking from the fan assembly, connected to the starter.
store it horizontally face down (hub flange up) or 20. Disconnect or remove all other items
vertically as shown. attached to the frame or cab that would
73 prevent engine removal, such as:
a. Clutch linkage
b. Ground straps
c. Electrical wiring
d. Coolant tubing
e. Air lines
f. Fuel lines
g. Hydraulic hoses or tubing
21. Remove the valve cover.
Cover the valve mechanism and gear train with a

suitable cloth or similar covering to prevent dirt
and debris from entering the engine.
Figure 73 — Viscous Fan Drive Assembly Storage
1. OK to Store with Fan 2. OK to Store with Fan Provide a transmission jack to support the
Blade in Vertical Position. Blade in Horizontal transmission when disconnected from the engine.
Position and Mounting
Flange Up. Do Not Store
with Mounting Flange
Down.
Page 74
22. With transmission jack in place, remove the 24. Remove the screws that secure the rear
screws attaching the transmission to the engine support brackets to the frame
engine. brackets.
a. If a manual transmission, make certain 25. Remove the bolts that secure the front
the clutch linkage and brackets have engine support to the frame crossmember.
been removed.
b. If an automatic transmission, make
certain the torque converter access
panel and the torque converter have While removing the engine, watch for
been removed. obstructions that may interfere, such as engine
and chassis components, brackets, clamps and
other parts still attached to the engine. Failure to
heed this caution may result in severe damage to
the engine and other components.
Obtain a helper and provide a lifting device, such
as engine lifting tool, J 47038, to support the
engine safely during removal. 26. Using the lifting device and the aid of the
helper, remove the engine from the vehicle.
23. Attach the engine lifting tool, J 47038, to the
engine. Secure the engine lifting tool to the
front of the cylinder head and to the rear at
the flywheel housing. Before attempting to remove the cylinder head
from the block, ensure that the screws holding the
head against the timing gear mounting plate have
been removed. Failure to heed this caution may
result in severe damage to the engine and other
Ensure all bolts and pins in the lifting tool are
components.
correctly positioned prior to removing the
engine from the chassis. Failure to properly
install all bolts and pins of the engine lifting
tool can result in personal injury or death.
Page 75
ENGINE DISASSEMBLY
MACK MP8 Euro 3 Engine
[200 EA]
Special Tools

9990013 Slide Hammer
9991821 Slide Hammer for Pilot Bearing Removal

and other various uses (Available)
9996966 Liner Hold-Down Tools (Essential)
9998249 Unit Injector Protection Sleeves (Essential)
9998251 Unit Injector Bore Sealing Plug (Essential)
9998267 Dowels (Locating Tools for the Timing Gear

Mounting Plate)
Page 76
9998511 Lever
85109034 Camshaft Lifting Bar (Essential)
85109250 Rocker Shaft Assembly Lifting Tool

(Essential)
85109980 Cam Cap Removal Tool, use with slide

hammer, 9990013
88800014 Engine Barring Tool (Essential)
88800021 Front Main Seal Remover/Installer

(Essential)
Page 77
J 41989-A Valve Spring Compressor
J 48922 Heavy-Duty Unit Injector Puller
J 48662 Engine Stand Adapter Plate (Available)
J 49002 Crankshaft Lifting Tool (Essential)
Page 78
General Instructions Mounting the Engine on a Repair
[210 EN] Stand
[200 EB]
This section includes step-by-step procedures for
disassembly of the engine. After cleaning If the engine is to be mounted on a repair stand
components, store them where they will remain by means of a mounting plate attached to its left
clean until needed for reassembly. side, the mounting surfaces must be clear of
obstruction.
The sequence in which components are removed 74
from the engine may vary depending on the type
of engine repair stand used. The repair stand
identified for this procedure uses a mounting
plate attached to the left side of the engine which
requires the removal of certain left side
components to provide space for attachment of
the mounting plate. This must be done prior to
mounting the engine on the repair stand.
Failure to follow the sequence of operations

may result in damage to components or
personal injury.
Figure 74 — Components to be Removed Before

Mounting on a Repair Stand — Conventional Chassis,
Typical
1. Wiring Harness Block 4. EECU

2. CCV Tubing 5. Fuel Filter Housing
3. EECU Cooling Plate Assembly
6. CCV Separator
Assembly
Page 79
In order to attach the mounting plate, J 48662, to 8. Loosen the fuel line banjo fittings. Remove
the left side of the engine, the following the banjo fittings, clamps and the following
components must also be removed if present. fuel lines from the side of the engine.
1. Remove the dipstick and oil fill pipe. 앫 Fuel return line — EECU cooling
plate-to-filter valve housing
2. Remove the crankcase ventilation (CCV)
separator and tubing. 앫 Fuel return line — cylinder head (at
front)-to-filter valve housing
3. Tag the electrical connectors on the left side
of the engine to facilitate reconnection upon 앫 Fuel supply line — filter valve
reassembly. housing-to-cylinder head (at rear)
4. Unlock and remove the harness end 앫 Fuel supply and return lines — fuel
connectors attached to the EECU. Remove pump-to-filter valve housing
the screws from the harness retainer
9. Remove the filter housing assembly.
clamps. Then, push the connector locks
inward and rotate outward to disconnect 10. Remove the cooling plate and the EECU
both wiring harnesses from the EECU. from the cylinder block.
75
11. Attach the engine mounting plate, J 48662,
to the left side of the engine.
12. Using a suitable hoist and the appropriate
lifting device, attach the engine to the repair
stand.
Cylinder Head (Valve) Cover

Removal
[211 JB]
1. Remove the fasteners and remove the
crankcase ventilation pipe.
Figure 75 — EECU Harness Connectors 76
Use care to avoid damaging the terminal pins.
5. Unlock and separate the external wiring

harness connectors at the various junctions
and sensors.
6. Remove the clamps holding the harness to
the cylinder block.
7. Remove the fasteners securing the wiring
harness block to the cylinder block. Position
the harness block and leads out-of-way.
Provide suitable rags and containers for collecting

fuel and coolant drainage at each of the following
steps. Figure 76 — Crankcase Ventilation Pipe
Page 80
2. Remove and set aside the spring-loaded 5. At the top of the cylinder head, disconnect
screws attaching the cylinder head (valve) the wiring harness at each unit injector.
cover to the cylinder head. 78
77
Figure 78 — Disconnecting Harness at Unit Injector
6. If so equipped, disconnect the harness from

the engine brake control valve.
79
Figure 77 — Cylinder Head Cover
3. Remove the cover from the cylinder head.
Engine Wiring Harness Removal

[723 KA]
1. To facilitate connection at reassembly, tag all
harness connectors to the various engine
sensors and components prior to
disconnecting them. Also, note the routing of Figure 79 — Engine Brake Control Valve Terminal
the harness and leads for proper installation
at reassembly. 7. Cut the cable ties holding the harness to the
cylinder head and the engine brake control
2. If not already done, unlock and remove the valve.
harness end connectors attached to the
EECU. 8. Carefully pull the harness through the hole
at the front of the cylinder head and remove
3. Unlock and separate the connectors at the the harness from the engine.
various sensors, engine components and
harness junctions.
4. Remove the clamps holding the harness to
the cylinder head and block.
Page 81
Timing Gear Cover Removal
81
[211 AA]
1. Remove the mounting fastener and remove
the camshaft position sensor from the timing
gear cover.
2. Remove all straps, P-clamps and other
retainers used to restrain harnesses, oil
lines and coolant tubes to the rear of the
engine. This will allow the support bracket at
the rear of the engine to be removed.
80
Figure 81 — Timing Gear Cover Fasteners Torque

Sequence
5. Remove the cover from the engine.

6. Remove and discard the elastomer seals.
82
Figure 80 — Harness, Oil and Coolant Lines
3. Remove the support bracket fasteners and

remove the rear support bracket.
4. Remove the screws attaching the timing
gear cover to the timing gear mounting plate Figure 82 — Timing Gear Cover Seals
and cylinder head (Figure 81).
Page 82
Camshaft Gear and Vibration Rocker Arm Shaft Removal
Damper Removal [213 LP]
[213 DE]
On engines fitted with the engine brake, use

If the engine is not being completely rubber bands to contain the pistons within the
disassembled for overhaul and only the camshaft rockers. The match between these pistons and
is to be removed, crank the engine manually their rockers must be maintained.
(using the engine turning tool, 88800014) so that If the rocker shaft is to be disassembled, the
the camshaft is positioned at top dead center order of rocker arm assembly must be
(TDC) by aligning the TDC mark on the camshaft maintained. Make certain the sets are kept
with the timing marks on the No. 1 camshaft together. Make certain the rocker arms are
bearing cap (Figure 83). identified so they can be returned to their original
83
positions on the shaft.
Failure to heed this caution may result in severe
engine damage.
1. Remove the engine brake oil control valve or

oil flow adapter (if so equipped) from the
engine.
84
Figure 83 — Camshaft Timing Marks
1. Remove the fasteners securing the vibration

damper and camshaft gear to the camshaft.
2. Remove the vibration damper from the
camshaft gear.
3. Remove the gear from the camshaft. Figure 84 — Removing Engine Brake Oil Control Valve
On engines without the engine brake, an oil flow

adapter is used in place of the oil control valve. It
is mounted in the same location on the cylinder
head and provides oil to the rocker shaft.
Page 83
2. Remove the screws and six engine brake
plate springs (if so equipped) attached to the
camshaft bearing caps.
85 Pistons and rocker arms are matched together
and should not be mixed.
4. Beginning at the center camshaft bearing

cap, begin loosening the fasteners at each
cap evenly in stages, following the sequence
shown in Figure 87 until all fasteners are
completely loose. Once loosened, remove
the fasteners.
The fasteners must be loosened evenly, in stages

and in sequence to prevent bending or damaging
Figure 85 — Engine Brake Plate Springs
the rocker arm shaft.
87
1. PowerLeash™ 2. PowerLeash™
(3-Rocker) (4-Rocker)
3. If equipped with an engine brake, secure the

pistons in the exhaust rocker arms using
rubber brands (or tie straps) to prevent
piston damage.
86
Figure 87 — Rocker Arm Shaft Fastener Loosening

Sequence
5. Attach the lifting tool, 85109250, to the

rocker arm shaft.
6. With the aid of an assistant, carefully
remove the shaft assembly using the lifting
tool. Place the shaft assembly in a secure
location.
Figure 86 — Securing Pistons in Exhaust Rocker Arms
Page 84
Camshaft Removal
88
[213 CH]
90
Figure 88 — Lifting Rocker Arm Shaft
1. Lifting Tool, 85109250 2. Rocker Arm Shaft

Assembly
Valve Yoke (Bridge) Removal

[213 NV]
89
Figure 90 — Camshaft Installation
1. Camshaft 3. Camshaft Upper Bearing

2. Camshaft Lower Bearing Caps
Supports (Saddles)
The camshaft is heavy. Do NOT attempt to

remove the camshaft without the help of an
assistant or the use of a suitable lifting
device. Failure to heed this warning may
result in personal injury and component
Figure 89 — Removing Valve Yoke (Bridge)
damage.
1. Inlet Valve Stems 2. Inlet Valve Yoke
1. Mark the camshaft bearing caps (if not
factory marked or identified), so that they
1. Tag the yokes to facilitate reassembly in the
can be reinstalled in the original bearing
locations from which they were removed.
support locations.
2. Remove the yokes and set them aside.
2. Remove the remaining fasteners (outboard
set) holding the upper bearing caps in place.
Page 85
3. Use the cam cap removal tool, 85109980, in 6. Remove the bearing inserts (shells) from the
combination with slide hammer, 9990013, to camshaft lower bearing supports (saddles)
remove the upper bearing caps. The upper and the upper bearing caps. Inspect the
bearing caps and lower supports (saddles) bearing inserts, bearing supports and caps
must be kept in sets and in their respective for wear or damage. Replace the parts if
locations at reassembly. excessive wear or damage exists.
92
4. Attach the lifting bar, 85109034, to the
camshaft between the lobes and carefully
remove the camshaft from the cylinder head.
91
Figure 92 — Lower Bearing Inserts
Figure 91 — Removing Camshaft

This procedure presumes that the camshaft lower
5. Carefully lift the camshaft and set it aside in bearing supports (saddles) are in place on the
a secure location for later inspection. cylinder head, held in position by guide sleeves. If
removed, the supports must be marked and
returned to their original locations along with the
respective bearing caps. If required, remove the
bearing supports using a pry bar. Remove the
If the camshaft is not being replaced, stand the
No. 7 rearmost support using a soft-faced mallet
camshaft on end and secure it in place for
by tapping side to side.
storage. Use care to avoid damage to the guide
pin.
Page 86
Unit Injector Removal 3. Remove the fasteners securing the injector
hold-down yokes.
[221 GP]
Use hand tools to remove the injectors. DO NOT

Do NOT use a steel scraper or a steel wire brush use air tools on the injector puller shaft. Using air
to clean injector tips. Use cleaning kit J 42885. tools may result in damage to components.
Failure to heed this caution may result in severe 4. Place a pry bar, tool 9998511 or equivalent,
component damage. in position under the hold-down yoke or
93 injector lip and pry up to remove the injector.
94
Figure 94 — Removing Injector with a Pry Bar
Use care when removing the unit injector

Figure 93 — Unit Injector because the injector hold-down is not secured
and could fall off if not held in place.
1. Injector Hold-Down Yoke 2. Unit Injector
and Screw 5. If the injector cannot be removed using the
pry bar, install the heavy-duty unit injector
1. Thoroughly clean around the unit injectors puller, J 48922, onto a unit injector. Position
and check to ensure that the engine is the puller forks in the grooves on the unit
completely drained of fuel. injector. Secure the puller by sliding the lock
2. Tag the injectors with the cylinder number collar down over the forks holding the unit
before their removal from the cylinder head. injector. Remove the injector from the
If new injectors are not being installed, it is cylinder head bore using hand tools. The
essential that the original injectors be injectors must be lifted out with their
reinstalled in the cylinders from which they hold-down yokes.
were removed.
Page 87
95
If the nozzle gasket (flat washer) is attached to

the injector, loosen it with gentle prying from a
thin flat gasket scrapper blade. If the gasket is in
the bottom of the injector sleeve, initially attempt
to remove it with a magnet. If this is unsuccessful,
use a standard flat blade screwdriver with a long
thin shank and narrow width blade to loosen the
gasket. Locate the blade in the recess between
the outside of the gasket and the injector sleeve.
Use the blade to apply force on the outside of the
gasket at different locations around the gasket.
Continue this until the gasket separates from the
Figure 95 — Unit Injector Puller, J 48922
sleeve.
7. Insert the injector into a protection sleeve,

9998249.
If excessive combustion leakage has resulted in 96
the copper sleeve being stuck-fast to the unit

injector by carbon, the unit injector must be
replaced. The condition is found when the unit
injector is removed and the copper sleeve comes
out with the injector.
6. Remove and discard all injector nozzle

gaskets (flat washers) from injector tips or Figure 96 — Injector Protection Sleeve, 9998249
bottoms of copper sleeves. Also, remove
and discard all O-rings and yoke screws. 8. If the injector is not being installed
New injector nozzle gaskets (flat washers), immediately, install the protective plug into
O-rings and yoke screws are required for the unit injector bore of the cylinder head to
installation. protect it from debris.
97
If an injector nozzle gasket (flat washer) had been

used for the seal joint between the injector copper
sleeve and the injector, discard the used gasket
immediately after the injector is removed. A used
gasket must not be reused. When the injector is
removed, this gasket may come out attached to
the injector or it may remain in the bottom of the
injector sleeve.
Figure 97 — Installing Injector Bore Protective Plug
Page 88
9. Repeat the process to remove the remaining Exhaust Pressure Governor (EPG)
injectors, if required.
Removal
Starter Removal 1. Disconnect the air supply line to the exhaust
governor end cover fitting.
99
[272 DH]
The starter is held in place by nuts assembled
over studs installed at the front right side of the
flywheel housing.
The starter is heavy. Do NOT attempt to

remove the starter without the help of an
damage.
1. If not already done, disconnect the wiring

harness from the starter motor.
2. Loosen the nuts fastening the starter to the
flywheel housing.
98
Figure 99 — EPG Air Line Attachment
2. Remove the exhaust clamp from the

Exhaust Pressure Governor (EPG) housing
to the turbocharger.
100
Figure 98 — Starter
1. Flywheel Housing 2. Attaching Nuts
3. With the help of an assistant or a lifting

device, remove the starter from the engine.
Figure 100 — EPG-to-Turbo Clamp
Page 89
3. Loosen the clamp and remove the exhaust 5. Separate the EPG housing from the exhaust
pipe from the EPG housing. pipe and turbocharger; lift and remove the
101
EPG unit from the engine.
103
Figure 101 — Exhaust Pipe-to-EPG Housing

Figure 103 — EPG Housing Separated from Turbo
4. Remove the gasket between the EPG
housing and exhaust pipe.
102
Figure 102 — EPG Housing Gasket
Page 90
Turbocharger Removal 2. Remove the turbocharger oil supply line
(upper).
[214 SC] 105
The turbocharger is heavy. Do NOT attempt to

remove the turbocharger without the help of
an assistant or the use of a suitable lifting
damage.
Thorough cleanliness is required. Small particles

can cause severe rotor damage and component
damage if inducted during high-speed operation.
Be sure to plug the inlet and outlet ports while
handling the turbocharger. Also, cap the oil line
openings to prevent contamination.
Figure 105 — Turbo Oil Supply Line
1. Remove the clamp from the EPG housing to
the turbocharger, if not previously removed. 3. Remove the oil return line (lower).
104 106
Figure 104 — EPG-to-Turbo Clamp Figure 106 — Turbo Oil Return
Page 91
4. Remove the lower charge air pipe from the Exhaust Manifold Removal
turbocharger and midpipe support fastener.
5. Remove the turbocharger flange mounting
nuts and spacers.
107
The exhaust manifold consists of three
castings that are not clamped together. These
could separate unexpectedly when the
attaching screws are removed from the
cylinder head. To prevent personal injury and
damage to the parts, take care to control all
pieces until they can be separated safely.
1. While supporting the exhaust manifold,

remove the attaching screws and spacers.
109
Figure 107 — Removing Turbocharger Fasteners
6. Lower the turbocharger away from the

exhaust manifold and lift out.
108
Figure 109 — Exhaust Manifold
2. Set the spacers and screws aside for

reassembly.
3. Remove the exhaust manifold from the
cylinder head.
4. Remove and discard the exhaust manifold
gaskets.
5. Inspect the exhaust manifold. If there are
signs of exhaust leakage between the cast
segments of the manifold, replace the seals.
Figure 108 — Removing Turbocharger
Page 92
Oil Filter Valve Housing Removal Coolant and Pump Inlet Housings
[219 EP] Removal
[215 SW]

oil drainage at each step. Provide suitable containers to collect coolant that
may escape during removal procedures.
1. Remove the screws and remove the oil tube
from the front of the oil filter housing and the 1. Remove the fasteners and remove the
cooling duct cover. Discard the gaskets. coolant pipe (bypass) housing from the
110
cylinder head. Discard the flange seal ring.
112
Figure 110 — Oil Tube (at Housing Front)

Figure 112 — Upper Coolant Pipe (Bypass) Housing
2. Remove the screws and remove the oil tube
between the valve housing at the rear and 2. Remove the screws and remove the pump
the duct cover. Discard the gaskets. inlet housing at the rear of the coolant pump.
111
Discard the flange seal ring.
113
Figure 111 — Oil Tube (at Housing Rear)

Figure 113 — Removing Pump Inlet Housing
3. Remove the fasteners and remove the oil
filter valve housing from the cylinder block.
Discard the gasket.
Page 93
Cooling Duct Cover and Oil Cooler 2. Carefully remove the seal from the perimeter
groove in the cover. Discard the seal; it
Removal cannot be reused.
115
[215 DW, 219 EP]
To remove the oil cooler, the cooling duct cover
must be removed first. The oil cooler is attached
to the inside of the cooling duct cover.
COOLING DUCT COVER REMOVAL

1. Remove the cooling duct cover fasteners
and remove the duct cover and oil cooler
assembly from the cylinder block.
Note the location of all fasteners for reassembly; Figure 115 — Removing Duct Cover Seal
different lengths are used.
3. Remove and discard the cover-to-pump
114 base plate seal.
116
Figure 114 — Cooling Duct Cover

Figure 116 — Cooling Duct Cover-to-Pump Base Plate
Seal
Page 94
OIL COOLER REMOVAL
119
1. Place the cooling duct cover assembly on a

clean work surface. Remove the fasteners
and remove the flow plate covering the oil
cooler.
117
Figure 119 — Removing Cooler O-Rings
Drive Belts and Fan Hub Removal

[232 HB]
Remove the drive belts, idlers and hub bracket
Figure 117 — Removing Flow Plate from the front of the engine as follows:
2. Remove the oil cooler fasteners and remove 1. Remove the fasteners and remove the fan
the cooler from the cover. drive and coolant pump belt tensioner from
118 the coolant pump housing.
accessory drive belt tensioner from the
cylinder block.
3. Remove and set aside the drive belts.
120
Figure 118 — Removing Oil Cooler
3. Remove the oil cooler sealing O-ring

gaskets between the oil cooler and cover.
Discard the O-rings.
Figure 120 — Fan Hub and Accessory Drive System
1. Fan Drive Belt 4. Accessory Drive Belt

2. Fan Hub Bracket 5. Fan Drive and Coolant
3. Accessory Drive Belt Pump Belt Tensioner
Tensioner
Page 95
4. Remove the fasteners and fan hub bracket
assembly.
Mark the cable locations before removal to
Inlet Air Preheater/Spacer Removal ensure correct installation at reassembly.
[291 DR] 3. Remove and discard the gasket between the

1. Remove the fasteners securing the inlet spacer block or preheater base and the inlet
adapter, spacer or preheater, if so equipped, manifold.
to the inlet manifold.
121
Crankcase Ventilation (CCV)
Separator Removal
1. If not already done, loosen the clamps and
disconnect the inlet and outlet hoses at the
CCV separator. Remove the retainers and
remove the hoses.
123
Figure 121 — Manifold Inlet Adapter
2. Remove the spacer block from the inlet air

manifold. Or, if so equipped, remove all
power and ground cables from the inlet air
preheater and remove the preheater from
the manifold.
122
Figure 123 — Crankcase Ventilation Separator

separator assembly from the cylinder block.
Figure 122 — Preheater Cable Connections
Page 96
Fuel Lines and Filter Valve Housing 124
Removal
If not already removed, remove the fuel lines and
filter valve housing using the following procedure.
Figure 124 — Fuel Pump, Filter Assembly and Lines
1. Washers 5. Fuel Pump

2. Banjo Fitting 6. Fuel Filter Bracket
3. Banjo Screw 7. EECU Cooler
4. Power Steering Pump
1. Loosen the fuel line banjo fittings. Remove

125
the banjo fittings, clamps and the following

fuel lines from the left side of the engine.
Be sure to capture the banjo sealing washers and

hollow screws while removing them.
앫 Fuel return line — EECU cooling

plate-to-filter valve housing
앫 Fuel return line — cylinder head (at
front)-to-filter valve housing
앫 Fuel supply line — filter valve
housing-to-cylinder head (at rear)
앫 Fuel supply and return lines — fuel
pump-to-filter valve housing
2. Remove the filter valve housing.
Figure 125 — Fuel Filter Valve Housing
Page 97
EECU and Cooling Plate Removal
126
Figure 126 — EECU and Cooling Plate
1. EECU 4. Cooling Plate

2. Module Mounting Screws 5. Cylinder Block
3. Cooling Plate Mounting Screws 6. Ground Strap
If not already done for mounting the engine in the

repair stand, or if the engine is not being
completely disassembled for overhaul and only
the EECU is to be removed, remove the EECU Use care to avoid damaging the terminal pins.
following the procedure below.
2. Position the harness connectors back out of
1. Unlock and remove the end connectors
the way.
attached to the EECU. Remove the screws
from the harness retainer clamps. Then,
push the connector locks inward and rotate
outward to disconnect both wiring harnesses
from the EECU. Provide suitable rags and containers for collecting
127 fuel drainage.
Figure 127 — EECU Harness Connectors
Page 98
3. Remove the fuel lines from the cooling plate Inlet Manifold Removal
and set aside.
128 1. Remove the two top intake manifold
mounting fasteners and install two alignment
pins to support the manifold during removal.
2. Remove the remaining inlet manifold
mounting fasteners. Using a plastic mallet,
carefully tap the manifold loose and remove
it from the cylinder head.
130
Figure 128 — EECU Mounting Screws
4. Remove the screws and the cooling plate

from the EECU.
5. Remove the screws and the EECU from the
engine.
129
Figure 130 — Removing Inlet Manifold
3. Using a sharp pick, remove the rubber seal

(molded gasket) from the groove in the inlet
manifold. Discard the manifold seal.
Figure 129 — EECU Mounting Screws
Page 99
Tandem Pump (Fuel and Power Air Compressor Removal
Steering) Removal [261 CK]
131
132
Figure 131 — Removing Tandem Pump

Figure 132 — Air Compressor and Fittings
1. Lubrication Line 3. Mounting Stud and Nut

2. Coolant Lines 4. Air Compressor
oil and fuel drainage at each step.
1. Disconnect and remove the compressor
Be sure to capture the banjo sealing washers and coolant lines from the engine.
hollow screws while removing them.
2. Disconnect and remove the compressor oil
supply line.
1. If not already done, remove the power
steering oil supply and return lines from the 3. While supporting the air compressor,
tandem pump and set aside. remove the flange nuts securing the
compressor to the flywheel housing and
2. Remove the fuel supply and return lines remove the compressor from the engine.
from the fuel pump and set aside.
3. Remove the fasteners securing the pump to
the flywheel housing and remove the
tandem pump assembly from the engine.
Page 100
Flywheel and Pilot Bearing Removal FLYWHEEL REMOVAL PROCEDURE
TIMING GEAR ALIGNMENT

If the engine is not being completely The flywheel is heavy. Do NOT attempt to
disassembled for overhaul and only the timing remove the flywheel without the help of an
gears are to be removed for replacement, make assistant or the use of a suitable lifting
sure that the camshaft is set at Top Dead Center device. Failure to heed this warning may
(TDC) for the No. 1 cylinder, before removing the result in personal injury and component
flywheel. If not, proceed as follows: damage.
1. Using the engine barring tool, 9996956, bar
the engine over manually so that the 1. Remove the retainer screw and remove the
camshaft TDC mark is between the two lines engine speed sensor from the flywheel
on the rear camshaft bearing cap. The housing.
134
flywheel will be at 0° with the camshaft at
TDC.
133
Figure 134 — Engine Speed Sensor
2. If present, remove the transmission pilot

bearing using bearing extractor tool,
9991821.
135
2. The timing gears can now be removed. Use

care to not rotate the gears as they are
being removed so that the camshaft and
crankshaft remain in the TDC position.
Figure 135 — Removing Pilot Bearing
Page 101
3. Install two M10 x 100 screws in holes 1. If equipped with the optional PTO assembly,
opposite each other at the outer perimeter of loosen and remove the fasteners securing
the flywheel. These screws will be used as the assembly to the flywheel housing.
handles to aid removal of the flywheel.
136 2. Remove the PTO assembly from the
flywheel housing and set aside.
3. Remove and discard the PTO housing seal.
138
Figure 138 — Removing PTO Housing Seal
Figure 136 — Removing Flywheel

Flywheel Housing Removal
4. Remove the flywheel mounting fasteners.
1. Remove the flywheel housing fasteners
5. While supporting the flywheel, carefully tap (item 2 in Figure 139) located at the front of
the flywheel, alternating from side to side, to the timing gear plate.
work it off the aligning dowel pin and remove 139
it from the crankshaft flange.
Power Take-Off (PTO) Assembly

Removal
137
Figure 137 — Power Take-Off Assembly Figure 139 — Timing Gear Plate-to-Flywheel Housing
Fasteners
1. PTO Assembly 3. Flywheel Housing
2. Intermediate Idler 1. Tandem Pump Fasteners 3. Engine Mounting Bolt
Gearset 2. Flywheel Housing Holes
Fasteners
Page 102
2. Support the flywheel housing and remove Timing Gear Train Removal
the fasteners at the rear of the flywheel
141
housing securing the housing to the cylinder
block.
140
Figure 141 — Timing Gears
1. Crankshaft Gear 5. Lower Idler Gear

2. Intermediate Idler 6. Tandem Pump Drive
Gearset Gear
3. Adjustable Idler Gear 7. Air Compressor Drive
4. Camshaft Gear Gear
8. PTO Drive Gear
Figure 140 — Flywheel Housing Fasteners (Shown with

Torque Sequence)
To simplify the reassembly process, avoid rotating
3. Remove the flywheel housing. It may be
the engine or timing gears while performing
necessary to tap lightly on the housing with
timing gear removal and reinstallation.
a soft mallet to separate the housing from
the timing gear plate.
CRANKSHAFT GEAR AND IDLER GEARSET
Crankshaft Rear Seal Removal REMOVAL
[212 JH] 1. Remove the two Allen-head screws that

secure the gear to the crankshaft flange.
With the flywheel housing removed, use a drift 2. Using a suitable puller, remove the
and hammer to remove the old seal from the crankshaft gear.
crankshaft bore in the housing. 3. Remove and set aside the lower (auxiliary)
idler gear. Remove the seal ring from the
bearing journal.
4. Remove the six Allen-head screws (inner
circle) securing the intermediate idler
gearset hub to the cylinder block and
remove the gearset from the engine.
Page 103
142
Do NOT disassemble the intermediate idler

gearset. The intermediate idler gearset consists
of two gears and back-to-back tapered roller
bearings set to specified bearing preloads. The
assembly is held together by a large spanner nut
and six hex-head screws. Loosening and/or
removing the fasteners in any way may change
the bearing preload settings and result in bearing
failure.
ADJUSTABLE IDLER GEAR REMOVAL

To remove the adjustable idler gear from the
engine:
1. Remove and discard the six screws securing
the adjustable idler gear hub to the cylinder
head and engine block.
Figure 142 — Cylinder Head-to-Timing Gear Plate Screw
Locations
The adjustable idler gear fasteners are one time Timing Gear Plate Removal
use only.
2. Remove the adjustable idler gear, hub and

thrust washers from the engine. If the engine is not being completely
disassembled for overhaul and only the timing
gears are being replaced, it is not necessary to
remove the gear plate unless it is damaged and
If the engine is not being completely requires replacement.
disassembled for overhaul and only the cylinder
head is to be removed, it is not necessary to
remove the adjustable idler gear. However, the six
screws A and B which secure the timing gear
mounting plate to the cylinder head and the four The timing gear plate is heavy. Do NOT
upper screws C securing the adjustable idler gear attempt to remove the plate without the help
to the cylinder head MUST BE REMOVED of an assistant or the use of a suitable lifting
(Figure 142). Refer to the “Cylinder Head device. Failure to heed this warning may
Removal” procedure which follows later in this result in personal injury and component
section. damage.
Page 104
Alternator and Refrigerant
143
Compressor Removal
[271 CB, 264 DP]
144
Figure 143 — Timing Gear Plate
1. Air Compressor Mounting 2. Alignment Dowels,

Stud 9998267
1. Remove the compressor studs from the

timing gear plate. Remove and discard the
sealing ring from the studs.
2. Install the alignment dowels, 9998267, and
tighten them to specification. This step is
necessary to ensure proper alignment of the
plate when reassembling the engine. Figure 144 — Alternator and Refrigerant Compressor
3. While supporting the plate to prevent it from Mounting
falling, remove the fasteners.
1. Fan Belt 4. Alternator
2. Tensioner 5. Refrigerant Compressor
3. Alternator Mounting 6. Front Engine Support
Bracket Mounting Bracket
When the timing gear plate is being removed, it
must be drawn straight out to avoid moving or
damaging the alignment dowels.
For this procedure, the engine is out-of-chassis,
4. Remove the plate from the engine. the fan drive and accessory drive belts are
removed, the alternator harness wiring is
disconnected, and the A/C compressor
refrigerant lines are removed.
1. While supporting the alternator, remove the

fasteners and remove the alternator from the
upper mounting bracket.
2. While supporting the refrigerant compressor,
remove the fasteners and remove the
compressor from its mounting pads on the
front engine support mounting bracket.
Page 105
3. If necessary, remove the fasteners and Coolant Pump Removal
remove the belt tensioner from the upper
mounting bracket. [215 SW, SG, SR]
4. Remove the fasteners and remove the upper 146
mounting bracket from the cylinder block.
It is not necessary to remove the front engine

support mounting bracket unless it is damaged
and in need of replacement.
Thermostat and Cover Removal

145
Figure 146 — Coolant Pump
1. Coolant Pump Impeller 3. Coolant Pump Base

Assembly Plate
2. Pump Seal
Figure 145 — Thermostat and Cover 1. Remove the fasteners and remove the belt
tensioner and idler bracket from the front of
1. Cylinder Head 3. Thermostat the cylinder block if not already done.
2. Sealing Ring 4. Thermostat Cover
2. Remove the pump impeller assembly
1. Remove the fasteners, thermostat cover, fasteners and remove the impeller assembly
thermostat and sealing ring. from the base plate.
2. Carefully clean the thermostat seat and all 3. Remove and discard the pump seal.
cylinder head-to-thermostat cover mating 4. Remove the fasteners and the coolant pump
surfaces. base plate from the cylinder block.
Page 106
Cylinder Head Removal REMOVING THE TIMING GEAR
PLATE-TO-CYLINDER HEAD SCREWS
[213 EV] If not already done, remove the 10 screws (A, B
and C in Figure 147) securing the cylinder head
to the timing gear plate as follows:
1. Remove the five screws through the timing
If the engine is not being completely gear plate on either side of the adjustable
disassembled for overhaul and only the cylinder idler gear.
head is to be removed, the six screws A and B 148
which secure the timing gear plate to the cylinder
head and the four upper screws C securing the
idler gear hub to the cylinder head MUST BE
REMOVED (Figure 147). Failure to do so may
result in severe damage to the cylinder head and
other engine components as the cylinder head is
removed. See “REMOVING THE TIMING GEAR
PLATE-TO-CYLINDER HEAD SCREWS” on
page 107.
147
Figure 148 — Head-to-Plate Attaching Screws
2. Bar the engine over to align a hole in the

adjustable idler gear with the hidden screw
through the plate into the cylinder head.
Remove the screw.
149
Figure 147 — Cylinder Head-to-Timing Gear Plate Screw

Locations
Figure 149 — Hidden Screw (Behind Gear)
Page 107
3. Remove the four upper screws in the REMOVING THE CYLINDER HEAD
adjustable idler gear hub.
150 With the timing gear mounting plate-to-cylinder
head screws removed (A, B and C in Figure 147),
proceed as follows to remove the cylinder head.
151
Figure 150 — Upper Four Adjustable Idler Gear Hub

Screws
4. Remove any residual engine oil from the Figure 151 — Cylinder Head Removal
“hollows” beneath the camshaft to prevent
oil from running into the coolant channels. 1. Cylinder Head 3. Cylinder Block
2. Lifting Tool, 88800188
1. Remove the cylinder head bolts.

2. Using the cylinder head lifting tool,
88800188, carefully remove and set aside
the cylinder head.
Page 108
3. Remove and discard the cylinder head
153
gasket.
4. Attach cylinder liner hold-down tools,
9996966, to the cylinder block to keep the
liners in place temporarily.
152
Figure 153 — Vibration Damper and Fan Pulley
1. Pulley, Fan Drive and 3. Crankshaft Hub

Coolant Pump
2. Vibration Damper/Pulley
1. If not already done, release the tensioners

and remove the drive belts.
2. Remove the front engine power take-off
(FEPTO) unit, if so equipped.
Figure 152 — Cylinder Liner Retainer
crankshaft vibration damper and fan pulley.
Crankshaft Vibration Damper and
Fan Pulley Removal
[212 RB, RP]
When handling a vibration damper, be careful not

to damage the housing. Dents in the outer
housing may render the damper ineffective,
causing an imbalance and vibration in the engine.
The vibration damper cannot be repaired.
The fan pulley nests within the damper using the

same attaching screws.
Page 109
Crankshaft Front Cover Removal
[211 JB]
Apply grease to the drill bit to collect metal chips
154 when drilling holes in the seal.
2. Using two self-tapping M5 screws of suitable

length, attach the front crankshaft seal
remover/installer, 88800021, to the seal.
3. Using two M10 screws of suitable length
threaded into the tapped holes in the
crossmember of the remover/installer,
remove the seal and discard it.
4. Clean the seal seating surface in the
crankshaft front cover and the sealing
surface on the crankshaft hub.
Oil Fill Pipe and Dipstick Retainer

Removal
Figure 154 — Crankshaft Front Cover Provide suitable rags and containers for collecting
oil drainage at each step.
1. Front Cover 2. Crankshaft Hub
1. If not already done, remove and set aside
1. While supporting the front cover, remove the the dipstick.
155
eight fasteners attaching the cover to the
cylinder block.
2. Remove the crankshaft front cover from the
engine by sliding it off the crankshaft flange.
Crankshaft Front Seal Removal

[211 JB]
With the crankshaft front cover removed, use a
drift and hammer to remove the old seal from the
cover bore.
If the engine is not being completely Figure 155 — Oil Dipstick Port
disassembled for overhaul and only the
crankshaft front seal is to be replaced, remove 1. Retainer Screw 2. Oil Level Sensor
the seal using the following procedure. Connector
1. Drill two 3.5 mm (0.138 inch) holes in the

metal rim of the front crankshaft seal using
the holes in the rim of the seal
remover/installer.
Page 110
2. Remove the retainer screw from the dipstick 1. If the vehicle is equipped with an optional
pipe flange and remove the pipe from the transmission oil cooler and not already done,
engine. remove the transmission cooler line bracket
nuts and separate the brackets from the oil
3. Remove the fasteners from the oil fill pipe
pan fasteners.
mounting flange and remove the oil fill pipe.
156
2. Remove the screws and springs securing
the oil pan to the crankcase.
The oil level sensor need not be removed unless

it is to be replaced.
3. Remove and set aside the oil pan.

4. Remove and discard any O-rings found on
the oil pan screws.
5. Remove the elastomer seal from the oil pan
and inspect it. If the seal is damaged, it must
Figure 156 — Oil Fill Pipe Mounting Flange be replaced.
158
Oil Pan Removal

[211 NB]
If the engine is in the vehicle, provide a lifting

device to assume the weight of the oil pan during
removal.
157
Figure 158 — Removing Oil Pan Gasket
Figure 157 — Oil Pan
1. Elastomer Seal 2. Oil Pan
Page 111
Front Engine Support Removal
160
[299 GV]
159
Figure 160 — Inlet, Outlet and Crossover Pipes (Front

Sump Shown)
1. Oil Pump 4. Strainer

2. Pump Outlet Pipe 5. Pump Inlet Pipe
Figure 159 — Front Engine Support 3. Crossover Pipe 6. Block Stiffener Plate
1. Left-Side Attaching 2. Right-Side Attaching

Screws Screws 2. Remove the fasteners from the pump outlet
(pressure side) pipe flange and remove the
pipe from the engine. Remove and discard
Remove the fasteners at the left and right sides of the seal rings.
the engine support and remove the support from
the mounting brackets at each side of the cylinder 3. Remove the fasteners from the crossover
block. pipe flange and remove the pipe.
4. Remove the remaining fasteners securing
Block Stiffener Plate Removal the stiffener plate to the cylinder block.
161
The inlet pipe with a front sump oil pan is longer

than the one with a rear sump oil pan. Both the
shorter and longer pipes attach to a bracket
mounted on the stiffener frame and cylinder
block.
1. Remove the support retaining fasteners and
remove the pump inlet pipe. Remove and
discard the seal ring.
Figure 161 — Block Stiffener Plate
5. With the help of an assistant, remove the

block stiffener plate.
Page 112
Oil Pump Removal Piston and Connecting Rod
[219 MU, 219 NT] Assembly Removal
[212 NP, 212 LP]
If the engine is not being completely
disassembled for overhaul and only the oil pump 1. Rotate the crankshaft so that the connecting
is to be replaced, instructions are provided in a rod bearing cap for the desired cylinder is
separate section entitled “OIL PUMP positioned for easy removal of the rod cap
REPLACEMENT (IN CHASSIS)” for removing bolts.
and reinstalling the oil pump with the engine in
the chassis.
1. If necessary for access to the oil pump
mounting fasteners, rotate the crankshaft The rod bearing caps can be removed in the
using engine barring tool, 88800014. companion cylinder sets: Nos. 1 and 6, 2 and 5,
and finally 3 and 4.
2. Remove the fasteners securing the oil pump
163
to the No. 7 main bearing cap.
162
Figure 163 — Connecting Rod Bearing Cap
1. Piston Cooling Nozzle 2. Bearing Cap Bolts
2. Remove the piston cooling nozzle to prevent

it from being damaged.
3. Remove the four bolts and remove the
Figure 162 — Oil Pump (Installed on No. 7 Bearing Cap) bearing cap.
3. Carefully remove the oil pump from the 4. Discard the lower bearing insert (shell) in the
bearing cap. cap.
5. Using a suitable tool, push up on the bottom
of the piston until the rings are free of the
cylinder liner. The upper inner surface of the
liner may have to be scraped and cleaned if
there is excessive carbon build-up to make it
easier to remove the piston.
Page 113
164 165
Figure 165 — Connecting Rod-Cap Markings
7. Remove and discard the upper bearing

insert in the connecting rod.
8. Repeat steps 1 through 7 to remove the
remaining pistons.
Figure 164 — Piston Removal
Main Bearing Cap Removal

[212 HH]
Use care to avoid contact between the
connecting rod and liner during removal. Contact
may cause damage to the liner.
Bearing caps are marked. Be sure to return each
6. From the cylinder deck, pull up to remove bearing cap to its original location at assembly.
the piston and connecting rod from the
engine. Mark the piston assembly to show 1. With the engine inverted (crankcase side up)
its location in the engine and set it aside for on the repair stand, loosen and remove the
disassembly and inspection (see the bolts securing the main bearing caps.
CONNECTING ROD AND PISTON BENCH 166
PROCEDURES section).
The connecting rod and bearing cap are a

matched set. Use care to ensure that the
respective bearing caps and rods are kept
together.
Figure 166 — Crankshaft No. 1 Main Bearing Cap
1. No. 1 Main Bearing Cap 3. Attaching Screws

2. Crankshaft Hub
Page 114
2. Using puller 9990114, adapter 9990262 and Crankshaft Removal
slide hammer 9996400, remove and set
aside the bearing caps. [212 HP]
167
The crankshaft is extremely heavy. Do NOT

attempt to remove the crankshaft without the
help of an assistant or the use of a suitable
lifting device. Failure to heed this warning
may result in severe personal injury and
component damage.
Exercise extreme care when lifting and moving

Figure 167 — Removing Main Bearing Caps the crankshaft to avoid striking other objects. No
nicks, scratches, burrs or other signs of distress
1. Tool No. 9996400 3. Tool No. 9990114 on the journals or fillets are acceptable.
2. Tool No. 9990262
1. With an assistant and using the crankshaft
3. Remove and make note of the part number lifting tool, J 49002, lift the crankshaft to
on the inserts (shells). Discard the inserts. remove it from the cylinder block.
169
In addition to the main bearing inserts, the No. 4

crankshaft journal includes four thrust washer
inserts, an upper and lower at each side of the
crankshaft journal.
168
Figure 169 — Removing the Crankshaft
2. Remove and discard the upper main bearing

inserts from the cylinder block.
Figure 168 — Crankshaft No. 4 Main Bearing Cap with

Thrust Washers
1. Thrust Washer Insert, 2. No. 4 Main Bearing Cap

Lower
4. Remove and discard the thrust washer

inserts.
Page 115
CYLINDER BLOCK RECONDITIONING
[211 DB]
Tools and Equipment
SPECIAL TOOLS
Tool No. Description Images

9992000 Handle with various uses (fits 25 mm hole)

(Essential)
9996599 Liner Installation Plate (Available)
9996966 Liner Hold-Down Tool (Essential)
PT-6435 or Cylinder Liner Puller (Available)

PT-6400-C Note: Alternate tools for liner removal —
9992955, 9996394, 9996395 and 9996645
in combination.
Page 116
Piston Cooling Spray Nozzle Cylinder Liner Removal
Removal [212 NC]
[219 RV] 1. Install the cylinder liner puller, tool PT-6435
or equivalent, in position over the cylinder
liner to be removed.
171
To avoid damaging the spray nozzles, remove

them before removing the liners.
It is best to use a 12 mm, 6-point socket on a

300 mm (12 inch) extension to remove the nozzle
retaining capscrews.
1. Remove the piston cooling spray nozzle by

removing the retaining capscrew.
2. Carefully pull outward on the spray nozzle to
remove it from the cylinder block.
3. Repeat steps 1 and 2 to remove the
remaining spray nozzles.
170
Figure 171 — Cylinder Liner Removal
1. Cylinder Liner 2. Liner Puller Assembly
Be sure the cogs on the puller legs do not extend

beyond the outside diameter of the liner. Failure
to heed this caution may result in severe
component damage.
Figure 170 — Spray Nozzle Removal 2. Hooking puller legs on the bottom of the
cylinder liner, tighten the center screw on the
1. Piston Cooling Duct 3. Spray Nozzle puller until the liner comes free of the
2. Attaching Screw cylinder block bore.
3. Remove the liner and puller assembly from
the cylinder block. Then, remove the puller
from the liner.
4. Repeat the procedure to remove the
remaining cylinder liners.
Page 117
SOLVENT TANK CLEANING
As an alternative, tool Nos. 9992955, 9996394,

9996395 and 9996645 in combination, can be
Use a cleaning tank large enough to
used for cylinder liner removal.
accommodate the largest component to be
cleaned. Fill the tank with a suitable solvent.
Parts may be dried with compressed air.
Block Cleaning and Inspection
The engine should have been thoroughly steam
cleaned prior to component removal. If heavy
accumulations of dirt and grease are still present, Always use caution while cleaning parts with
steam clean the block as thoroughly as possible solvents. Failure to heed this warning may
before attempting to clean with solvents. result in personal injury.
1. Scrape any remaining gasket material from

the cylinder block.
Cleaning solvent is flammable and toxic to the 2. Using a wire brush or rotary wheel, remove
eyes, skin and respiratory tract. Skin and eye any rust, corrosion or other debris from the
protection is required. Avoid repeated or cylinder block.
prolonged contact. Use only in a
well-ventilated area. Failure to heed this 3. Clean all other cylinder block surfaces with
warning may result in severe personal injury. mineral spirits or other suitable solvent.
4. Using due care and caution, clean and dry
the cylinder block with compressed air.
Compressed air used for cleaning can create INSPECTION

airborne particles that may enter the eyes or
irritate the skin. Pressure must not exceed
207 kPa (30 psi). Eye protection is required.
Use only with effective chip guarding and A complete discussion of the proper methods for
personal protective equipment precision measuring and inspection is outside the
(goggles/shield, gloves, etc.). Failure to heed scope of this procedure. However, every shop
this warning may result in severe personal should be equipped with standard gauges, such
injury. as bore gauges, dial indicators, outside and
inside micrometers, thickness gauges and
straightedges.
Cleaning the cylinder block is important. While Check the cylinder block for indications of
cleaning the cylinder block, carefully inspect the cracking or coolant leakage. If any damage is
areas around the cup plugs and the coolant duct suspected, use a standard dye penetrant to
cover. If cup plugs or pipe plugs show signs of determine if cracks exist. A cracked cylinder block
leaking, they should be replaced. must be replaced and never reused.
Cleaning the cylinder block is a good time to
inspect it for cracks or other possible defects that
may be reason for rejection. Refer to the
TROUBLESHOOTING section for information on
testing for leaks in the cylinder head and cylinder
block. If damage is not found until after the engine
is assembled, the engine must be disassembled
and rebuilt again.
Page 118
Counterbore Inspection and 3. Reset the tip of the dial indicator against the
high point on the convex surface of the
Cleaning cylinder liner. Measure and record the height
of the liner ledge above the cylinder block
[211] deck.
173
If the cylinder liner counterbore surface shows
excessive pitting or erosion, recut the
counterbore as required. Shims are available if
the counterbore depth must be changed. Do not
resurface the block deck.
This procedure can be performed either in or out

of the chassis. If performing the procedure in the
chassis, be sure to cover the crankshaft and any
holes in the cylinder block to prevent
contamination from machining chips.
Liner Height Measurement

[212 NC]
To determine liner height above the cylinder block
deck, proceed as follows:
1. Insert a replacement liner (without sealing Figure 173 — Measuring the Cylinder Liner Height
rings) into the cylinder block bore. Secure
the liner in place, using two hold-down tools, 4. Measure and record the height of the liner
9996966. ledge above the cylinder block deck at four
points, 90 degrees apart.
2. Mount the dial indicator, tool 9989876, in the
holder, tool 9992479. Place the holder and 5. Calculate an average height, using the
dial indicator in position across the top of the highest recorded measurement and the
cylinder liner. Set the tip of the dial indicator measurement taken diagonally across the
against the cylinder block deck and zero the cylinder bore. Check the calculated height
dial indicator gauge. against specifications. Then, calculate the
172
thickness of the shim(s) required, if any. Use
the fewest possible number of shims.
6. Using a marking pen, mark the position of
the liner in the cylinder bore for final
installation. Then, remove the liner and
adjustment spacer (if required) from the
cylinder block and place on a clean work
surface.
7. Repeat the procedure for the remaining
cylinders.
Figure 172 — Zeroing the Dial Indicator to the Block

Deck
Page 119
Cylinder Liner Installation
175
[212 NC]
174
Figure 175 — Applying Sealant to Counterbore
3. Using liner installation plate, 9996599, and

handle, 9992000, press the liner (with
spacer if appropriate) into the bore until
seated.
176
Figure 174 — Seal Ring Installation
1. EPDM (Black) 3. Viton (Purple)

2. EPDM (Black)
1. Apply lubricant (included in liner kit) to new

seals and install them in the four annular
grooves, one under the flange of the cylinder
liner and three near the bottom. The purple
gasket is installed in the lowest groove.
2. If the cylinder liner is being installed with a
spacer (shim), apply a 0.8 mm (0.03 inch)
bead of 342SX33 MACK-approved sealant
to the counterbore ledge in the cylinder Figure 176 — Cylinder Liner Installation
block. Do NOT apply the sealant between
the spacer and the cylinder liner flange. 1. Handle 9992000 3. Liner Hold-Down Tool
2. Liner Installation Plate 9996966
9996599 4. Cylinder Liner
4. Secure the liner in place using two liner

hold-down tools, 9996966.
The liners must be installed and secured in place

within 20 minutes after application of the sealant
to the liners.
Page 120
FLYWHEEL BENCH
178
PROCEDURES
Flywheel Ring Gear Replacement

[21687-5]
1. Heat the ring gear around the outer edge
with a torch.
177
Figure 178 — Ring Gear Heating
5. Install the heated ring gear on the engine

flywheel. Let the ring gear air cool naturally.
179
Figure 177 — Ring Gear Removal
2. Use a punch to remove the ring gear from

the engine flywheel.
3. Use a steel brush to clean the engine
flywheel.
Use caution not to heat the ring gear excessively

or damage will occur to the new ring gear.
4. Heat the new ring gear with a torch or in a

furnace to 180–200°C (356–392°F). Heat
the gear evenly around the entire surface. A Figure 179 — Ring Gear Installation
good indication that the correct temperature
has been reached is when bright metal turns
a bluish color.
Page 121
CONNECTING ROD AND It is essential that a cap and rod be kept together
when removed from the engine and when
PISTON BENCH PROCEDURES installed. Each rod and cap is marked with
matching numbers to identify them as a set. At
Connecting Rod — Piston assembly, the numbers must appear side by side
and the notches must be aligned. Refer to
Disassembly Figure 180. Tag the sets on removal so each set
can be returned to the cylinder from which it was
[212 LP] removed.
New rods for service arrive with caps attached.

The cap must be separated by holding the rod in
a soft-jawed vise and striking the cap with a Do not install a damaged connecting rod
rubber-faced hammer. Care must be taken to assembly. Failure to heed this caution may result
prevent damage to the rod, cap and bearing in severe component damage.
surfaces.
180
Do NOT use a pneumatic impact wrench to

tighten connecting rod screws. It will damage the
mating surfaces. Failure to heed this caution may
result in severe component damage.
WRIST PIN REMOVAL

1. Using snap ring pliers, remove the snap ring
at each end of the wrist pin.
2. Remove the wrist pin from the piston and
connecting rod.
Figure 180 — Connecting Rod
1. The word, Front, faces 2. The numbers must agree

the front of the engine. and be aligned on the
same side.
Page 122
INSPECTION CONNECTING ROD ALIGNMENT
181
Visually inspect the connecting rod for twist and
bend. Replace the connecting rod if necessary.
Piston Inspection and Cleaning

[212 NP]
DISASSEMBLY
1. Using a suitable piston ring expander,
remove the piston rings.
2. Clean the piston ring grooves, combustion
bowl area and the snap ring grooves
thoroughly.
Remove all carbon. Carbon left in the grooves

reduces ring clearance and prevents proper
Figure 181 — Piston Assembly — Exploded View
seating.
Be sure that the cleaning solvent is approved for
1. Piston Rings 3. Wrist Pin steel and aluminum. Incompatible solvents may
2. Piston damage the pistons.
Inspect each connecting rod and cap for the
engine damage.
following conditions. If any fault appears, replace
both rod and cap.
3. Using a brass brush and an approved
1. Inspect the connecting rods for nicks, cleaning solution, clean the pistons.
cracks, signs of overheating and
unacceptable bending and twisting.
2. Inspect the bolt holes for elongation and
damaged threads. Avoid damaging the pistons while cleaning.
3. Inspect the mating surfaces between the
connecting rod and cap for correct fit.
INSPECTION
4. Inspect the bolt holes for elongation or
stripped threads. Inspect the piston ring grooves, lands, skirt and
combustion bowl for wear, scuff marks, cracks
5. Inspect the wrist pin. and blow-by. Pistons are NOT repairable. Discard
6. Inspect the wrist pin bearing surface in the worn or damaged pistons.
connecting rod.
7. Inspect the crankshaft journal bearing
surfaces of the connecting rod and cap.
Do not stamp or engrave on the TOP of the
piston. Failure to heed this caution may result in
severe engine damage.
If it is determined that any component is in
questionable condition, replace it.
Page 123
Piston Ring Inspection and RING END GAP INSPECTION
Replacement 1. Using an inverted piston, push a piston ring
into a cylinder liner making sure it is
[212 NV] squarely aligned.
2. Using thickness gauges, measure the gap
OIL RING GROOVE SIDE CLEARANCE between the ring ends. Refer to Fits and
INSPECTION Limits in the SPECIFICATIONS section for
gap information.
1. Using a thickness gauge, measure oil ring
groove side clearance. 3. Repeat steps 1 and 2 for each ring.
182
Do not file or grind chrome-plated piston rings.

This may cause the chrome to flake resulting in
ring failure. Failure to heed this caution may result
in severe engine damage.
RING INSTALLATION
Identification markings on the rings should face

the piston top. The keystone ring goes in the top
ring groove.
Follow the directions on each piston ring packet.
183
Figure 182 — Side Clearance Measurement
1. Ring Groove Side Clearance
a. Insert a new oil control ring in the

groove. Figure 183 — Piston Rings
b. Insert a thickness gauge between the
ring and upper land of the groove. 1. Upper Compression Ring 2. Lower Compression Ring
(Keystone-Shaped) 3. Oil Control Ring
c. Record the measurement and compare
the reading with the information in Fits
and Limits in the SPECIFICATIONS
section.
Page 124
1. To prevent distortion, use the proper size Connecting Rod — Piston
piston ring expander, to insert the rings in
the grooves. Assembly
2. Stagger the ring gaps so that they are not [212 LP & NP]
aligned and none is directly over the
wrist-pin bore.
184
Be sure that the piston and rod assemblies are

clearly marked with their cylinder location. They
must be returned to the same cylinder from which
they were removed. Failure to heed this caution
may result in severe engine damage.
1. Insert a snap ring in one of the wrist pin

retaining grooves.
2. Insert the connecting rod in the piston
assembly.
Align the FRONT mark on the connecting rod with

the arrow on the piston. Refer to Figure 180.
185
Figure 184 — Ring Gap Locations
Figure 185 — Connecting Rod Piston Assembly
1. Wrist Pin 3. Piston

2. Snap Ring 4. Connecting Rod
Page 125
3. Using a generous amount of clean engine oil A screw with four punch marks (A) must be
on the wrist pin and rod bearing, press the replaced with a new screw.
wrist pin into the bore. 186
4. Insert a snap ring in the other wrist pin

retaining groove.
5. Set the assembled piston aside in a clean
location until it is needed.
6. Repeat steps 1 through 5 for each piston.
Connecting rod capscrews can only be re-used

four times. Screw heads must be punched at
each overhaul to indicate the number of times
used. Failure to heed this caution may result in
severe component damage.
Figure 186 — Connecting Rod Screw with Maximum

Punch Marks (Replace)
Used connecting rod screws must be lightly oiled

on the threads and under the head. New screws
are coated with phosphate and oil and must be
assembled dry.
If the capscrews are incorrectly assembled or

tightened to an incorrect torque, the assembly
must be discarded. Failure to heed this caution
may result in severe component damage.
Page 126
CYLINDER HEAD OVERHAUL
[213 EV]
Tools and Equipment
SPECIAL TOOLS

9809667 9 mm Tap, use with 9998252 (Available)
9809668 9 mm Bit, use with 9998253 (Available)
9809729 Hydraulic Ram (Available)
9990176 Tool Press for Valve/Valve Guide

Replacement (Available)
9990210 Valve Spring Compressor (Essential)
Page 127
9996222 Hydraulic Pump (Available)
9998246 Valve Spring Compressor Adapter

(Available)
9998249 Unit Injector Protection Sleeve (Essential)
9998250 Unit Injector Bore Gallery Sealing Rings

(Available)
9998252 Unit Injector Sleeve Tap (Essential)
Page 128
9998253 Unit Injector Sleeve Remover (Essential)
9998263 Valve Guide Removal Tool (Available)
85112460 Valve Stem Seal Installation Tool
88800011 Valve Stem Seal Protection Tool
88800014 Flywheel Turning Tool (Essential)
88800062 Inlet and Exhaust Valve Guide Installation

Tool (Available)
Page 129
88800196 Swaging Tool for Installing Unit Injector
Copper Sleeve (Essential)
88880010 Swaging Bit for Copper Sleeve (Available

Separately)
J 42885 Unit Injector Bore Cleaning Kit (Essential)
PT-2900 Chip Vacuum
Page 130
Inlet and Exhaust Valve Removal REMOVAL PROCEDURE
1. Using the spring compressor, 9990210,
[213 NB] compress a valve spring set to access the
keepers.
GENERAL INFORMATION 2. Using a magnet, remove the keepers from
The MP8 has a single cylinder head, valves in the the valve stem.
head and a single overhead camshaft. The single 3. Remove the valve spring set.
rocker arm shaft rests on the inboard end of
seven camshaft bearing caps. The seventh 4. Using a suitable tool, remove the valve stem
bearing cap also provides a connection for seals.
lubricant. The optional engine brake electronic oil 5. Remove the valves.
control valve connects the oil passages in the 188
head and rocker arm shaft.
A copper sleeve and washer lines the bottom of

each injector port. An O-ring seals each sleeve.
An opening in the right front corner receives the
thermostat. There are three special screws and
washers used to align the cylinder head, two in
the block and one in the cylinder head. Valve seat
counterbores are cut in the block side. Valve
guides pressed into place project from the upper
side.
A gallery delivers fuel to the injectors and fuel

pressure regulator. The inlet manifold attaches to
the left (driver's) side of the head: the exhaust
manifold to the right side.
187
Figure 188 — Valve Spring Keeper Removal
1. Valve Spring Compressor 2. Valve Spring

9990210
Valve Stem Seals
For standardization, the valve guide and seal are

used at the inlet locations as well as the exhaust
locations.
Figure 187 — Cylinder Head
Page 131
Cylinder Head Cleaning and Using care and caution at all times:
Inspection 1. Fill a tank with a suitable solvent.
2. Immerse the parts in the solvent to loosen
Cleaning the cylinder head is important. While dirt and debris.
cleaning the cylinder head, carefully inspect the
areas around the expansion plugs and the 3. Scrape remaining gasket material from the
cooling duct cover. If the cup or pipe plugs show cylinder head.
signs of leaking, they should be replaced. The 4. Using a wire brush or rotary wheel, remove
cylinder head should also be inspected for cracks rust and other debris from the cylinder head.
or other possible defects that may be reason for
replacement. If damage is not found until after the 5. Rinse the cylinder head making sure that all
engine is assembled, the cylinder head must be surfaces are clean and free of debris.
removed, disassembled and rebuilt again. 6. Using compressed air, blow dry the cylinder
head.
SOLVENT TANK CLEANING
INSPECTION
Check the cylinder head deck surface for
warping, pitting and other imperfections.
Cleaning solvent is flammable and toxic to the
eyes, skin and respiratory tract. Skin and eye
protection are required. Avoid repeated or
prolonged contact. Use only in a well
ventilated area. Do NOT machine the cylinder head. This will
change the extension of the injector and upset
Compressed air used for cleaning can create injector timing.
airborne particles that may enter the eyes or
irritate the skin. Pressure must not exceed
207 kPa (30 psi). Eye protection is required.
Use only with effective chip guarding and
personal protective equipment
(goggles/shield, gloves, etc.).
Page 132
Valve Guide Replacement
189
[213 EP]
Refer to the “ENGINE MECHANICAL
SPECIFICATIONS” section for dimensions
applicable to the valve guides.
INSPECTION
Worn valve guides may result in poor

valve-to-seat contact, valve damage or excessive
oil consumption.
1. Inspect the valve guides for wear, damage,

cracks and looseness.
2. Using a suitable gauge, measure the inside
diameter of each guide.
3. Using a suitable gauge, measure the valve
guide extension.
When reconditioning the cylinder head, it is Figure 189 — Valve Guide Removal
recommended that all valve guides be replaced.
1. Press Tool 9990176 3. Valve Guide Remover
2. Hydraulic Ram 9809729 9998263
4. Valve Guide
VALVE GUIDE REMOVAL
2. Press out the old valve guides from the top
of the cylinder head using the press.
Clean the exhaust valve guide OD (shoulder) 3. Clean all surfaces thoroughly.
before removal. With the guide removed, use a
rotary brush to prevent scoring while cleaning the
exhaust valve guide bore.
1. Assemble the hydraulic ram, 9809729, press

tool, 9990176, pump, 9996222, and valve
guide remover, 9998263, on top of the
cylinder head.
Page 133
VALVE GUIDE INSTALLATION Valve Spring Inspection
1. Heat the cylinder head with hot water and at
the same time cool valve guide to minus [213 MB]
60–200°C (76–328°F) using dry ice or
equivalent. Lubricate cylinder head valve
guide bore before installation.
2. Using protective gloves, place a new valve If the inside surface of a spring coil is rough or
guide in position on the cylinder head. grooved, it must be replaced.
3. Assemble the hydraulic ram, 9809729, press If spring strength is not within specifications, it
tool, 9990176, pump 99996222, and the must be replaced.
appropriate valve guide installer (88800062
for inlet and exhaust) on top of the cylinder For indications of grooving or roughness:
head.
1. Inspect the inside surfaces of each spring
4. Oil the outside of the guide before coil visually.
installation.
2. Feel the inside surfaces of each spring coil
5. Using the press tool setup, press the valve with a finger.
guide into its bore from the top of the
cylinder head. 3. Replace faulty springs with new ones.
4. Using a spring tester as shown in
Figure 190, measure the effort required to
compress a spring.
It is essential that the correct valve guide 190
installation tool (88800062 for inlet and exhaust)

be used to install the current valve guide. If the
incorrect tool is used, the valve guide and seal
installed height will be incorrect and may result in
premature failure of the components.
6. Thoroughly clean all debris from the valve

guides and surrounding area.
7. Install the valves in the cylinder head and
check for binding, looseness and other
conditions that may result in premature valve
or valve guide failure.
Figure 190 — Checking Valve Spring Pressure
1. Spring Tester 2. Valve Spring
Page 134
Injector Sleeve Replacement
192
[213 GB]
CYLINDER HEAD REMOVED
The injector sleeve is swaged in place in its bore.
REMOVAL PROCEDURE
1. Remove the injector or the plug, 9998251, to
access the injector sleeve bottom.
2. Remove and discard the sealing washer in
the bottom of the copper sleeve.
3. Install two sealing rings to prevent dirt from
entering the fuel gallery when the copper
sleeve is removed.
191
Figure 192 — Copper Sleeve Tapping Tool
This ensures that the tip of the copper sleeve is

tapped all the way through.
5. Lubricate the tip of the 9 mm tap with

grease.
6. Thread the tap in small increments. Remove
the tap and wipe off the grease and copper
sleeve shavings. Apply fresh grease,
reinstall the tapping tool and thread more of
the copper sleeve. Continue this process to
thread the tap all the way through the copper
sleeve until no resistance is felt and the tap
turns freely. Tapping in small increments and
Figure 191 — Fuel Gallery Sealing Rings removing the shavings minimizes the
chance of the sleeve turning in the cylinder
head. Ensure that the tap is completely
through the copper sleeve.
Two sealing rings are required to cover the fuel

gallery.
4. Adjust the 9 mm tap so that it extends a

minimum of 25 mm or 1 inch (dimension A)
from the end of the tapping tool.
Page 135
10. Tighten the set screw of the extractor tool to
193
secure the bolt. Make sure that the set screw

is seated against the flat part of the extractor
bolt.
11. Place the extractor tool with the bolt into the
injector bore. Make sure the nut on the
spindle is backed off so that the threaded
end can be completely installed through the
copper sleeve tip. Hand tighten until the bolt
bottoms out in the sleeve.
195
Figure 193 — Tapping Injector Sleeve
1. Tap 9998252 2. Cylinder Head
7. Remove the tap and tapping tool. Figure 195 — Extractor Tool Installation
8. Using the chip vacuum, remove any
remaining shavings from the copper sleeve.
9. Install the extractor bolt into the end of the
extractor tool. Adjust the bolt until it extends Make sure the extractor bolt is threaded
approximately 22 mm (0.9 inch) beyond the completely into the copper sleeve before
end of the tool (dimension A). attempting to remove it or the tip of the sleeve
194 may break off as it is removed.
12. Screw the injector sleeve removal tool,

9998253, completely into the injector sleeve
and then back it out 1/2 turn. Remove the
sleeve by turning the nut while holding the
threaded shaft of the removal tool.
Figure 194 — Adjusting Copper Sleeve Extractor Bolt
Page 136
13. Remove the two sealing rings from the fuel
196
passage. Using the chip vacuum, remove

any remaining debris from the injector bore.
197
Figure 197 — Fuel Gallery Sealing Rings
14. Install the injector bore sealing tool

Figure 196 — Removing Injector Sleeve (J 42885-25) to protect the fuel passage
area and prevent debris from entering. Use
1. Injector Sleeve Remover 2. Injector Sleeve the unit injector hold down bolt to secure the
9998253 tool in the cylinder head.
15. Using the injector bore cleaning kit, clean
the copper sleeve seat of the cylinder head.
When the copper sleeve is removed, make sure

that the extractor bolt is extended at least one
thread beyond the copper sleeve. If not, make The injector bore sealing tool must be used to
sure that no part of the copper sleeve has broken prevent dirt from entering the fuel passage.
off.
Do not use air tools to remove copper sleeves, or

damage to the injector bore can result.
Page 137
17. Using the brush, clean the copper sleeve
198
opening in the cylinder head.

200
Figure 198 — Cleaning Copper Sleeve Seat
16. Using the brush, clean the cylinder head

Figure 200 — Cleaning Injector Tip Bore
injector bore walls for the copper sleeve.
199
The injector bore sealing tool must be used to

prevent debris from entering the fuel passage.
When replacing the copper sleeves, it is
important to check that the sleeve bore in the
cylinder head is free from any carbon deposits or
other residue (i.e., pieces of O-ring, etc.) before
installing a new copper sleeve. Reclean if
necessary.
18. Using the chip vacuum, remove all debris

from the copper sleeve bore.
Do not attempt to blow away debris using

compressed air. Doing so can result in eye injury.
Figure 199 — Cleaning Copper Sleeve Bore Walls 19. Remove the injector bore sealing tool from
the cylinder head. Using the chip vacuum,
remove any remaining debris.

Page 138
INSTALLATION PROCEDURE
202
1. Before installing the copper sleeve, inspect it

to ensure that it is the correct part. The
correct sleeve is identified by two concentric
circular grooves machined into the top
surface.
201
Figure 202 — Installation Tool Identification
Before installing the sleeve on the installation

tool, inspect the tool to ensure that it is the correct
Figure 201 — Copper Sleeve Identification tool. The correct tool is identified by a bottom
surface that is perfectly flat with no machined
2. Lubricate a new copper sleeve O-ring with circular recess. Use of a tool with a machined
coolant. Install the O-ring on the copper circular recess on the bottom may result in
sleeve and lubricate again with coolant. damage to the copper sleeve.
Always use a new O-ring.
3. Place the new copper sleeve on the 4. Using calipers, measure the swaging bit to
installation tool. make sure that the proper swaging tool is
used. Measurement should read
approximately 7.8 mm. Also, verify that the
length of the swaging bit is 108 mm.
Do not place the injector nozzle gasket (flat
washer) in the copper sleeve, as this will damage
the swaging bit.
Failure to use the proper bit can result in the bit
breaking off into the cylinder head.
Page 139
6. Screw the swaging tip through the copper
203
sleeve and completely into the swaging tool

holder, 88800196, until it stops (finger tight).
Ensure that the tool is fully seated in the
copper sleeve.
205
Figure 203 — Swaging Bit Verification
Swaging bit can be ordered as a spare part if the

bit is worn or broken. Figure 205 — Swaging Tool
204 7. Loosen the swaging bit 180 degrees before

installing the tool in the cylinder head.
Failure to loosen the swaging bit can result in the

bit being twisted or broken.
8. Lubricate the swaging bit and the threads on

the tool with oil.
9. Carefully place the sleeve installation tool
(with new copper sleeve attached) into the
unit injector bore of the cylinder head.
Carefully move the copper sleeve downward
into the injector bore so that the swaging bit
is guided into the injector tip bore in the
cylinder head. Push downward on the
installation tool using hand force to move the
copper sleeve downward until it bottoms out
on the injector sleeve seat in the bottom of
Figure 204 — Swaging Bit the injector bore. Use the unit injector hold
down and bolt to hold the tool in position. To
5. Thread the swaging bit completely into the ensure that the copper sleeve is bottomed in
flaring tool until it stops (finger tight). the cylinder head, tighten the unit injector
hold down bolt to specification.
Page 140
207
Remove any oil from the injector hold down bolt

holes to avoid hydraulic lock for this step and
when the injector is installed.
206
Figure 207 — Flaring Copper Sleeve Using Installation

Tool
1. Flaring Tool 88800196
11. Remove the sleeve installation tool from the

injector bore.
Figure 206 — Injector Yoke and Sleeve Installation Tool
12. Using brush, J 42885-9, and extension,
10. Flare the copper sleeve by turning the nut J 42885-1, ensure that the copper sleeve
(1) clockwise while holding the spindle until bore is clean. Insert a new washer and the
the swaging bit has been pulled completely injector or a sealing plug, 9998251.
If the injector is not being installed immediately,

Failure to hold the spindle can result in a twisted install the sealing plug into the injector bore to
or broken swaging bit. protect it from debris.
The swaging tip has three sections of increasing

diameter. Resistance increases as the swaging
tip advances through the hole. Continue to pull
the tip until it is free of the hole.
Page 141
208 209
Figure 208 — Unit Injector Bore Sealing Plug Figure 209 — Expansion Plug Installation
1. Socket and Extension 2. Hammer

Expansion Plug Replacement
[213 FP] Valve Inspection
1. Inspect the valves for cracks, pits and other
The cylinder head has three expansion plugs of
conditions that may cause improper
different sizes.
operation.
— 29 mm (1-9/64 or 1.142 inch)
2. Inspect the stem ends of the valves for nicks
— 40 mm (1-37/64 or 1.575 inch) and burrs that may damage the seals at
assembly.
— 50 mm (1-31/32 or 1.968 inch)
3. Measure the valve seat angle.
All are installed using the following procedure:
4. Measure valve stem length and diameter.
1. Clean the plug bore thoroughly.
5. Discard and replace damaged or worn
2. Apply Loctite® 277 sealer, or equivalent, to valves.
the expansion plug and plug bore.
3. Using a socket, extension and a hammer,
press the expansion plug into the plug bore.
4. Repeat steps 1–3 for each new plug.
The plug should be installed flush to 0.508 mm

(0.020 inch) below the surface.
Page 142
Valve Installation
210
Figure 210 — Valve, Springs and Stem Seals
1. Inlet Valves and Springs 4. Exhaust Port

2. Exhaust Valves and Springs 5. Inlet Port
3. Valve Stem Seal
211
The inlet and exhaust valve head diameters are

different. Take care when installing the valves.
Incorrect installation may result in engine failure
with extensive damage.
1. Using engine oil, lubricate the valve stems.

2. Slide the stem back and forth in its guide to
spread the lubricant.
3. Using the appropriate valve seal installer,
85112460, assemble the seals on the valve
guides.
4. Drop a bottom washer, a spring set and a
top washer over each stem.
5. Using the spring compressor, 9990210, to Figure 211 — Valve Spring Keeper Installation
compress the springs, assemble the
keepers on the stems. 1. Valve Spring Compressor 2. Valve Spring
9990210
Page 143
ROCKER ARM SHAFT BENCH Rocker Arm Shaft Disassembly
PROCEDURES
(MACK MP8 EURO 3 ENGINE) WITH OR WITHOUT ENGINE BRAKE
[213 LP] Disassemble the shaft and components as

follows.
1. Mark the rocker arms and bridges so they
Description can be put back in their original locations.
The MP8 rocker arm shaft assembly is held in 2. Slide the rocker arms off the shaft.
213
place by the same screws that hold the inboard
ends of the camshaft bearing caps. A specific
sequence for tightening these screws is
described in the ENGINE TORQUE
SPECIFICATIONS section.
212
Figure 213 — Rocker Arm Removal
Figure 212 — Rocker Arm Shaft Assembly
Page 144
Inspection 2. Lubricate the shaft and the rocker arm
bores. Then, slide the rocker arm sets onto
the shaft according to the markings made at
ALL COMPONENTS disassembly.
214
1. Inspect all components of the rocker arm
assembly for damage and excessive wear. If
the roller does not move or binds, replace
the rocker arm.
2. Check the valve and piston action on the
exhaust rocker arms for any signs of binding.
Replace as necessary.
3. Inspect the rocker shaft for galling, scoring
or excessive wear. Replace as necessary.
Rocker Arm Shaft Assembly
WITH OR WITHOUT ENGINE BRAKE

The assembly procedure for the rocker arm shaft
is described below.
1. Arrange the rocker arms in sets according to
the markings made at disassembly.
Figure 214 — Rocker Arm Lubrication
Page 145
CAMSHAFT BENCH
PROCEDURES
The vibration damper and camshaft timing gear
are separate components attached to the shaft by
Camshaft Inspection the same screws.
[213 CH]
The timing gear and vibration damper can be
removed while the camshaft remains on the
CAMSHAFT GEAR REMOVAL
cylinder head.
1. Provide means of controlling the damper
and gear when the attaching screws are
Handle the camshaft carefully to avoid bending it. removed.
Slight but harmful bends can go unnoticed. 2. Remove the attaching screws.
Failure to heed this caution could result in
premature engine failure. 3. Set aside the damper and gear in a safe
place.
215
Figure 215 — Camshaft Assembly Components
1. Spacer 5. Upper Bearing Cap

2. Vibration Damper 6. Bearing Inserts
3. Camshaft Gear 7. Thrust Bearing Inserts
4. Camshaft 8. Lower Bearing Cap (Support)
Page 146
INSPECTION CAMSHAFT GEAR INSTALLATION
1. Clean the camshaft thoroughly. The camshaft can be installed on a properly
installed cylinder head before attaching the timing
gear and vibration damper.
1. Using two or three attaching screws, loosely
If any component displays cracking, pitting, assemble the damper, gear and shaft.
scoring or excessive wear, replace it.
2. Install the remainder of the screws loosely.
2. Inspect the camshaft, lobes and journals. 3. Tighten the screws according to the
sequence specified in the ENGINE
3. Inspect the camshaft gear.
TORQUE SPECIFICATIONS section.
4. Inspect the vibration damper.
Page 147
EXHAUST PRESSURE GOVERNOR, OVERHAUL
Special Tools

9992610 Drift (Available)
9998246 Valve Spring Installer (Available)
Page 148
216
Figure 216 — Exhaust Pressure Governor
1. Set Screw 13. Cover

2. Bolts 14. Heat Shield
3. Plunger 15. Securing Flange
4. Seals 16. Nut
5. Plunger Rod 17. Nut
6. Spring 18. Housing
7. Spring Holder 19. Seals
8. Spring 20. Seals
9. Seal 21. End Cover
10. Shutter 22. End Cover Bolts
11. Valve Keepers 23. End Cover Fitting
12. Bolts
Page 149
Disassembly
218
1. Remove the end cover from above the

plunger.
2. Remove the bolts and take out the plunger.
3. Remove the seals (4, 20 and 19). Refer to
Figure 216.
4. Remove the set screw on the plunger rod.
5. Place the exhaust pressure governor into a
press. Compress the spring enough to
remove the valve keepers.
Do not press more than necessary to remove the

keepers. Compressing the spring fully can
damage the cover.
217
Figure 218 — Removing Spring Holder
9. Clean all parts and replace any that are

damaged or worn.
Assembly
1. Install the plunger rod into the housing from
behind so as to center the spring holder.
Install a new seal with the beveled edge
facing inside the housing. Install the spring
and a new spring holder.
219
Figure 217 — Removing Valve Keepers
1. Tool 9998246 2. Valve Keepers
6. Remove the plunger rod, spring and shutter.

7. Remove the bolts holding the cover, heat
shield and securing flange.
8. Carefully tap out the spring holder that
secures the spring and seal (9) (Figure 216).
Figure 219 — Housing Assembly
Page 150
2. Put the plunger rod onto drift 9992610 in a
221
press. Using drift 9998225, press on the

spring holder until it bottoms in the housing.
Remove the plunger rod. Check to make
sure that the spring holder is correctly
centered.
220
Figure 221 — Depressing Spring
1. Tool 9998246 2. Spring
6. Install the set screw into the plunger rod.

Apply sealant to the set screw before
Figure 220 — Plunger Rod Installation installing. Tighten the set screw to
specification.
1. Tool 9998225 2. Tool 9992610
7. Install a new seal into the plunger rod and
install the plunger. Apply sealant to the bolts
3. Install the securing flange, heat shield and and tighten them to specification.
cover. Tighten the bolts to specification.
8. Install the end cover using new seals. Make
4. Install the shutter, spring and plunger rod sure that the seal bottoms in the housing.
into the housing. Install the seal with the flat side facing the
5. Compress the spring by hand, making sure housing. Tighten the end cover bolts to
that the shutter shaft and plunger rod fit specification.
together and that the plunger rod fits
correctly into the seal. Stop applying
pressure if undue resistance is felt. Install
the valve keepers.
Page 151
COOLING SYSTEM
COMPONENTS BENCH
PROCEDURES
Oil Cooler Reconditioning

[215 DW]
The oil cooler cannot be disassembled. Should it
fail, replace it.
222
Figure 222 — Oil Cooler Assembly
1. Cooling Duct Cover 3. Flow Plate

2. Oil Cooler
Page 152
ENGINE REASSEMBLY
MACK MP8 Euro 3 Engine
[200 EA]
Special Tools

9990008 Set of Test Pins
9992000 Handle with various uses (fits 25 mm hole),

use with 9990113 (Essential)
9992564 Driver for Installation of Pilot Bearing, use

with 9991801 (Essential)
9998170 Front Cover Spacer Ring (Essential)
Page 153
9998238 Rear Main Seal Remover/Installer, use with
9992000 (Essential)
9998267 Guide Tool (Essential)
9998531 Piston Ring Compressor (Essential)
9998649 Stiffening Frame Tool
Page 154
85109208 Bearing Cap Press Tool (Essential)

(Essential)
85111422 Upper Rear Cover Alignment Tool

(A, B) (Essential)

(Essential)
Page 155
88800022 Cooling Duct Cover Installation Tool
88800031 Camshaft Sensor Depth Gauge (Essential)
J 42885 Injection Bore Cleaning Kit (Essential)
J 44392 Belt Tensioner Release Tool (Essential)
J 44514-B Engine Timing Kit (Essential)
Page 156
Page 157
General Instructions Crankshaft Installation
[210 EN] [212 HP]
This section includes step-by-step procedures for
complete reassembly of the engine. Major
components that were inspected and overhauled The crankshaft is heavy. Do NOT attempt to
or replaced under the respective bench install the crankshaft without the help of an
procedure sections of this manual are reinstalled assistant or the use of a suitable lifting
here as assemblies. Screw tightening sequences, device. Failure to heed this warning may
torque specifications and sealant application result in severe personal injury and
patterns for major component parts appear in this component damage.
section and also in the ENGINE TORQUE
SPECIFICATIONS section.
1. Perform a visual inspection of the crankshaft
journals, block and bearing caps for signs of
wear and/or damage. Check the back of the
bearing for bearing size. Bearings can be
Failure to follow the sequence of operations stamped as “STD” for standard, or with a
may result in damage to components or number indicating the oversize of the
personal injury. bearing insert (shell).
2. Clean the main bearing seats in the cylinder
block and install new bearing inserts
(shells). Lubricate the bearing insert
앫 After cleaning the components, store them surfaces with engine oil.
where they will remain clean until needed for
reassembly.
앫 When required for installing components, be
The bearing shells should not be lubricated on
sure to use clean engine oil of the approved
the outside.
type.
223
앫 Do not reuse M8 bolts. Lubricate threads,
washers and under screw heads with clean
engine oil except as noted.
앫 Do not lubricate coated bolts.
Room temperature vulcanizing (RTV) sealant

cures in 20 minutes of exposure to the
atmosphere. If it should cure before assembly of
mating components, remove it and apply fresh.
Figure 223 — Main Bearing (Upper)
1. Locating Tab 2. Bearing
Page 158
3. Using the crankshaft lifting tool, J 49002, 3. Lubricate the threads of the fasteners with
carefully position the crankshaft in the clean engine oil and insert in the caps.
cylinder block.
224 4. Position the No. 1 bearing cap over the No. 1
crankshaft journal and start the capscrews in
the threaded holes in the cylinder block.
Make sure the bearing caps are correctly fitted

(see markings on the cap).
5. Using a plastic mallet, tap the bearing cap

down until it contacts the machined
mounting surface.
6. Tighten the capscrews finger-tight.
226
Figure 224 — Crankshaft Installation
Main Bearing Cap Installation

[212 HH]
1. Clean the bore in the bearing cap and back
of the lower bearing.
2. Install the bearing in the bearing cap. The
bearing must be installed dry.
Figure 226 — No. 1 Main Bearing Cap — Assembled

Lubricate the bearing insert surfaces with clean
engine oil. 1. No. 1 Main Bearing Cap 3. Cap Attaching
2. Crankshaft Hub Capscrews
225
7. Repeat the above steps for the bearing cap

Nos. 2, 3, 5, 6 and 7. The center bearing
cap, No. 4, is installed later.
8. Using a torque wrench, tighten the bearing
capscrews according to specification.
앫 Thrust washers are steel with a bronze

facing. The facing has oil grooves cut into
the material.
앫 Use standard thickness thrust washers
Figure 225 — Main Bearing Cap Installation (Lower) initially.
1. Locating Tab 3. Bearing Cap

2. Bearing Insert
Page 159
9. Place the upper thrust washer sections in
228
position in the cylinder block at the center

bearing location. The steel side of the thrust
washer faces the block. The bronze side
faces the crankshaft. This applies to both
upper and lower thrust washer sections.
227
Figure 228 — Main Bearing Cap/Thrust Washer

Installation
1. Thrust Washer, Lower 2. No. 4 Main Bearing Cap

Insert
11. Using a torque wrench, tighten the

capscrews according to specification.
12. Using a suitable pry bar, move the
crankshaft toward the front or rear of the
engine until it stops.
13. Using the pry bar, move the crankshaft in the
opposite direction.
Refer to allowable crankshaft end play tolerances

under Fits and Limits in the SPECIFICATIONS
Figure 227 — Crankshaft Thrust Washer Installation section.
1. Thrust Washer Groove 3. No. 4 Crankshaft Journal

2. Thrust Washer, Upper
Insert
10. Position the lower thrust washer sections on

the center bearing cap with the bronze side
facing the crankshaft and assemble the cap
and capscrews in the engine block.
Lubricate thrust washer sections with engine oil

upon installation.
Page 160
14. Using a magnetic base indicator tool with its Piston and Connecting Rod
tip against a crankshaft counterweight,
check crankshaft end play as follows. Assembly Installation
a. Set the dial indicator to zero. [212 NP, 212 LP]
b. Using the pry bar, move the crankshaft
endwise and read the indicator. PISTON AND ROD ASSEMBLY
c. If end play is out of specification, 1. Rotate the crankshaft so that the journals for
remove the thrust washers and install the No. 1 and No. 6 cylinders are at Bottom
washers of suitable thickness to meet Dead Center (BDC).
specification. 229
The thickness of the thrust washers in the bearing

cap must match the thickness of the thrust
washers in the block. Be sure to put the bronze
bearing surface against the crankshaft. Failure to
heed this caution may result in severe component
damage.
15. Using a torque wrench with the correct

thrust washer sections in place, tighten all
bearing cap capscrews according to
specification.
16. Recheck the end play to be sure that the
thrust washers have been installed correctly
and that end play is within specification.
17. Rotate the crankshaft by hand several
rotations to verify that the bearings have
been properly installed and that the Figure 229 — No. 1 Cylinder (Crankshaft at BDC)
crankshaft turns freely.
1. Crankshaft 2. No. 1 Journal
2. Apply a light coat of clean engine oil to the

piston and rings. Check that the piston ring
gaps are equally displaced around the
circumference of the piston at a 120-degree
relationship to one another.
inside surface of the piston ring compressor
tool.
4. Carefully clean the bearing contact on the
connecting rods and bearing caps. Also,
clean the bearing seats.
5. Position a new upper bearing insert into the
connecting rod. Align the tab in the bearing
with the notch in the rod.
Page 161
9. Using the ring compressor, slide the piston
and rod assembly into the cylinder until the
compressor contacts the top of the liner.
The bearing size is found on the back of the
bearing shell.
230
The arrow on top of the piston and the word

FRONT on the connecting rod must be facing the
front of the engine. This ensures that the notch in
the lower rim of the skirt clears the piston cooling
nozzle.
232
Figure 230 — Connecting Rod Bearing Shell

bearing surface.
inside surface of the cylinder liner.
8. Temporarily remove the press tool, 9996966,
when the piston is to be installed. Reinstall
the press tools when the piston is in position.
231
Figure 232 — Piston and Connecting Rod Installation
1. Connecting Rod 2. Piston Ring Compressor

Assembly Tool
3. Cylinder Block
10. Make sure the connecting rod is aligned with

the crankshaft journal.
Figure 231 — Piston Installation
1. Piston Ring Compressor, 2. Press Tool, 9996966

9998531
Page 162
11. While using a hammer handle to push the 13. Ensure that the correct cap is fitted to the
piston through the tool, apply pressure to the correct connecting rod (refer to the marks).
ring compressor tool to maintain contact with 234
the cylinder liner. Continue pushing the

piston until the top ring has passed into the
cylinder liner.
233
Figure 234 — Connecting Rod Bearing Shell
14. Install the fasteners and tighten to

specification.
235
Figure 233 — Pushing Piston into Cylinder Sleeve
1. Piston Ring Compressor 2. Piston

Tool 3. Cylinder Block
Do not use excessive force on the piston. High

resistance indicates an incorrectly aligned ring. Figure 235 — Connecting Rod Cap Installed
Remove the piston assembly, correct the
problem, and then reinsert it. Make sure the 1. Connecting Rod Cap 2. Attaching Capscrews
compressor tool remains in contact with the
cylinder sleeve until the piston clears the tool. 15. Repeat the above steps to install the No. 6
Failure to heed this caution may result in severe piston.
engine damage.
16. Rotate the crankshaft so that the journals for
the No. 2 and No. 5 cylinders are at bottom
12. Lubricate the crankshaft bearing inserts and dead center and install the No. 2 and No. 5
crankshaft journals with engine oil. pistons following the above steps.
Page 163
17. Rotate the crankshaft so that the journals for
237
the No. 3 and No. 4 cylinders are at bottom

dead center and install the No. 3 and No. 4
pistons, again following the above steps.
18. Install all piston cooling nozzles using new
fasteners. Tighten the fasteners to
specification.
236
Figure 237 — Oil Pump Fastener Access
Figure 236 — Piston Cooling Nozzle Installation

2. Torque-tighten pump fasteners to
specification.
1. Piston Duct 3. Piston Cooling Nozzle
2. Attaching Screw
BLOCK STIFFENER FRAME
Oil Pump and Block Stiffener Plate 238
Installation
[211 DD]
OIL PUMP
Clean the oil pump mounting surface of the rear

main bearing cap before installing the new oil
pump.
1. Position the oil pump to the rear main Figure 238 — Block Stiffener Plate
bearing cap and install the pump fasteners.
The engine stiffening frame has sharp edges

The crankshaft may need to be rotated to allow that can cause injury. To prevent injury, wear
access for the oil pump fasteners. protective gloves when handling.
Page 164
1. Assemble the stiffener plate on the block 2. Assemble the oil strainer, suction, pressure
with new fasteners. Do NOT tighten the and crossover pipes into the pump as
fasteners at this time. follows:
앫 Slide the oil pressure pipe into the oil
pump, position the pipe flange to the
cylinder block, install the fasteners and
앫 The engine stiffening frame attaching torque-tighten to specification.
fasteners are ONE TIME USE ONLY. New
fasteners must be installed. 앫 Position the oil crossover pipe to the
skirts of the cylinder block, install the
앫 The available tool, 9998649, can be used to fasteners and torque-tighten to
hold stiffening frame in position while specification.
fasteners are started.
앫 Assemble the oil strainer and oil pickup
pipe. Slide the oil pickup pipe into the
2. Install the oil pressure pipe and the
oil pump, position the oil strainer to the
crossover pipe before torque-tightening the
engine stiffening frame, install the
stiffening frame.
fasteners and torque-tighten to
3. Using a torque wrench, tighten the attaching specification.
fasteners in sequence according to 240
specification.
Oil Pump Pipes and Strainer

Installation
[219 MU, 219 NT]
1. Replace the O-rings on the oil pressure pipe,
oil suction pipe and oil crossover pipe.
Lubricate the O-rings with engine oil before
installation.
Figure 240 — Oil Pump Pipe Installation

Separate the oil suction pipe from the oil strainer
as needed to replace the O-ring. Clean and
inspect the oil strainer, suction pipe, crossover
pipe and pressure pipe for cracks. Replace if
necessary.
239
Figure 239 — Oil Pump Pipe O-Ring Replacement
Page 165
Front Engine Support Installation
242
[299 GV]
1. If removed, assemble the front engine
support mounting bracket to the cylinder
block and tighten fasteners to specification.
The bracket also serves as the A/C compressor

mount.
2. Assemble the front engine support onto the

block mounted brackets and install the six Figure 242 — Crankshaft Front Cover Seal Installation
fasteners.
1. Front Main Seal 2. Plastic Spacer, 9998170
3. Using a torque wrench, tighten all fasteners Remover/installer,
in sequence to specification. 88800021
241
2. Apply a 2 mm (5/64 inch) bead of

MACK-approved silicone sealant to the rear
face of the cover according to the pattern
shown.
Make sure that the crankshaft front cover and

block flanges are cleaned thoroughly before
applying sealant.
243
Figure 241 — Front Engine Support
Crankshaft Front Cover and Seal

Installation
[211 JB]
1. Place the crankshaft front cover with spacer,
9998170, in the center on a flat surface.
Install a new crankshaft seal with plastic ring
in the crankshaft front cover. The spacer ring
prevents the plastic ring from sliding off.
Carefully tap the crankshaft seal into the Figure 243 — Sealant Application Pattern — Crankshaft
Front Seal Cover to Block
front cover with drift, 88800021, and handle,
9992000, until the crankshaft seal is level
A. 2 mm (5/64 inch) bead of MACK-approved silicone
with the front cover. sealant
Page 166
3. Within 20 minutes of sealant application,
245
install the front cover to the engine block.

Center the crankshaft front cover against the
crankshaft using the plastic ring.
4. Install the front cover. Note that there are
two different types:
244
Figure 245 — Front Cover Torque Sequence

Figure 244 — Crankshaft Front Cover
6. Remove the plastic ring from the crankshaft
앫 For earlier type (A), the following
hub. Drive in the crankshaft seal with drift,
installation instructions apply:
88800021, and handle, 9992000, until the
Install the bolts without tightening them. drift bottoms against the crankshaft.
Using a straightedge rule, make sure 246
the cover is flush with the lower edge of

the engine block.
앫 For later type (B), the following
installation instructions apply:
Install the bolts in both bolt holes that
align the cover to the correct position.
Tighten by hand so that the cover is
fixed. Install the remaining bolts.
For the later type cover, the left-hand hole is

smaller and the right-hand hole is oval. This
change allows the later cover to be correctly
aligned.

capscrews in sequence according to
specification.
Figure 246 — Crankshaft Front Seal Installation
7. Remove the tool and check the seal to be

sure it has been evenly installed.
Page 167
Timing Gear Plate Installation
247
[211 AA]
Rotate the engine block so the rear surface is at

the top.
If the cylinder head is installed after the timing

gear plate is in place, do not apply sealant in the
cylinder head area until ready to assemble the
head on the block.
1. Clean the timing gear plate on both sides.

2. Clean the contact surfaces on the engine
block and cylinder head. Remove sealing Figure 247 — Sealant Application Patterns — Head and
compound from the groove on the engine Block to Plate
block side.
3. Apply a 2 mm (5/64 inch) bead of 342SX33 4. Within 20 minutes of the application of the
MACK approved silicone sealant (A) to the sealant, assemble the timing gear plate over
front face of the plate according to the alignment guides, 9998267, that were
pattern shown. installed into the block at disassembly.
248
Sealing compound must be applied outside the

groove in the timing gear plate. This causes the
excess compound to be forced down into the
groove, which allows for better sealing.
Figure 248 — Gear Plate Installation
5. With timing gear plate in position over guide

pins, install new timing gear mounting
attaching fasteners.
Page 168
6. Using a torque wrench, tighten the attaching Cylinder Head Installation
fasteners in sequence according to
specification. [213 EV]
Clean away excessive sealing compound before The cylinder head is heavy. Do NOT attempt to
it dries. install the cylinder head without the help of an
249 assistant and the use of a suitable lifting
result in severe personal injury and
component damage.
All MACK head gaskets are precoated and do not

require any type of additional sealing compound.
1. If necessary, clean the unit injector copper

sleeves with brush J 42885-9 and extension
J 42885-1 with J 42885-25 installed to
protect the fuel passages. These tools are
available in kit J 42885.
251
Figure 249 — Timing Gear Plate Torque Sequence
7. Install the compressor stud with a new

sealing ring and new fastener.
250
Figure 251 — Injector Copper Sleeve Cleaning
With any cleaning of the unit injectors, under no

circumstances may rotary wire brushes, hand
wire brushes or similar tools be used on the
injector nozzle. Use of such tools poses a risk
that the injector holes could be damaged and
Figure 250 — Compressor Stud
blocked, causing power delivery problems.
Instead, use a rag soaked in paraffin or
8. Remove alignment guides, 9998267, from
equivalent.
the timing gear plate.
Page 169
2. Install fuel injector bore plugs, 9998251. 6. Apply a 2 mm (5/64 inch) thick bead of
silicone sealant to the surface at the side of
3. Ensure that the engine block and deck are
the “track” on the timing gear plate (as
clean and free from any dirt, grease or oil.
shown in the illustration).
4. Carefully clean the cylinder head and install
the head lifting tool, 88800188. Check that
the guide washers on the engine block and
cylinder head are clean and free of rust. The cylinder head must be installed and
252
torque-tightened within 20 minutes after the
sealant has been applied.
254
Figure 252 — Guide Washer Locations
1. Cylinder Head 3. Cylinder Block

2. Guide Washers Figure 254 — Sealant Application Pattern — Head to
Plate
5. If in place, remove the cylinder liner
clamping tools, 9996966, from the block. 7. Place a new head gasket on the engine
253 block deck.
앫 Check that the seals are correctly positioned

with their holes all centered.
앫 There are points embossed in the gasket
that will temporarily protect the seals from
the head. These will be compressed when
the head bolts are tightened.
앫 The head gasket should be discarded if the
head is removed. A new gasket should be
used when the head is installed.
Figure 253 — Cylinder Liner Clamping Tools
Page 170
8. Carefully lower the cylinder head about 9. Temporarily install the adjustable idler gear
9 mm (3/8 inch) forward of the gear hub and insert bolts through the timing gear
mounting plate until it makes contact with plate and the adjustable idler gear hub.
the cylinder head gasket. Press the cylinder Tighten the bolts to 85 ±15 N•m
head against the timing gear cover and the (63 ±11 lb-ft) to draw the cylinder head
guide washers at the left side. (There are toward the plate.
two guide washers on the cylinder block and
one on the cylinder head.)
If not loosened, there is a risk that the bolts will

break when the cylinder head bolts are tightened.
A three-step process is used for installation of the
cylinder head. 10. Check the condition of the cylinder head
a. It is first lowered onto the block deck attaching capscrews and lubricate the heads
and gasket, about 9 mm (3/8 inch) (underside) and threads with clean engine
forward of the gear plate. As it is oil.
lowered, the guide washers ensure
proper alignment of the cylinder head
with the left side of the cylinder block.
Do NOT oil the threads in the block.
b. Once lowered, screws inserted through
the adjustable idler gear hub and plate
are used to draw the cylinder rearward 11. The cylinder head capscrews must not be
against the plate. used more than five times. Mark the cylinder
head capscrews by punching them.
c. In the final step, the head bolts are
inserted and tightened to specification, 12. Insert four cylinder head capscrews into
securing the cylinder head to the block. locations 24, 26, 28 and 30. Tighten the
capscrews to specification.
255
13. Remove the cylinder head lifting bracket.
14. Torque-tighten and angle-tighten all cylinder
head capscrews in sequence to
specification.
15. Install the fasteners securing the timing gear
plate to the rear of the cylinder head.
Tighten the fasteners to specification.
16. Ensure that the crankshaft is at the top dead
center (TDC) position and assemble the
camshaft, camshaft gear and damper
according to the instructions under Timing
Gear Train Installation.
Figure 255 — Guide Washer Locations
1. Cylinder Head 2. Guide Washers

3. Cylinder Block
Page 171
Camshaft Installation
257
[213 CH]
The camshaft is heavy. Do NOT attempt to

install the camshaft without the help of an
result in severe personal injury and
component damage.
1. If removed, install the camshaft bearing Figure 257 — Camshaft Installation

saddles to the original positions. Carefully
tap the bearing saddles onto the guide pins 6. Install the camshaft upper bearing inserts
using a soft-faced hammer until fully seated. into the camshaft bearing caps, lubricate the
2. Insert the camshaft lower bearings and bearings and install the bearing caps to the
apply a generous coating of clean engine oil respective bearing saddles. Use a soft-faced
to the camshaft bearings. mallet to seat the bearing caps over the
dowel pins.
3. Make sure there is a bearing insert on each
lower bearing saddle. The bearing inserts at 7. Insert and hand-tighten the exhaust side
the No. 7 camshaft journal have integral bearing cap bolts and tighten to
thrust washers. specification. Final tightening to the
256 specified torque value will be done later
when the rocker arm shaft is installed.
8. Install the bearing cap press tool (two
required) at the number 7 and the number 1
bearing caps as shown in the illustration.
The tool is used when adjusting the timing gear

backlash when the rocker shaft assembly is not
installed.
258
Figure 256 — No. 7 Camshaft Lower Bearing Insert
4. Clean and inspect the camshaft using

solvent and compressed air.
5. Lower the camshaft carefully into place on
the lower bearing saddles and remove the
lifting tool, 85109034. Rotate the camshaft
by hand to ensure the camshaft is not
binding on the lower bearing saddles.
Figure 258 — Bearing Cap Press Tool
Page 172
Timing Gear Train Installation 3. Assemble the adjustable idler gear (item 3 in
Figure 260), hub, bushing, thrust washer
and fasteners on the plate. Hand tighten the
fasteners.
260
Apply a light coat of clean engine oil to all parts
before assembly.
DO NOT overtighten the mounting flange

fasteners when installing any of the gears in the
timing gear train. Overtightening the fasteners
can cause stripped threads in the cylinder block.
1. Assemble a new O-ring on the crankshaft

rear hub.
2. Apply a film of oil to the O-ring and assemble Figure 260 — Adjustable Idler Gear
the crankshaft gear on the crankshaft hub.
Gearset Gear
Leave two fasteners loose enough to aid in 4. Camshaft Gear Gear
turning the crankshaft with a lever for gear 8. PTO Drive Gear
alignment purposes.
259 4. Check that the camshaft is positioned at
TDC.
261
Figure 259 — Crankshaft Gear-to-Hub Assembly
1. Crankshaft Rear Hub 3. Crankshaft Gear Figure 261 — Camshaft Positioning

2. O-Ring
Page 173
5. Align the punch marks on the camshaft gear 7. Remove the alignment pin and clamp plate
teeth to straddle the alignment hole in the tool from the camshaft gear and install the
timing gear plate and install the camshaft vibration damper and clamp plate using new
gear without the damper as shown in fasteners. Tighten the fasteners to
Figure 262. Install the clamp plate tool, specification.
J 44514-1A, using Position B of the gauge
plate tool to secure the camshaft gear to the
camshaft and loosely install the two
retaining bolts. Mark the bolts to aid in tightening the bolts to the
262
degree rotation specification.
8. Insert a 0.1 mm (0.004 inch) thickness

gauge. Adjust the idler gear so that there is
slight pressure on the thickness gauge.
Tighten the bolts by hand only.
264
Figure 262 — Camshaft Gear Check
6. Insert the alignment tool J 47450-1, into the

hole in the cylinder head to engage the
camshaft gear teeth with the rod of the tool
in the slot of the clamp tool. It may be
necessary to rotate the camshaft until this
Figure 264 — Camshaft Thickness Gauge Check
occurs. With the alignment pin properly
positioned in the clamp plate slot, check that
9. Remove the thickness gauge.
the camshaft TDC mark is still positioned
between the two timing marks on the
bearing cap.
263
There should be a slight resistance on the

thickness gauge when removed.
Figure 263 — Camshaft Gear Timing Marks Alignment
Page 174
10. Install the J 44514-5 clamp assembly tool to
266
the timing gear plate. Screw the hold-down

against the adjustable idler gear so the
adjustable idler gear does not rotate.
265
Figure 265 — Clamp Assembly Tool
11. Install the magnetic stand, 9999696, and Figure 266 — Camshaft Backlash Check
dial indicator, 9999683, so that the tip of the
dial indicator rests on a tooth of the 1. Idler Gear 2. Camshaft Gear
camshaft gear.
Check the gear backlash by rotating the 12. If the backlash measurement is out of
camshaft gear back and forth slightly to specification, adjust the gear flank clearance
measure the backlash. For backlash as follows:
specification, refer to the SPECIFICATIONS
section. a. Loosen the J 44514-5 clamp assembly
tool from the adjustable idler gear hub.
b. Loosen the adjustable idler gear hub
screws slightly. Loosening the hub
screws will allow the idler gear to be
moved slightly in/out from the camshaft
gear.
c. Insert a 0.1 mm (0.004 inch) thickness
gauge on the pressure side of the
adjustable idler gear tooth and
camshaft gear tooth by using feeler
gauge holder J 44935 and J 44514-6
feeler gauge.
d. While holding the adjustable idler gear
in against the thickness gauge and
camshaft gear, tighten, but DO NOT
torque the adjustable idler gear hub
fasteners.
e. Reinstall and tighten the J 44514-5
clamp assembly tool against the
adjustable idler gear.
Page 175
f. Remove the feeler gauge from the 15. Tighten the intermediate gearset (double
adjustable idler gear and camshaft idler) mounting bolts in sequence to
gear. specification.
g. Recheck the backlash. With the 16. Install the auxiliary idler gear onto the timing
specified backlash attained, replace gear plate.
each adjustable idler gear hub screw
17. Remove the bearing cap press tools,
with new and tighten the screws to
85109208.
specification one at a time so the
attained backlash is not disturbed.
13. Install the intermediate idler (double idler) Unit Injector Installation
gearset (2) to the timing gear plate, using
new fasteners. [221 GP]
267
If a unit injector is reused, it must be fitted to the

bore from which it was removed.
1. If not previously performed, install protective

sleeve, J 42885-25, and clean the unit
injector copper sleeve with the appropriate
brush and extension.
269
Figure 267 — Intermediate Idler (Double Idler) Gearset

Gearset Gear
4. Camshaft Gear Gear
8. PTO Drive Gear
14. Check that the idler gear marking aligns with

the markings on the crankshaft gear teeth.
268 Figure 269 — Unit Injector Copper Sleeve Cleaning
After cleaning the copper sleeve, carefully inspect

the inside surface of the sleeve, especially the
bottom surface where the injector seal is located.
Any remaining contamination is unacceptable
and must be removed. Also, if there is any
indication of a discrepancy that raises concern
about suitability of the sleeve for reuse, replace it
with a new sleeve.
Figure 268 — Camshaft and Double Idler Gear Check
Page 176
2. Before reusing an injector, cleaning is
271
required to ensure suitability for reuse.

Before doing any cleaning, the injector fuel
inlet and outlet ports and the electrical
connector opening must be covered to
prevent contamination from the cleaning
process. Also, there must be no lower O-ring
installed in the injector. Refer to “UNIT
INJECTOR CLEANING” on page 244 for
further information.
3. Remove the bore protection sleeve,
9998251.
270
Figure 271 — Injector Nozzle Gasket
Some early production MP8 engines used the

original design copper sleeves with integral
“raised bead” at the bottom of the copper sleeve.
This design does NOT use a gasket (flat washer)
between the injector tip and the copper sleeve.
These original raised-bead design copper
sleeves can be identified by a single groove, or no
groove at all around the upper circumference.
Figure 270 — Unit Injector Bore Protection Sleeve The current production “flat-bottom” design
copper sleeves, which require the gasket (flat
1. Unit Injector Protection 2. Unit Injector Bore washer) at the injector tip, can be identified by
Sleeve, 9998251
two grooves around the upper circumference of
the sleeve.
4. Install new O-rings on the unit injector as
272
follows:
앫 Upper ring — large diameter, violet
앫 Lower ring — small diameter, violet
5. Lubricate both O-rings and the cylinder head
injector bore with clean engine oil.
6. Install a new injection nozzle gasket (flat
washer) on the injector, using hand force to
push it over the tip and down until it is fully
seated against the bottom of the injector. DO
NOT use grease or any other material to
secure the gasket to the injector; the gasket
must be installed dry. Three small
projections (grippers) on the inside diameter
of this gasket retain it to the injector during
installation.
Figure 272 — Copper Sleeve (Shown Removed for

Clarity)
Page 177
10. Ensure that the injector electrical connector
is central between the valve springs with
equal space on both sides. If the harness is
A revised gasket (flat washer) having a thin black installed, plug in the injector electrical
rubber coating for improved sealing was connector until fully engaged. Push in the
implemented in production beginning mid-August connector until you hear a distinct “click”.
2008. Service replacement gaskets now have the 274
rubber coating. DO NOT remove the rubber

coating.
The gasket (flat washer) is preassembled on new
injectors.
7. Slip the injector hold down and a new screw

of correct length onto the unit injector.
273
Figure 274 — Electrical Connector for Unit Injector

hold-down screw in stages to specification.
12. When replacing unit injectors, the control
unit must be programmed with the new
injector's trim codes. The code is printed on
Figure 273 — Unit Injector Retainer
top of the unit injector electrical connector.
The programming is performed using
1. Injector Hold-Down Yoke 2. Unit Injector
VCADS/TT and is necessary to ensure that
engine timing and emission levels are
correct.
8. Make sure that the injector is reinstalled to 275
the same cylinder from which it was
removed (or injector trim codes will need to
be reprogrammed in the EECU).
9. Center the unit injector between the valve
springs and then push down on the unit
injector using hand pressure to seat the
O-rings. Hand tighten the new hold-down
screw.
The unit injector hold-down screw must be

replaced whenever it is removed from the
hold-down and cylinder head Figure 275 — Injector Trim Codes
Page 178
3. Set the yokes on their respective valve
stems. Make sure that they are properly
seated.
앫 Due to the Engine Electronic Control Unit
(EECU) self learning capability, it is
necessary to reset learned EECU Rocker Arm Shaft and Engine Brake
parameters after servicing some Installation
engine-related components. This allows the
EECU to learn the new component's [213 LP]
behavior. After servicing is complete,
perform the “Learned Data Reset” located in 1. Oil the valve yokes and the camshaft lobes
VCADS/TT. with engine oil.
앫 If reinstalling an injector into the same 2. Using the lifting tool, 85109250, and an
location, reprogramming is not required. assistant, place the shaft with rocker arms in
position on the inboard side of the camshaft
13. Repeat the installation steps for the bearing caps.
remaining injectors.
Valve Yoke (Bridge) Installation On engines with an engine brake, the exhaust
rocker arm includes an integral valve and piston.
[213 NV]
277
Used yokes have established wear patterns.

Yokes being returned to service must be installed
in the same cylinder location from which they
were removed.
1. Lubricate the tip of a valve stem with a small

drop of clean engine oil.
2. Lubricate the yoke sockets with a small drop
of clean engine oil in each one.
276
Figure 277 — Rocker Shaft Assembly Installation
1. Lifting Tool, 85109250 2. Rocker Shaft Assembly
3. Remove the lifting tool. Then, install and

tighten the rocker arm shaft bolts a little at a
time, evenly across the entire shaft so that
the shaft does not become distorted, bent or
fractured.
Make sure that the rocker arm shaft is seated

Figure 276 — Installing the Inlet Valve Yoke properly in the guide dowels of the camshaft
bearing caps. On engines equipped with an
1. Valves 2. Valve Yoke engine brake, remove the restraints (rubber
bands or tie straps) securing the exhaust rocker
arm pistons.
Page 179
6. Insert all remaining fasteners into the rocker
278
arm shaft.
7. Torque-tighten and angle-tighten all
camshaft bearing cap and rocker arm shaft
bolts in sequence according to specification.
The bolts have limited reusability and must be

marked (A) with a punch each time they are
installed in service. Bolts with four punch marks
when removed have been tightened five times
and must be discarded.
280
Figure 278 — Engine Brake Restraint
4. Lubricate the rocker arm rollers.

5. Insert the long fasteners (Nos. 8–20 in
Figure 279) through the shaft, camshaft
bearing caps and into the cylinder head.
279
Figure 280 — Usage Marks on Rocker Fasteners
8. Replace the O-ring at the bottom of the

engine brake control valve (if equipped with
engine brake) or oil flow adapter.
On engines without the engine brake, an oil flow

adapter is used in place of the oil control valve. It
is mounted in the same location on the cylinder
head and is installed in the same manner as the
engine brake control valve in steps 8 through 13.
The adapter provides oil to the rocker shaft.
Figure 279 — Rocker Arm Shaft Screw Installation

Sequence
Page 180
281 283
Figure 281 — Engine Brake Control Valve O-Ring Figure 283 — Engine Brake Control Valve Pipe
Installation
9. Clean the engine brake control valve oil pipe
and replace the O-rings. Lubricate the pipe 11. Position the control valve on the cylinder
hole in the rocker arm shaft and the O-rings head.
284
on the pipe.
282
Figure 284 — Control Valve Position

Figure 282 — Control Valve Pipe O-Ring
12. Align the engine brake oil pipe and O-ring
10. Insert the oil pipe into the oil hole of the with the hole in the rocker shaft.
285
engine brake control valve.
Make sure that the O-ring is seated fully in the

valve.
Figure 285 — Engine Brake Control Valve Pipe

Installation
Page 181
15. If installed, reposition the fuel injector
harness over the control valve and secure
with high temperature tie straps (983472).
Make sure the engine brake oil pipe O-ring is fully 288
seated.
13. Install the control valve bolts and tighten to

specification.
286
Figure 286 — Engine Brake Control Valve Installation

Figure 288 — Harness Routing Over Engine Brake
14. If harness is installed on engine, plug in the Control Valve
control valve harness connector.
287
1. Tie Straps 2. Control Valve
Flywheel Housing Installation

[211 HD]
Inspect the flywheel housing machined surfaces,
bolt holes and pilot locations for cracks or wear.
Replace the housing if cracks are evident.
1. Thoroughly clean the sealing area in the
flywheel casing and the sealing surface
against the crankshaft.
2. Apply an even 2 mm (5/64 inch) thick bead
Figure 287 — Engine Brake Control Valve Connector of MACK-approved sealant to the timing
gear plate side of the flywheel housing
according to the pattern shown.
The flywheel housing must be installed within 20

minutes of the sealant being applied.
Page 182
289
If the engine was originally built with the longer

idler gear bolts, the flywheel housing may need to
be updated to block the idler gear bolt hole with a
plug and washer from plug kit 21090322. Use the
following procedure to thread the hole and install
the plug:
a. Using a 3/4-16 UNF x 11.5 tap, thread
the hole indicated in Figure 290.
b. Apply thread locking compound
(Loctite® 277 or equivalent) to the
threads of the plug.
c. Insert the plug with washer and tighten
to specification.
290
Figure 289 — Flywheel Housing Sealant Application

Pattern
Be sure to apply beads of sealant around the

holes in the bosses as shown in the graphic.
Temporarily install guide pins in the two lower

flywheel housing mounting holes in the timing
gear plate/engine block.
3. Within 20 minutes of the application of the Figure 290 — Flywheel Housing Plug
sealant, assemble the flywheel housing over
the guide pins in the timing gear plate. 5. Using a torque wrench, tighten the attaching
bolts in sequence according to specification.
4. Insert and hand-tighten the attaching bolts.
Remove the two guide pins and install the 6. Remove any excess sealant.
remaining bolts. 7. Install the timing gear plate to the flywheel
housing bolts (item 2 in Figure 291).
앫 Item 1 secures the power steering and fuel

pump mounting and is not installed at this
time.
앫 Item 3 secures the rear engine mount to the
flywheel housing and will be install upon
installation into the chassis.
Page 183
2. Lubricate the seal lips with clean engine oil.
291
3. Insert the handle, 9992000, in the

remover/installer, 9998238.
Inspect the remover/installer carefully. Any

damage on the tool will destroy the seal.
4. Position the new seal on the drift, making

sure that the seal is turned in the proper
direction. Carefully tap the seal into the
flywheel housing using the handle and drift
until the drift evenly contacts the crankshaft
gear.
Position the drift so that it does not interfere with

Figure 291 — Timing Gear Plate Attachment
the alignment dowel during installation. The rear
crankshaft seal depth is set by the drift tool when
1. Power Steering Attaching 3. Rear Engine
fully seated.
Bolts Mount-to-Flywheel 293
2. Timing Gear Housing Attaching Bolt
Plate-to-Flywheel and Nut
Attaching Bolts
Crankshaft Rear Seal Installation

[212 JH]
1. If not previously done, thoroughly clean the
sealing surfaces of the flywheel housing and
the crankshaft gear wheel.
292
Figure 293 — Crankshaft Rear Seal Installation
1. Rear Main Seal 2. Rear Main Seal Installer,

9998238
Figure 292 — Cleaning Sealing Surfaces

5. Remove the tools.
6. Inspect the seal ring for proper seating.
Page 184
Flywheel and Pilot Bearing 4. With the aid of the two lifting bolts
(M10 x 100), position the flywheel over the
Installation dowel pin and alignment studs on the
flywheel mounting surface at the rear of the
[212 VC] crankshaft.
295
After resurfacing, any flywheel with drilled

balance holes on the clutch side requires
rebalancing by a machine shop.
On vehicles equipped with an automatic

transmission, it may be necessary to install
different components to the flywheel retaining
fasteners. Refer to the Automatic Transmission
Drive Arrangement Assembly Instructions, 5-902,
for installation instructions.
1. Clean the surface in the places where the

flywheel lies flush against the crankshaft
gear wheel.
Clean the flywheel. Check that the grooved
Figure 295 — Flywheel Installation
surfaces for the flywheel sensor are clean.
294
5. Install the flywheel mounting bolts in the
exposed mounting holes. At this time,
tighten the bolts finger-tight only.
6. Remove the two alignment studs and insert
the remaining mounting bolts.
7. Remove the plug from the flywheel housing
and install cranking tool, 88800014, and a
handle as a counterhold.
296
Figure 294 — Cleaning Sealing Surfaces
2. Make sure that the flywheel guide pin is

correctly inserted in the crankshaft gear
wheel. Ensure that there is no damage or
leakage at the rear crankshaft seal.
3. Insert two alignment studs in the crankshaft
flange to aid in installation.
Figure 296 — Flywheel Turning Tool
8. Using a torque wrench, tighten the fasteners

in sequence according to specification.
Page 185
297
Do not tighten adjacent screws sequentially.

Doing so can result in uneven flywheel alignment.
Failure to heed this caution can result in severe
engine damage.
9. Remove the cranking tool. Insert the plug.

10. Using tool assembly, 9991801 and 9992564,
install a new pilot bearing in the flywheel
bore.
For this engine, NO snap ring is required on the Figure 297 — Depth Sensor Gauge
pilot bearing. Do NOT substitute pilot bearings
that do not bear the correct part number for this 12. Carefully install the flywheel position sensor
application. Failure to heed this caution may with the appropriate shim(s) and new
result in severe engine damage. O-ring. Secure the sensor with a bolt
tightened to specification and plug in the
harness connection.
11. Check for proper flywheel-to-position sensor 298
clearance using the sensor depth gauge to
determine if shims are required for sensor
depth. The flywheel position sensor
clearance specification is 0.3–1.0 mm
(0.0118–0.0393 in.).
a. Rotate the engine using the flywheel
turning tool until a tooth of the flywheel
toothed wheel is aligned with the
sensor bore.
b. Insert the tool into the sensor bore until
the outer part of the tool is fully seated
against the flywheel housing.
c. Loosen the thumb screw of the tool and
Figure 298 — Flywheel Position Sensor
push the inner part of the tool until it
contacts a tooth of the toothed wheel.
d. Tighten the thumb screw to secure the
inner part of the tool.
e. Carefully remove the tool from the
flywheel sensor bore and observe the
location of the steps between the inner
and outer portions of the tool:
앫 Both steps below the surface of
the tool = no shims required.
앫 One step below the surface of the
tool = one shim required.
앫 Both steps above the surface of
the tool = two shims required.
Page 186
Oil Pan Installation
300
[211 NB]
1. Apply a 2 mm (0.079 inch) wide bead of
MACK-approved sealant at the seams
between the flywheel housing and the timing
gear mounting plate. Also, apply a 2 mm
(0.079 inch) wide bead of sealant at the
seams between the timing gear mounting
plate and the engine block.
299
Figure 300 — Sealant Application for Oil Pan — Front
3. For plastic pan applications, install the oil

pan seal into the groove of the oil pan.
Check that the seal locating tabs are
properly aligned and seated in the locating
holes on the mounting flange.
301
Figure 299 — Sealant Application for Oil Pan — Rear
2. Apply a 2 mm (0.079 inch) bead of

MACK-approved sealant to the seam
between the front seal cover and the block.
Figure 301 — Plastic Oil Pan
Page 187
4. For steel pan applications, install the oil pan 6. Tighten the bolts from the middle and
gasket on the oil pan flange. Check that the outwards in order 1–4 as shown.
gasket locating tabs are properly aligned Torque-tighten the bolts to specification.
and inserted in the correct holes on the Finish by checking the torque for bolts A
mounting flange. and B.
302
Install the transmission oil cooler bracket studs in

locations marked previously.
7. Install the oil drain plug and torque-tighten to

specification.
Do not use a copper washer with the hex-head oil

drain plug. Always use the steel washer with the
rubber gasket.
Figure 302 — Steel Oil Pan
1. Gasket 2. Oil Pan
5. With assistance, position the oil pan to the Do not use air tools when installing the oil drain
engine block and install the bolts marked A plug.
and B. Torque-tighten the bolts to
specification. 8. Ensure that the 12 locating pins on the seal
are properly seated in the locating holes in
the mounting flange.
앫 Use care to prevent damage to the oil

pickup.
Be sure the oil pan seal is properly placed before
앫 The oil pan must be installed within
tightening the fasteners.
20 minutes of the sealant being applied.
303
9. If harness is installed, reconnect the oil
level/temperature sensor connector to the
side of the oil pan.
304
Figure 303 — Oil Pan Installation
Figure 304 — Oil Level/Temperature Sensor
Page 188
Oil Filler Pipe and Dipstick Pipe Power Take-Off Installation
Installation
If equipped with a power take-off (PTO), install
1. Install a new O-ring on the oil fill tube and the assembly using this procedure.
install the tube to the side of the oil pan.
Install the oil fill tube fasteners and tighten to 1. Lubricate and assemble a seal in the groove
secure. in the PTO assembly housing.
307
305
Figure 307 — PTO Housing Seal Installation

Figure 305 — Oil Fill Tube
2. Install a new O-ring on the dipstick tube, 2. Assemble the PTO assembly on the flywheel
then install the tube and secure with the housing.
308
fastener. Install the dipstick.
306
Figure 308 — Power Take-Off Installation

Figure 306 — Oil Dipstick
1. PTO Housing 3. Flywheel Housing
2. Intermediate Idler
Gearset

according to specification.
Page 189
Timing Gear Cover Installation 4. Position the timing gear cover on the
flywheel housing at the rear of the cylinder
[211 AA] head. Install the fasteners marked 1 and 2.
311
1. Apply sealant in the bottom corners where

the timing gear plate and the flywheel
housing meet. Also apply sealant to the top
of the timing gear plate (in the corner) next
to the cylinder head.
309
Figure 309 — Sealant Application — Engine

Figure 311 — Timing Gear Cover Installation Sequence
2. Install the timing gear cover seals and
gaskets. 5. Install the timing gear cover alignment tools,
310 85111422-A and 85111422-B, to the
cylinder head and timing gear cover as
illustrated. Cover surface must be flush with
the seal surface of the cylinder head.
The timing gear cover must be installed within

20 minutes of the sealant being applied.
312
Figure 310 — Timing Gear Cover Seals
3. Apply sealant to the mating surfaces of the

timing gear cover. Figure 312 — Timing Gear Cover Alignment Tools
Page 190
6. Install the remaining fasteners, 3, 4 and 5. 2. Check for proper camshaft position sensor
Torque all of the timing gear cover fasteners clearance using the sensor depth gauge,
to specification. 88800031, to determine if shims are
required for sensor depth.
7. Remove the timing cover clamp tools. 315
8. Position the rear support bracket onto the

rear of the engine and install the support
bracket fasteners to secure.
9. Install all tie straps, P-clamps and other
retainers used to restrain the engine
harnesses, oil lines and coolant tubes to the
rear of the engine.
313
Figure 315 — Camshaft Position Sensor
a. Rotate the engine until a tooth of the

camshaft toothed wheel is aligned with
the sensor bore.
b. Insert the depth gauge into the sensor
bore until the outer part of the gauge is
fully seated against the timing gear
cover.
c. Loosen the thumb screw of the gauge
and push the inner part of the gauge in
until it contacts a tooth of the toothed
wheel.
d. Tighten the thumb screw to secure the
Figure 313 — Rear of Engine
inner part of the gauge.
CAMSHAFT SENSOR DEPTH, CHECK e. Carefully remove the gauge from the
camshaft sensor bore and observe the
1. Remove the plug from the flywheel housing location of steps between the inner and
and install the flywheel turning tool. outer portions of the gauge:
314
앫 Both steps below the surface of
the gauge = no shims required.
앫 One step below the surface of the
gauge = one shim required.
앫 Both steps above the surface of
the gauge = two shims required.
Page 191
Coolant Pump Installation
316
[ 215 SW, SG, SR]

1. If removed, place the coolant pump base
plate in position at the front of the cylinder
block and install the mounting bolts. Tighten
the bolts to specification.
2. Press a new sealing ring into the groove of
the replacement coolant pump.
318
Figure 316 — Depth Sensor Gauge
3. Install the camshaft position sensor with the

appropriate shim(s) and new O-ring. Secure
the sensor with a bolt and plug in the
harness connector.
317
Figure 318 — Inserting Coolant Impeller Housing Seal
3. Position the replacement coolant pump

impeller housing on the base plate and align
the bolt holes.
Make sure the sealing ring remains seated in the

groove of the pump impeller housing.
Figure 317 — Camshaft Position Sensor
4. Use care to ensure that the sealing ring

remains properly seated and install the
coolant pump bolts and tighten to
specification.
5. Position the tensioner pulley on the front of
the engine and install the tensioner bolts.
Tighten the bolts to specification.
Page 192
Thermostat and Cover Installation Coolant Pipe Installation
[215 NU, NG & LD] [215 SW]
319
UPPER COOLANT PIPE (BYPASS) HOUSING

1. Lubricate and assemble a new seal in the
upper coolant pipe housing flange.
320
Figure 319 — Thermostat and Cover Installation
1. Cylinder Head 3. Thermostat

2. Thermostat Seal 4. Thermostat Cover
Figure 320 — Seal Installation — Upper Coolant Pipe

1. Use crocus cloth to remove any surface Housing
nicks, burrs, sharp edges and tool marks
from the thermostat cover and cylinder head. 2. Assemble the upper coolant pipe housing
2. Lubricate the inner surface of the cover. flange on the head.
321
3. Install the new thermostat.
Make sure that the rubber seal remains properly

seated.
4. Position the thermostat cover to the cylinder

head and install the bolts. Using a torque
wrench, tighten the fasteners in a cross
pattern according to specification.
Figure 321 — Upper Coolant Pipe Installation
3. Using a torque wrench, tighten the upper

coolant pipe fasteners in sequence
4. Assemble the fan ring bracket to the upper
coolant pipe housing.
Page 193
PUMP INLET HOUSING Oil Cooler and Cooling Duct Cover
1. Lubricate and assemble new sealing rings Installation
on the pump inlet pipe at the joint with the
bypass connector. [215 DW, 219 EP]
2. Place the inlet housing in position between
the upper coolant pipe and the pump inlet. The oil cooler must be attached to the cooling
Replace and lubricate all sealing O-rings. duct cover before attaching the cover to the
322 cylinder block.
OIL COOLER INSTALLATION

1. Using a sharp pick, carefully remove the
rubber seal (molded gasket) from the groove
in the oil cooler cover, if not already done.
Clean the cover of any dirt, adhesives and
inspect for damage to the sealing surface.
Also, inspect the cylinder block and ensure
the sealing surface is clean and undamaged.
2. Install a new formed gasket in the groove of
the cover.
Figure 322 — Installing Pump Inlet Housing
3. Install the M8 fasteners and tighten to Apply a minimal amount of silicone sealant in the
specification. Then, install the M10 fastener seal groove to hold the seal in place during
and tighten to specification. assembly. Install the cover within 20 minutes of
applying the sealant.
323
Secure the inlet housing flange to the pump first

and then to the cylinder block.
Figure 323 — Oil Cooler Cover Gasket
3. Install new oil cooler sealing O-rings

between the oil cooler and cover. Install the
sealing O-rings into the grooves in the cover.
Page 194
COOLING DUCT COVER INSTALLATION
324
1. Replace the water pump inlet housing

formed rubber gasket with a new gasket.
Lubricate new gasket upon installation.
327
Figure 324 — Installing Cooler Seals
4. Install the oil cooler in the oil cooler cover.

325
Figure 327 — Water Pump Inlet Housing Formed Gasket
2. With assistance, set the cooling duct cover

assembly in place. Install the upper left
corner fastener.
This mounting location is slotted for adjustment.
3. Using the assembly tool, 88800022, push

the cover forward to compress the formed
rubber gasket at the water pump inlet. Install
Figure 325 — Installing the Oil Cooler the upper right corner fastener.
6. Install the oil cooler flow plate over the oil A small piece of metal stock should be used to
cooler. Tighten fasteners to specification. keep from deforming the stamped cover that the
326
tool foot is pressing against.
328
Figure 326 — Oil Cooler Flow Plate
Figure 328 — Cooling Duct Cover Adjustment Tool
Page 195
4. Adjust cover as required to allow upper and 3. Install the gasket to the engine block.
lower center fasteners to be installed.
4. Install the oil filter housing onto the engine
block and position the rear pipe. Torque the
bolts to specification.
The upper center mounting location has a tighter 5. Install the fasteners to the rear pipe in the oil
tolerance than other mounting locations. filter housing. Torque the bolts to
specification.
5. Start all remaining cover fasteners and 6. Install the front pipe with new seals between
torque-tighten fasteners to specification. the oil filter housing and the oil cooler cover.
331
Oil Filter Housing Installation

[219 EP]
1. Install the rear pipe to the oil cooler cover
with a new gasket. Place the retaining
clamps in position on the oil cooler duct
cover, install the fasteners and tighten to
specification.
329
Figure 331 — Front Pipe Installation
7. Install all hard pipes (coolant and oil) to the

oil cooler cover. Replace and lubricate all
sealing O-rings. Also, replace sealing
washers for the banjo fitting on the oil cooler
cover. Tighten banjo fittings to specifications.
332
Figure 329 — Rear Pipe to Oil Cooler
2. Install two alignment pins — to hold the

gasket in place and to aid in the alignment of
the housing.
330
Figure 332 — Oil Cooler Hard Pipes
Figure 330 — Alignment Pins and Gaskets
Page 196
Exhaust Manifold Installation
334
[214 EG]
The exhaust manifold mounting fasteners can be

used five times unless the manifold is being
replaced. If the manifold is being replaced, use
new fasteners.
1. Clean the manifold mounting surface on the

cylinder head.
2. Temporarily install an alignment stud at each Figure 334 — Manifold Gasket
exhaust manifold flange location on the
cylinder head. 1. Manifold Side (Metal) 2. Cylinder Head Side (with
Seal)
4. Apply anti-seize compound to the threads

This is done to hold the manifold while positioning and under the heads or contact surfaces of
the manifold gaskets for installation of the bolts all the manifold fasteners.
and spacers.
333
Anti-seize helps prevent fastener oxidation

corrosion and reduces friction to help achieve the
intended clamp load on the component when
tightening the fasteners to specification.
5. Install the exhaust manifold over the

alignment pins. Install fasteners with spacers
in the lower holes. Now the upper alignment
pins can be removed one at a time and
replaced with mounting fasteners and the
original spacers.
Figure 333 — Alignment Pin Installation

앫 Make sure the spacers are seated properly
3. Install new gaskets onto the alignment pins in the manifold step bore hole location.
with the seal side facing the cylinder head.
앫 Exhaust manifold fasteners can be used up
to five times.
The gaskets are marked “MANIFOLD SIDE” to 6. Tighten the fasteners to specification.
aid in installation. Make sure to place this side of
the gasket toward the exhaust manifold. The
graphite fiber side of the gasket faces the cylinder
head.
Page 197
Turbocharger Installation
335
[214 SC]
앫 Use only new and approved gaskets at the

various air, oil and exhaust connections to
the turbocharger. Avoid the use of sealing or
joint compounds at all flanged connections.
앫 Thorough cleanliness is required. Small
particles can cause severe rotor damage if
inducted during high-speed operation. Be
sure to plug the inlet and outlet ports while
handling the turbocharger.
앫 After completing engine reassembly, fill the
turbocharger oil passage with clean engine
oil before starting the engine. Refer to the
procedure under Turbocharger in the
ENGINE PREPARATION AND Figure 335 — Turbocharger Installation
OPERATIONAL CHECK section.
7. Install the turbocharger flange nuts and
1. Inspect the intake and exhaust systems spacers to the exhaust manifold and
leading to and from the turbocharger to torque-tighten to specifications.
make sure there is no foreign material
including burrs and loose lining fragments.
2. Clean the contact surface on the exhaust
manifold, oil return/drain back pipe and Apply anti-seize compound to the threads and
adapter block. under the contact surfaces of the fasteners.
336
3. Retain the protective caps over the
turbocharger ports to keep debris and dirt
out of the turbocharger as engine
reassembly progresses.
4. Apply anti-seize compound to the threads
and under the heads or contact surfaces of
the fasteners. Anti-seize helps prevent
fastener oxidation corrosion and reduces
friction to help achieve the intended clamp
load on the component when tightening the
fasteners to specification.
5. Install new high-temperature gaskets
between the turbo flange and exhaust
manifold.
6. Position the turbocharger and gaskets
against the exhaust manifold.
Figure 336 — Turbo Attachment
Page 198
8. Install the turbocharger oil return pipe Exhaust Pressure Governor (EPG)
(lower) with a new gasket.
337 Installation
234 BD
1. Lower the EPG housing into position
between the exhaust pipe and turbocharger.
2. Install a new high-temperature gasket EPG
housing and exhaust pipe.
339
Figure 337 — Turbo Oil Return
9. Install the oil supply line (upper) with a new

gasket. Torque-tighten the bolts to
specification.
Pre-fill the turbocharger with clean engine oil.

Starting the engine without oil pressure and a
Figure 339 — EPG Housing Gasket
“dry” turbocharger can damage the turbo.
338 3. Tighten the clamp attaching the exhaust
pipe-to-EPG housing.
340
Figure 338 — Turbo Oil Supply Figure 340 — Exhaust Pipe-to-EPG Housing
Page 199
4. Install the exhaust clamp from the Starter Installation
EPG-to-turbocharger.
341
[272 DH]
The starter is held in place by nuts assembled
over studs inserted in the block. If a stud is
missing, replace it.
1. Using a torque wrench, tighten replacement
studs according to specification.
2. Assemble the starter on the studs in the
flywheel housing.
343
Figure 341 — EPG-to-Turbo Clamp
5. Connect the air supply line to the EPG.

342
Figure 343 — Starter Installation
3. Using a torque wrench, tighten the nuts

Figure 342 — EPG Air Line Attachment
Page 200
Air Compressor Installation 2. Assemble the air compressor on the
mounting flange of the timing gear plate.
[261 CK] 345
1. Install a new seal in the air compressor

housing mounting flange.
344
Figure 344 — Installing Air Compressor Mounting Seal
Figure 345 — Air Compressor Installation
3. Using a torque wrench, tighten the attaching

nuts in two stages according to specification.
Page 201
346
Figure 346 — Air Compressor Coolant and Lubrication Fittings
1. Lubrication Line 4. Attaching Stud and Nut

2. Banjo Fitting 5. Air Compressor
3. Coolant Lines
4. Install the coolant lines to the air

347
compressor.
5. Install the lubrication lines to the air
compressor.
Tandem Pump (Fuel and Power

Steering) Installation
[231 AA, 262 EB]
1. Install a new O-ring in the groove on the
tandem pump mounting flange.
2. Assemble the tandem pump on the flywheel
housing.
Figure 347 — Tandem Pump (Fuel and Power Steering)

Installation

fasteners according to specification.
Page 202
Inlet Manifold Installation
349
[214 HD]
1. Using a sharp pick, carefully remove the
rubber seal (molded gasket) from the groove
in the intake manifold, if not already done.
Clean the manifold of any dirt, adhesives
and inspect for any damage to the sealing
surface. Also, inspect the cylinder head and
ensure the sealing surface is clean and
undamaged.
2. Install a new rubber seal (molded gasket)
into the groove of the intake manifold.
Figure 349 — Intake Manifold
4. Torque-tighten the intake manifold bolts in

Apply a minimal amount of silicone sealant in the sequence to specification.
seal groove to hold the seal in place during 5. Secure the engine harness to the intake
assembly. Install the manifold within 20 minutes manifold using previously removed
of applying sealant. P-clamps.
348 6. Install the electrical connector to the charge
air temperature sensor located on the top of
the intake and secure the harness with tie
straps.
350
Figure 348 — Installing Inlet Manifold Seal
3. Position the intake manifold onto the two

previously installed alignment pins. Start two
mounting bolts with mounting spacers to Figure 350 — Charge Air Temperature and Pressure
hold the manifold in place, then remove the (Boost) Sensor
alignment pins and install the remaining
manifold bolts with spacers. 7. Using a torque wrench, tighten the sensor
Use new screws with mounting spacers when

installing the intake manifold.
Page 203
Engine Preheater/Spacer
352
Installation
[214 HL]
1. Clean the forward sealing surface on the
intake manifold, air preheater or spacer, and
inlet adapter.
2. Position the inlet adapter and inlet air
preheater (if equipped), or spacer block with
new gaskets onto the intake manifold. Next,
start the bolts to hold the assembly to the
intake manifold.
351
Figure 352 — Inlet Air Preheater Relay
EECU and Cooler Installation

[230 EK]
The sequence in which the fuel filter valve

housing, fuel lines and EECU are assembled on
the engine depends on the type of engine stand
used. For engine stands that use an adapter plate
attached to the left side of the engine, these
Figure 351 — Inlet Adapter components cannot be installed until after the
engine has been removed from the repair stand.
in a cross pattern according to specification.
Fuel fresh from the tank serves as coolant for the
4. Install the fan ring support bracket mounting EECU. The cooler connects into the line carrying
fastener. Torque-tighten the bolt to the fuel from the tank into the fuel pump.
specification.
5. If equipped, position and install the inlet air
preheater relay bracket (with relay attached)
to the mounting surface on the intake Make sure the cooling plate and EECU mating
manifold. Connect and secure the power surfaces are clean.
and ground cables as marked at
disassembly. 1. Position the EECU on the engine block and
install the mounting fasteners.
Page 204
Make sure that rubber isolators are correctly
installed and that the ground strap is grounded to Fuel Lines and Filter Housing
the engine block. Installation
353
The sequence in which the fuel filter housing, fuel

lines and EECU are assembled on the engine
depends on the type of engine stand used. For
engine stands that use an adapter plate attached
to the left side of the engine, these components
cannot be installed until after the engine has
been removed from the repair stand.
355
Figure 353 — EECU Installation

3. Assemble the cooler on the EECU. When
positioning the module, make sure that the
small ground strap at the upper right of the
unit is properly secured and pressed in
close.
If the EECU is painted in the region contacting

the cooler, remove the paint to provide for the
most efficient cooling.
354
Figure 355 — Fuel Filter and Housing Assembly
1. Assemble the fuel filter housing on the block.

3. Attach the pipe between the side of the head
at the rear and the filter housing.
Figure 354 — EECU Cooling Plate
Page 205
356
Figure 356 — Fuel Supply Pump, Filter Assembly and Lines
1. Seal Rings 5. Low-Pressure Fuel Supply Pump (Mounted to Power

2. Banjo Coupling Steering Pump)
3. Hollow Screw 6. Filter Valve Housing
4. Power Steering Pump 7. EECU Cooler
4. Attach the line to the block with a P-clamp. Crankcase Ventilation Separator
5. Install the fuel return line between the 1. Clean the crankcase ventilation separator
cylinder head at the front and the filter valve mating surface on the engine block. Install a
housing. new rubber gasket into the separator
6. Install the line to the block with P-clamps. housing groove.
357
7. Install the fuel return line connecting the
filter valve housing to the EECU cooler.
8. Install the fuel supply and return lines
between the fuel pump and the filter
housing.
9. Using a torque wrench, tighten the banjo
fittings according to specification.
Figure 357 — Separator Mating Surface
2. Assemble the separator on the block and

install fasteners.
Page 206
1. Assemble the crankshaft vibration damper
358
and fan pulley on the crankshaft hub using

new fasteners.
Fasteners are one-time use only. Do NOT reuse

fasteners.
359
Figure 358 — Separator Installation

4. Assemble the outlet hose on the separator
outlet connector and install hose clamps.
5. Using a torque wrench, tighten the hose
clamp fasteners according to specification.
6. Assemble the inlet hose on the separator Figure 359 — Fan Drive Pulley and Crankshaft Damper
inlet and prepare for valve cover connection Assembly
in a future step. Install hose clamps.
1. Fan and Coolant Pump 2. Vibration Damper
7. Using a torque wrench, tighten the hose Drive Pulley 3. Crankshaft Hub
clamp fasteners according to specification.
Crankshaft Vibration Damper and fasteners in sequence in two steps
Fan Pulley Installation
3. Assemble the front engine power take-off
[212 RB, 216 1A] (FEPTO) if equipped. Tighten the attaching
fasteners in sequence in two steps

housing will render the damper ineffective. The
vibration damper cannot be repaired. Failure to
heed this caution may result in severe engine
damage.
Inspect the vibration damper for dents, nicks or

fluid leaks in the outer housing. If any of these are
evident, the damper must be replaced. Due to the
close clearance between the damper housing
and the rotor inside, dents or nicks may cause
contact between the two components. Fluid loss
will deteriorate the dampening effect of the
damper.
Page 207
6. Assemble the alternator and refrigerant
360
compressor on their pads.

361
Figure 360 — Front Engine Power Take-Off (FEPTO)

Assembly
Figure 361 — Alternator and A/C Compressor

Alternator and Refrigerant
1. Drive Belt 4. Alternator
Compressor Installation 2. Belt Tensioner 5. A/C Compressor
3. Alternator Mounting 6. Mounting Bracket, Front
[271 CB, 264 DP] Bracket Engine Support
1. Assemble the alternator mounting bracket

onto the cylinder block. Tighten the 7. Using a torque wrench, tighten the fasteners
fasteners according to specification. according to specification.
2. If removed and not previously installed, 8. If a harness is installed, securely connect
assemble the front engine support mounting the electrical wiring as tagged during
bracket on the cylinder block. This bracket disassembly.
also provides the mounting points for the 9. Assemble the belt pulleys on the alternator
A/C compressor. and compressor hubs, if removed.
for the bracket and mount according to
specification.
4. If removed, assemble the belt tension idler
on the bracket.
Page 208
Wiring Harness Installation
363
362
Figure 362 — Internal Wiring Harness
1. Tie Straps 3. Wiring Harness

2. Tie Bar Notch
Figure 363 — Harness Routing Over Engine Brake
1. Route and position the harness on the Control Valve
engine as noted during disassembly.
1. Tie Straps 2. Control Valve
2. Insert the unit injector portion of the harness
through the hole in the timing gear housing.
The external portion of the wiring harness is
3. Connect the harness to each injector. encased in accordion tubing. There are several
4. Connect the harness to the engine brake units each of which is fitted with end connectors
control valve if installed. that permit convenient stringing, joining and
attachment to the block in various locations.
5. Using high-temperature wire ties, 983472,
attach the harness to the cylinder head.
CONNECTING THE EECU
6. If not previously done, carefully route the
wiring harness over the engine brake control 1. Check the tension of the terminal connector
valve. Secure the harness to the control pins using the test pins tool kit 9990008.
valve as shown in Figure 363. Make sure
that the harness is positioned to the side of
the boss at the top of the valve assembly.
If terminal pins are damaged or corroded, replace
as necessary.
Do NOT route the harness over the boss at the 2. Carefully engage the upper and lower wiring
top of the engine brake control valve. There is not harness connectors to the EECU. Verify that
enough clearance between the valve and the the connectors are latched and properly
valve cover for the harness when the cover is locked in position.
installed. The harness must be positioned to the
side of the boss to avoid damage to the harness.
Use care to ensure that the EECU terminal pins

are straight and undamaged.
Page 209
Cylinder Head (Valve) Cover
364
Installation
[211 JB]
1. Clean the gasket sealing surface of the
cylinder head. The surfaces should be clear
of any dirt or debris and free of any oil.
2. Inspect the gasket for damage. If
replacement is necessary, carefully place a
new gasket into the channel, making sure
that it is properly seated and follows the
contour of the channel.
366
Figure 364 — EECU Harness Connectors
3. Install the bolts to secure the wiring harness

clamps to the EECU.
365
Figure 366 — Cylinder Head Cover Gasket
3. Apply a 2 mm (0.079 inch) bead of MACK

sealant to the area where the timing cover
and the cylinder head meet. This parting line
Figure 365 — EECU Harness Clamps
is on both sides of the cylinder head.
Carefully position the valve cover on the
4. Connect the various terminals as tagged at
cylinder head and make sure that the seal
disassembly to all sensors, relays and
remains properly seated.
components such as the starter, alternator 367
and refrigerant compressor among others.
5. Attach the clamps to hold the harness on the
block.
Figure 367 — Sealant Application
Page 210
4. Install the spring-loaded bolts in the valve Fan Hub and Drive Belt Installation
cover. Torque-tighten the valve cover bolts in
sequence to specification. [216 AA]
1. Place the fan hub bracket assembly in
position at the front of the cylinder head and
앫 The cylinder head cover must be installed block. Install the mounting fasteners and
within 20 minutes of the sealant being tighten to specification.
369
applied.
앫 The bolt springs provide even tension on the
valve cover gasket.
5. Install the fasteners securing the crankcase

ventilation tube and bracket to the valve
cover and intake manifold. Torque-tighten
the fasteners to specification.
Inspect the crankcase ventilation tube O-ring and

replace if necessary.
368
Figure 369 — Fan Hub and Accessory Drive System
1. Fan Drive Belt 4. Accessory Drive Belt

2. Fan Hub Bracket 5. Fan Drive and Coolant
3. Accessory Drive Belt Pump Belt Tensioner
Tensioner
2. Place the fan drive and pump drive belt

tensioner in position on the coolant pump
housing. Install the fasteners and tighten to
specification.
3. If not already done, place the accessory
drive belt tensioner in position on the
cylinder block. Install the fasteners and
tighten to specification.
Figure 368 — Crankcase Ventilation Tube
4. Check the condition of both of the original
A/C/alternator and water pump/fan belts.
Check for dry cracks or scuff marks and
replace with new belts if any of these
conditions are present.
5. Per the accessory routing decal, route the
A/C/alternator and fan/water pump belts.
Page 211
7. Using tool J 44392, pry the belt tensioner
370
away from the fan and water pump drive belt

and install the belt. Release the tension and
remove the tool.
372
Figure 372 — Fan and Water Pump Drive Belt Installation
Figure 370 — Drive Belt Arrangement

Removing Engine from Engine
1. Conventional 2. LCF Stand
6. Place a 1/2-inch ratchet or special tool [200 EB]
J 44392 in the accessory drive belt tensioner
notch. Install the drive belt by prying the
tensioner away from the belt to relieve the
tension on the adjuster and allow the belt to The engine is very heavy and extreme caution
slip onto the A/C compressor pulley. must be exercised while it is being lifted from
Release the tension and remove the tool. the stand. Failure to use proper equipment
371
and failure to keep your body clear may result
in serious personal injury or death if the
engine should fall or suddenly shift out of
position.
1. Attach engine lifting tools J 47038-1,

J 47038-6 and J 47038-8 as follows:
a. Slide the center engine lifting bar over
the cylinder head cover and install the
clevis pin. Connect the center lifting bar
clevis to the chain on the hoist.
b. Place the lifting chain to the engine lift
eyes and secure the chain to the
Figure 371 — Accessory Drive Belt Installation bracket.
c. Slide the rear lifting plate into the center
lifting bar and install the pin.
d. Bolt on the front section of the engine
lifting bracket to the cylinder head and
install the pin in the bar.
e. Torque-tighten lifting bracket fasteners
to specification.
Page 212
1. If not already done, assemble the following
components on the engine using the
procedures covered earlier in this section.
Use only the chains, clevis and lifting plate
provided with these special tools. Failure to 앫 Engine wiring harness
use the correct special tool components may 앫 Crankcase ventilation tubing
allow the engine to fall, causing serious
personal injury or death. 앫 EECU and cooling plate
앫 Fuel filter valve housing and fuel lines
2. Support the weight of the engine using a
앫 Crankcase ventilation separator
mobile floor crane such as OTC 16-1813 or 373
equivalent crane capable of lifting the
engine. Position the crane and hook up to
the bar as close as possible. Raise the crane
slightly to apply tension to the chain.
3. With the lifting device now supporting the
engine weight, remove the mounting
fasteners from the engine stand.
4. Using the engine hoist, place the engine in a
suitable support rack or install the engine in
the vehicle (see Engine Installation in the
REPAIR INSTRUCTIONS, PART 1 section).
Filters and Miscellaneous

Components Installation
[219 EV, 215 LD]
This section covers installation of filters and other
components that might get in the way of other Figure 373 — Components for Installation After Removal
assembly operations and to which nothing is from Repair Stand
assembled.
1. Engine Wiring Harness 4. EECU
2. Crankcase Ventilation 5. Fuel Filters
Tubing 6. Crankcase Ventilation
3. EECU Cooler Separator
The sequence in which the fuel filter valve
housing, fuel lines and EECU are assembled on
the engine depends on the type of engine stand 2. Assemble the full-flow oil filters and tighten
used. For engine stands that use an adapter plate to contact plus 3/4 to 1 turn.
attached to the left side of the engine, these 3. Assemble the bypass oil filter and tighten to
components cannot be installed until after the contact plus 3/4 to 1 turn.
engine has been removed from the repair stand.
4. Assemble the coolant filter and tighten to
contact plus 3/4 to 1 turn.
Page 213
ENGINE INSTALLATION
Special Tools

DBT2V700 Coolant Extractor/Injector
J 47038-3 Engine Lifting Tool Set

J 47038-4
J 47038-6
J 47038-8
General Instructions
Details of the engine installation procedure vary Refer to the SPECIFICATIONS section for
from one vehicle to another. This section provides information about the fasteners mentioned below.
general guidelines for installing an MP8 engine in Some groups of fasteners must be tightened in a
a vehicle. specific sequence. Patterns of sequence are also
specified in the torque specification section.
Before installing the engine, make sure tools and

equipment are inspected for safety and available
Installation
for use.
1. Position the vehicle on a flat, level surface

with ample work space. The engine is obviously heavy and difficult to
handle. Obtain a helper and provide a suitable
2. Apply the parking brake and block the lifting device to support it safely during
wheels. Observe all safety precautions. installation. Failure to heed this warning may
result in severe personal injury.
Page 214
11. Install the transmission and, using a torque
wrench, tighten the transmission attaching
screws according to specification.
While installing the engine, watch for obstructions
that may interfere, such as engine and chassis 12. Withdraw the transmission jack.
components, brackets, clamps and other parts 13. As applicable:
attached to the frame and cab. Failure to heed
this caution may result in severe damage to the a. If manual transmission, attach the
engine and other components. clutch linkage and bracket retaining
screws.
1. Remove the valve cover. b. If automatic transmission, attach the
torque converter access panel and
2. Cover the valve mechanism and gear train
torque converter.
with a suitable cloth or similar covering to
prevent dirt and debris from entering the 14. Attach the hood rest crossmember if
engine. applicable.
3. Attach the engine lifting tool, J 47038, to the 15. Connect starter wires and cables.
engine. Secure the engine lifting tool to the
16. Attach the power steering hoses and
front of the cylinder head and to the rear at
reservoir if applicable.
the flywheel housing. Adjust the tool to
assume the load. 17. Attach the exhaust system brackets.
18. Attach the exhaust system to the
turbocharger.
Ensure all bolts and pins are correctly
positioned prior to removing the engine from
the engine stand. Failure to properly install all
The radiator and CAC assembly is heavy and
bolts and pins of the engine lifting tool can
difficult to handle. Provide a suitable lifting
result in personal injury and/or death.
device and a helper to support it safely during
installation. Failure to heed this warning may
4. Using the engine lifting tool, J 47038, and result in severe personal injury.
with the aid of the helper, lift and lower the
engine into position.
19. Attach the radiator and CAC assembly.
5. Align the engine with the transmission.
20. Attach the fan assembly.
6. Install and, using a torque wrench, tighten
the rear engine support attaching screws
7. Install and, using a torque wrench, tighten To allow for chassis articulation in severe service
the front engine support attaching screw applications, the fan ring rubber seal does not fit
according to specification. flush against the shroud on GU model chassis. A
gap of 15–20 mm (0.59–0.79 inch) exists
8. Remove the engine lifting tool from the between the front face of the aluminum fan ring to
engine. the back face of the fan shroud.
9. Apply an even 2 mm (5/64 inch) bead of
sealant at the joint lines between the
cylinder head and the timing cover.
Install the valve cover within 20 minutes of

applying the sealant.
10. Install the valve cover.
Page 215
29. If the vehicle is equipped with air
374
conditioning:
a. Connect the A/C compressor discharge
hose.
b. Connect the A/C line at the
receiver/dryer.
c. Connect the pressure switch on the
receiver/dryer.
d. Connect the low pressure cutout
switch.
e. Recharge the A/C system with
refrigerant using refrigerant recovery
Figure 374 — Fan Ring-to-Shroud Clearance and recycling equipment for R134A.
21. Connect the fan actuator. 30. Install the inlet air system components
including the filter.
22. Connect the engine coolant temperature
sensor. 31. Connect the inlet air heater if present.
23. Attach the charge air cooler outlet 32. Attach the oil and fuel filters and the coolant
components. conditioner.
24. Attach the charge air cooler inlet 33. Close all drains and drain valves.
components. 34. Connect all sensors and actuators.
25. Attach the coolant expansion tank. 35. Install the drive belts.
26. Attach the lower radiator tube. 36. Add oil and coolant. If available, use coolant
27. Connect the cab heater and fuel heater extractor/injector when adding coolant.
coolant return lines to the lower radiator 37. Attach the hood, or replace the tilted cab.
tube.
28. Attach the upper radiator tube.
Page 216
Page 217
IN-CHASSIS CAMSHAFT BEARING
PART/COMPONENT BRACKETS, REPLACEMENT
PROCEDURES (MACK MP8 ENGINE)
This section presents standalone replacement [213 CJ]
operations which can be done in-chassis without
a complete engine overhaul. These operations This information covers guidelines when
include: replacing factory or aftermarket camshaft bearing
brackets (lower journals) on the MACK MP8
앫 CAMSHAFT BEARING BRACKETS, engine.
REPLACEMENT
앫 OIL THERMOSTAT AND PRESSURE
SAFETY VALVE REPLACEMENT
Preliminary Steps
앫 CRANKSHAFT FRONT SEAL The following components need to be
REPLACEMENT removed for access to the camshaft bearing
앫 CRANKSHAFT REAR SEAL brackets:
REPLACEMENT 앫 Valve Cover
앫 CRANKCASE VENTILATION (CCV) 앫 Compression Brake Solenoid Valve
SEPARATOR REPLACEMENT
앫 Rocker Arm Shaft
앫 OIL PUMP REPLACEMENT
앫 Camshaft Assembly
앫 INJECTOR COPPER SLEEVE
REPLACEMENT
General Information
앫 UNIT INJECTOR CLEANING
앫 VALVE STEM HEIGHT MEASUREMENT Camshaft bearing journals are numbered 1–7,
PROCEDURE with matching upper and lower halves. Be sure to
앫 VALVE STEM SEAL REPLACEMENT note and mark the corresponding journal
numbers and install them in the correct sequence
Due to the Engine Electronic Control Unit (EECU) with matched upper and lower halves.
375
self-learning capability, it is necessary to reset
learned EECU parameters after servicing some
EECU to learn the new component's behavior.
After servicing is complete, perform the “Learned
Data Reset” located in VCADS/PTT.
Figure 375 — Camshaft Bearing Bracket Installed
Page 218
Camshaft Inspection
376
To avoid unnecessary overhauling, conduct a

thorough inspection of the camshaft before
reinstalling it after replacing the bearing bracket
assemblies.
Bracket Replacement Procedure

1. Remove the lower bearing brackets using a
pry bar. The rearmost No. 7 bracket can be
removed by using a soft-faced mallet and
tapping side to side. (The alignment pins
should come off the cylinder head with the
Figure 376 — Camshaft Bearing Bracket Lower Half
brackets. If not, remove the pins.)
377
WHEN REPLACING FACTORY-INSTALLED

JOURNALS
앫 If a camshaft journal has seized, DO NOT
MIX a replacement bearing bracket with the
original factory-installed bearing brackets.
This is because the original bearing brackets
were align-bored when the engine was
manufactured. All seven brackets must be
replaced.
앫 When replacing a cylinder head, do not mix
new bearing brackets with original bearing
brackets from the old cylinder head. Use
only new bearing brackets on a new cylinder
head.
WHEN REPLACING/INSTALLING
AFTERMARKET JOURNALS
앫 If there are already replacement bearing
bracket assemblies on the engine, and one Figure 377 — Camshaft Lower Bearing Brackets
or more assemblies are damaged, all seven
assemblies must be replaced. Replacement 2. Clean the contact surfaces of the cylinder
bracket assemblies can be identified by the head and the lower bearing brackets.
oval-shaped alignment pin holes.
3. Using a metal stamp or electric etching tool,
앫 For replacement bracket assemblies used in mark the new bearing brackets and caps
locations 2 through 6, both alignment pin with the numbers, 1 through 7, indicating the
holes are oval-shaped for side-to-side location at which each assembly will be
adjustment. For brackets used in locations 1 installed.
and 7, one alignment pin hole is oval-shaped
for front-to-rear adjustment; the second pin
hole is round with an alignment pin
preassembled in it. Do not use excessive force to punch the bracket
앫 Mark the bearing caps to indicate that assemblies when marking their position on the
aftermarket bearing bracket and cap cylinder head. Damage to components can result.
assemblies have been installed.
Page 219
4. Install 12 new locating pins from the parts kit Final Steps
at the cylinder head locations illustrated
(Figure 378). Use a plastic mallet so as not Install the following components which were
to damage the locating pins. removed for access to the camshaft bearing
378
brackets (see appropriate component for
installation procedures):
앫 Camshaft Assembly
앫 Compression Brake Solenoid Valve
앫 Valve and Unit Injector Adjustment
앫 Valve Cover Assembly
1. Install all previously removed cables to the
ground (negative) battery terminals.
2. Start the engine, check for leaks and proper
operation.
Figure 378 — Locating Pin Installation
5. Install the new lower bearing brackets at

their respective marked positions on the
cylinder head.
6. Check that the bearing brackets can move
slightly on the locating pins.
앫 Bracket Nos. 1 and 7 should turn
slightly forward and back at one side.
앫 Bracket Nos. 2 through 6 should move
slightly side to side.
379
Figure 379 — Bracket Movement on Alignment Pins
Page 220
OIL THERMOSTAT AND
381
PRESSURE SAFETY VALVE

REPLACEMENT
Pressure Safety Valve Removal

Before attempting to remove the oil pressure
safety valve, apply the parking brake, shift into
neutral and thoroughly clean around the safety
valve cover.
380
Figure 381 — Oil Pressure Safety Valve and Cover
2. Clean the cover and cylinder block sealing

surface.
3. Replace the O-ring on the cover.
382
Figure 380 — Oil Valves — Thermostat and Pressure

Safety
1. Thermostat Valve 2. Oil Pressure Safety Valve
1. Using the oil valve socket, J 43051, remove

the safety valve cover and valve as a unit.
Ensure that the seal is also removed with the
cover and valve. Dispose of the valve.
Figure 382 — Removing Safety Valve Cover O-Ring
4. Install a new valve in the cover.

5. Install the new valve and cover into the
cylinder block.
6. Using a torque wrench, tighten the valve
Page 221
Oil Thermostat Valve Replacement 1. Remove the thermostat valve from the oil
filter housing and discard.
Before attempting to remove the thermostat 2. Replace the O-ring.
valve, apply the parking brake, shift into neutral 384
and thoroughly clean around the valve head.

383
Figure 384 — Thermostat Valve O-Ring
Figure 383 — Oil Valves — Thermostat and Pressure 3. Install a new thermostat valve with a new
Safety gasket.
1. Thermostat Valve 2. Oil Pressure Safety Valve 4. Start the engine and check for leaks.
Page 222
CRANKSHAFT FRONT SEAL REPLACEMENT
Special Tools

(Essential)
J 44392 Drive Belt Tensioner Tool

(Essential)
Seal Removal 3. Compress the accessory belt tensioner

(using J 44392) and remove the drive belt
1. Remove the fan blade from the fan clutch from the vibration damper pulley, refrigerant
hub. compressor pulley and alternator pulley.
2. Compress the belt tensioner (using J 44392) 4. If equipped, remove the front engine PTO
to release pressure on the fan and coolant fasteners and PTO.
pump drive belt and remove the belt.
385 5. Remove the mounting fasteners that secure
the drive belt pulley and vibration damper to
the crankshaft hub. Separate the pulley and
damper from the hub.
Figure 385 — Drive Belt Tensioner Tool
Page 223
Seal Installation
386
1. Clean the seal seating surface in the

crankshaft front cover and the sealing
surface of the crankshaft hub.
2. Assemble the handle (9992000) and front
main seal remover/installer (88800021).
3. Place a new crankshaft front seal on the
crankshaft front seal remover/installer.
The crankshaft front seal should be installed dry.

Figure 386 — Vibration Damper and Pulley Removal No sealant or lubricant is necessary.
1. Fan and Coolant Pump 3. Crankshaft Hub 4. Position the crankshaft front seal
Drive Pulley remover/installer and new seal over the
2. Vibration Damper
crankshaft hub and crankshaft front cover.
Carefully drive the seal into the cover until
the tool bottoms against the crankshaft hub
and front cover.
387
housing can render the damper ineffective. If
damaged, the vibration damper cannot be
repaired and must be replaced.
6. Remove the crankshaft seal as follows:

A. Drill two 3.5 mm (0.138 inch) holes in
the metal rim of the crankshaft front
seal. Use the holes in the rim of the
front main seal remover/installer
(88800021) as a guide.
Apply grease on the end of the drill bit to prevent

chips from getting into the engine.
B. Using two self-tapping M5 screws of

suitable length, attach the crankshaft
front seal remover/installer to the seal. Figure 387 — Seal Installation
C. Using two M10 fasteners threaded into 5. Remove the tool and inspect the seal to
the crankshaft front seal make sure that it is properly installed.
remover/installer, remove the
crankshaft front seal. 6. Place the vibration damper and fan pulley on
the crankshaft hub and align the fastener
holes. Install and tighten the mounting
fasteners in two steps to specification.
Page 224
8. Compress the accessory drive belt tensioner
388
(using J 44392) and install the drive belt over

the crankshaft pulley, fan drive pulley and
coolant pump pulley.
9. Compress the lower belt tensioner (using
J 44392) and install the drive belt over the
crankshaft pulley, fan drive pulley and
coolant pump pulley.
390
Figure 388 — Vibration Damper and Pulley Installation
1. Fan and Coolant Pump 3. Crankshaft Hub

Drive Pulley
2. Vibration Damper
7. If equipped, install the front engine PTO and

fasteners. Tighten the mounting fasteners to
specification.
389 Figure 390 — Drive Belt Tensioner Tool
10. Place the fan blade on the fan clutch hub,

install the mounting fasteners and tighten to
specification.
Figure 389 — Front Engine PTO Installation
Page 225
CRANKSHAFT REAR SEAL REPLACEMENT
Special Tools

9990192 Crankshaft Seal Puller

(Essential)
9998238 Rear Main Seal Remover/Installer, for

neoprene type seal (Essential)
Neoprene Seal Removal 2. Install two M10 screws to use as handles to

aid in removal.
3. Remove the flywheel.
4. Using the puller, 9990192, and the slide
The flywheel is heavy. Do not attempt to remove hammer, 9996400, carefully remove the
the flywheel without the help of an assistant or a seal.
suitable lifting device. Failure to heed this caution
may result in severe personal injury and property
damage.
1. Carefully remove the flywheel sensor.
Page 226
Neoprene Seal Installation
392
1. Clean the flywheel, housing and crankshaft

sealing surfaces.
2. Align properly and assemble the new seal
on the seal installer, 9998238.
391
5. Insert the flywheel mounting screws finger

tight. Remove the M10 screws to insert the
remaining mounting screws.
6. Using a torque wrench, tighten the mounting
Figure 391 — Seal Installation
screws in sequence according to
specification.
1. Rear Main Seal 2. Seal Installer, 9998238 7. Carefully install the flywheel sensor and
connect it to the harness.
3. Using the handle, 9992000, and the seal
installer, carefully tap the seal into the
flywheel housing until there is even contact.
4. Using the M10 screws as handles, with the
help of an assistant or a lifting device,
assemble the flywheel over the dowel and
alignment studs on the mounting surface.
Page 227
Teflon® Seal Removal Teflon® Seal Installation
1. Install the plate and thrust screw part of tool,
9990166, to the crankshaft. Tighten the
assembly screws securely.
The flywheel is heavy. Do not attempt to remove
the flywheel without the help of an assistant or a
suitable lifting device. Failure to heed this caution
may result in severe personal injury and property
Make sure that the plate of the tool is positioned
damage.
properly in the crankshaft internal guide and is
flat against the crankshaft before tightening the
1. Remove the clutch assembly. screws.
2. Carefully remove the flywheel sensor. 394
3. Install two M10 screws to use as handles to

aid in removal.
4. Remove the flywheel.
5. Using the puller, 9990192, and the slide
hammer, 9996400, carefully remove the
seal. Make sure that the tools are free of
burrs and dirt.
Take care not to damage the crankshaft or

flywheel sealing surfaces. Slant the tools inward
to get a good grip on the crankshaft rear seal.
393
Figure 394 — Install Plate and Thrust Screw Assembly
2. Install the spacer, 88880013, of tool,

9990166, on the thrust screw.
The spacer is important because it determines

the installation depth of the crankshaft rear seal.
Figure 393 — Removing Crankshaft Rear Seal
6. Tap out the crankshaft rear seal.

7. Thoroughly clean the sealing surfaces of the
flywheel, flywheel housing and crankshaft.
Page 228
3. The sealing ring is supplied with a plastic 5. Install the cover and handle over the
installation ring that should be left in place assembly. Center the cover over the
during installation. crankshaft rear seal and thread the handle
395
to keep the cover in position.
397
Figure 395 — Crankshaft Rear Seal

Figure 397 — Cover and Handle Installed
4. Install the seal without removing the
installation ring over the thrust screw, spacer 6. Turn the handle to press the crankshaft rear
and plate assembly. seal over the crankshaft and into the
396
flywheel housing. When the cover bottoms
out against the spacer, the rear seal is in
proper position.
7. Remove the crankshaft rear seal installation
tools.
Figure 396 — Crankshaft Rear Seal Positioned on Tool
Page 229
8. Using the M10 screws as handles, with the 9. Insert the flywheel mounting screws finger
help of an assistant or a lifting device, tight. Remove the M10 screws to insert the
assemble the flywheel over the dowel and remaining mounting screws.
alignment studs on the mounting surface.
398 10. Using a torque wrench, tighten the mounting
screws in sequence according to
specification.
11. Carefully install the flywheel sensor and
connect it to the harness.
Page 230
CRANKCASE VENTILATION CCV Separator Installation
(CCV) SEPARATOR 1. Clean the mounting surfaces on the cylinder
REPLACEMENT block and the CCV separator.
2. Using a new gasket, assemble the CCV
CCV Separator Removal separator on the cylinder block.
3. Using a torque wrench, tighten the screws
1. Disconnect the batteries, or turn off the main
switch.
4. Attach the CCV hoses.
2. Clean the cylinder block around the CCV
separator mounting. 5. Turn on the main switch, or reconnect the
batteries.
3. Detach the CCV hoses.
6. Start the engine and check for leaks.
4. Remove the CCV separator from the
cylinder block.
OIL PUMP REPLACEMENT (IN CHASSIS)

[219 MU]
Special Tools

9998649 Block Stiffener Plate Assembly Tool
Page 231
399 400
Figure 399 — Oil Pump, Pickup and Distribution System Figure 400 — Oil Pump
1. Oil Pump 4. Strainer 6. If necessary, rotate the crankshaft out of the

2. Pump Outlet Pipe 5. Pump Inlet Pipe way using flywheel turning tool, 88800014.
3. Crossover Pipe 6. Block Stiffener Plate
7. Remove the oil pump from the bearing cap.
Oil Pump Removal
Oil Pump Installation
1. If not already done, remove the oil pan.
1. Clean all parts to be reused.
2. Remove the pump inlet pipe and strainer.
2. Attach the oil pump to the No. 7 main
3. Remove the pump outlet pipe.
bearing cap.
4. Remove the crossover pipe.
5. Remove the block stiffener plate. according to specification.
Wear gloves when handling the block stiffener Make certain that the bearing insert is in good
plate. It has sharp edges. Failure to heed this condition and properly installed on the bearing
caution could result in severe personal injury. cap. Failure to heed this caution may result in
severe component damage.
4. Using new screws and assembly tool,

9998649, attach the block stiffener plate to
the block. Do NOT torque-tighten the screws
at this time.
5. Lubricate and assemble new O-rings on the
inlet, crossover and outlet pipes.
Page 232
6. Assemble the crossover and outlet pipes in 12. Apply a 2 mm (5/64 inch) bead of 342SX33
the pump housing and install the mounting MACK-approved sealant to the seams
screws to secure the pipe flanges to the between the flywheel housing and timing
stiffener plate and block. gear plate and between the mounting plate
and the cylinder block.
7. Using a torque wrench, tighten the stiffener 402
plate screws (including pipe flange screws)
8. Assemble the inlet pipe and strainer.
9. Assemble the pipe and strainer in the pump
housing and on the block.
11. Inspect the oil pan seal and replace it if
necessary. Lubricate and assemble the seal
on the oil pan.
401
Figure 402 — Sealant Points — Front Seal Cover to

Block
13. Apply a 2 mm (5/64 inch) bead of 342SX33

MACK-approved sealant to the seams
between the front seal cover and the cylinder
block.
14. Attach the oil pan to the cylinder block.
15. Using a torque wrench, tighten the screws in
sequence according to specification.
Figure 401 — Sealant Points — Flywheel Housing to

Timing Gear Plate and Plate to Block
Use a steel washer. Do not use a copper washer.
Do not use an impact wrench to install the drain
plug. Failure to heed this caution may result in
property damage.
16. Install the drain plug.

17. Check system oil pressure through the
pressure sensor port in the oil filter housing.
Page 233
INJECTOR COPPER SLEEVE REPLACEMENT
[213 EV]
Tools and Equipment
SPECIAL TOOLS

9809667 Injector Copper Sleeve Tap (Essential)
9809668 Injector Copper Sleeve Extractor

(Essential)
9998250 Unit Injector Bore Gallery Sealing Rings

(Available)
9998252 Unit Injector Sleeve Tap (Essential)
Page 234
88800196 Swedging Tool for Installing Unit Injector

88880010 Swedging Tip for Copper Sleeve Swedging

Tool (Available separately)
PT-2900 Chip Vacuum (Essential)
Page 235
Preliminary Steps
404
The following components need to be

removed for access to the injector copper
sleeves (see ENGINE DISASSEMBLY for
procedures):
앫 Cylinder Head Cover
앫 Unit Injector(s)
Copper Sleeve Removal

1. If the injector sleeve is not being removed
immediately, install the protective plug into
the unit injector bore of the cylinder head to
protect it from debris.
403
Figure 404 — Fuel Gallery Sealing Rings
Two sealing rings are required to cover the fuel

gallery.
3. Remove the plug from the lower front side of

the flywheel housing and install the flywheel
turning tool. Turn the flywheel until the piston
is at its lowest position in the cylinder.
405
Figure 403 — Unit Injector Bore Protective Plug
2. Install two sealing rings to prevent dirt from

entering the fuel gallery when the copper
sleeve is removed.
Page 236
This is to ensure that the copper sleeve tapping Applying grease will capture copper cuttings and
tool does not damage the piston due to tool prevent them from falling down into the cylinder.
length.
Ensure the turning tool is well greased before 6. Thread the tap in small increments. Remove
attempting to turn the flywheel. the tap and wipe off the grease and copper
sleeve shavings. Apply fresh grease,
reinstall the tapping tool and thread more of
4. Adjust the 9 mm tap so that it extends a
the copper sleeve. Continue this process to
minimum of 25 mm or 1 inch (dimension A)
thread the tap all the way through the copper
from the end of the tapping tool.
406 sleeve until no resistance is felt and the tap
turns freely. Tapping in small increments and
removing the shavings minimizes the
chance of shavings falling into the cylinder
and the sleeve turning in the cylinder head.
Ensure that the tap is completely through the
copper sleeve.
407
Figure 406 — Copper Sleeve Tapping Tool
This ensures that the tip of the copper sleeve is

tapped all the way through.
Figure 407 — Tapping Tool Installation
If the copper sleeve is not completely tapped

If threads are not cut completely through the tip of
through to the opening of the tip, an end piece of
the copper sleeve, the tip can break off and fall
the tip can break off and fall into the cylinder
into the cylinder. This can result in damage to the
during removal.
cylinder, piston, valves or turbocharger.
5. Lubricate the tip of the 9 mm tap with
7. Remove the tap and tapping tool.
grease.
8. Using the chip vacuum, remove any
remaining shavings from the copper sleeve.
Page 237
9. Install the extractor bolt into the end of the
extractor tool. Adjust the bolt until it extends
approximately 22 mm (0.9 inch) beyond the
end of the tool (dimension A). Make sure the extractor bolt is threaded
408 completely into the copper sleeve before
attempting to remove it or the tip of the sleeve
may break off as it is removed. This broken
sleeve tip can seriously damage the piston,
valves or turbocharger.
12. While holding the top of the tool stationary,

turn the large nut clockwise to extract the
copper sleeve.
410
Figure 408 — Adjusting Copper Sleeve Extractor Bolt
10. Tighten the set screw of the extractor tool to

secure the bolt. Make sure that the set screw
is seated against the flat part of the extractor
bolt.
11. Place the extractor tool with the bolt into the
injector bore. Make sure the nut on the
spindle is backed off so that the threaded
Figure 410 — Copper Sleeve Extraction
end can be completely installed through the
copper sleeve tip. Hand tighten until the bolt
bottoms out in the sleeve.
409
When the copper sleeve is removed, make sure

that the extractor bolt is extended at least one
thread beyond the copper sleeve. If not, make
sure that no part of the copper sleeve has broken
off and fallen into the cylinder.
Do not use air tools to remove copper sleeves, or

damage to the injector bore can result.
Figure 409 — Extractor Tool Installation
Page 238
13. Remove the two sealing rings from the fuel
412
passage. Using the chip vacuum, remove

any remaining debris from the injector bore.
411
Figure 412 — Cleaning Copper Sleeve Seat
16. Using the brush, clean the cylinder head

injector bore walls for the copper sleeve.
Figure 411 — Fuel Gallery Sealing Rings 413
14. Install the injector bore sealing tool

(J 42885-25) to protect the fuel passage
area and prevent debris from entering. Use
the unit injector hold down bolt to secure the
tool in the cylinder head.
15. Using the injector bore cleaning kit, clean
the copper sleeve seat of the cylinder head.

prevent dirt from entering the fuel passage.
Figure 413 — Cleaning Copper Sleeve Bore Walls

Page 239
17. Using the brush, clean the copper sleeve Copper Sleeve Installation
opening in the cylinder head.
414 1. Ensure the piston is at the lowest position in
the cylinder. If not, use the flywheel turning
tool to place the piston at its lowest position.
415
Figure 414 — Cleaning Injector Tip Bore

When replacing the copper sleeves, it is This is to ensure that the copper sleeve
important to check that the sleeve bore in the installation tool does not damage the piston due
cylinder head is free from any carbon deposits or to tool length.
other residue (i.e., pieces of O-ring, etc.) before
installing a new copper sleeve. Reclean if
necessary.
18. Using the chip vacuum, remove all debris

from the copper sleeve bore.
Do not attempt to blow away debris using

compressed air. Doing so can result in eye injury.
19. Remove the injector bore sealing tool from

the cylinder head. Using the chip vacuum,
remove any remaining debris.
Page 240
2. Before installing the copper sleeve, inspect it
to ensure that it is the correct part.
416
Failure to use the proper bit can result in the bit

breaking off into the cylinder head.
418
Figure 416 — Copper Sleeve and O-Ring
3. Lubricate a new copper sleeve O-ring with

coolant. Install the O-ring on the copper
sleeve and lubricate again with coolant.
Always use a new O-ring.
4. Place the new copper sleeve on the
installation tool.
417
Figure 418 — Swedging Bit Verification
Figure 417 — Installation Tool Identification
Before installing the sleeve on the installation

tool, inspect the tool to ensure that it is the correct
tool. The correct tool is identified by a bottom
surface that has a machined circular recess. Use
of a tool with a perfectly flat bottom may result in
damage to the copper sleeve.
5. Using calipers, measure the swedging bit to

make sure that the proper swedging tool is
used. Measurement should read
approximately 7.8 mm. Also, verify that the
length of the swedging bit is 108 mm.
Page 241
6. Thread the swedging bit completely into the 9. Carefully place the sleeve installation tool
flaring tool until it stops (finger tight). (with new copper sleeve attached) into the
unit injector bore of the cylinder head.
Carefully move the copper sleeve downward
into the injector bore so that the swedging bit
Swedging bit can be ordered as a spare part if is guided into the injector tip bore in the
the bit is worn or broken. cylinder head. Push downward on the
installation tool using hand force to move the
419
copper sleeve downward until it bottoms out
on the injector sleeve seat in the bottom of
the injector bore. Use the unit injector hold
down and bolt to hold the tool in position. To
ensure that the copper sleeve is bottomed in
the cylinder head, tighten the unit injector
hold down bolt to specification.
Remove any oil from the injector hold down bolt

holes to avoid hydraulic lock for this step and
when the injector is installed.
420
Figure 419 — Swedging Bit
7. Loosen the swedging bit 180 degrees before

installing the tool in the cylinder head.
Failure to loosen the swedging bit can result in

the bit being twisted or broken.
8. Lubricate the swedging bit and the threads

on the tool with oil.
Figure 420 — Copper Sleeve Installation Tool
Page 242
10. Flare the copper sleeve by turning the nut
422
(1) clockwise while holding the spindle until

the swedging bit has been pulled completely
Failure to hold the spindle can result in a twisted

or broken swedging bit.
421
Figure 422 — Unit Injector Bore Protective Plug
Final Steps
Install the following components which were
removed for access to the injector copper
sleeves (see ENGINE REASSEMBLY for
procedures):
앫 Unit Injector(s)
Figure 421 — Flaring Copper Sleeve Using Installation
Tool
11. Remove the sleeve installation tool from the
injector bore.
If the injector is not being installed immediately,

install the protective plug into the injector bore to
protect it from debris.
Page 243
UNIT INJECTOR CLEANING Cleaning and Inspection
Preliminary Steps
Since the unit injectors operate at very high fuel
Remove the following components from the injection pressures, the nozzle tip spray holes
engine (see ENGINE DISASSEMBLY for and the immediate area around the spray holes
procedures): remain clean and free of carbon deposits. This
앫 Cylinder Head Cover leaves the cap nut seat surface as the only
surface which requires a thorough cleaning.
앫 Rocker Arm Shaft Assembly
앫 Unit Injectors
Clean the injector cap nut surface as follows:
Install the sealing plug, 9998251, into the unit 1. Remove the two O-rings from the injector
injector bore of the cylinder head to prevent dirt and discard the O-rings.
and debris from entering the bore.
423 2. Cover the O-ring grooves and the complete
area between the grooves with tape or
equivalent to prevent contaminants from
getting into the injector.
3. Cover the opening for the electrical
connection.
4. Slide a short section of 6 mm (0.25 inch) ID
hose over the injector nozzle tip until it
covers approximately half the nozzle tip
length. This is necessary to protect the
nozzle spray holes from damage when
cleaning the cap nut seat surface.
424
Figure 423 — Installing Injector Bore Sealing Plug,

9998251
Figure 424 — Injector Nozzle Tip Cover
1. Injector Cap Nut Seat 2. Hose (covering Nozzle

Surface Tip)
Page 244
5. With the unit injector nozzle tip spray holes 6. Clean any remaining carbon using hand
protected, carefully clean the cap nut seat tools such as a hand scraper or medium grit
surface of hard carbon deposits using a wire emery cloth.
wheel. Apply only light nominal pressure to
7. After cleaning, inspect the injector nozzle
hold the wire wheel against the injector
cap nut seat surface for pitting or related
surface for short periods of time.
425 damage. If there is pitting or other damage,
replace the injector.
Pitting on surfaces other than the cap nut seat

does not affect the function of the unit injector and
is acceptable.
8. Install new O-rings in the grooves on the

injector.
9. Lubricate the injector O-rings with clean
engine oil.
Figure 425 — Cleaning Injector Cap Nut Seat Surface

Final Steps
Install the following components on the engine
(see ENGINE REASSEMBLY for procedures):
The carbon will be very hard and difficult to
앫 Unit Injectors
remove. Avoid the tendency to use excessive
pressure in holding the wire wheel against the 앫 Rocker Arm Shaft Assembly
injector cap nut surface. Excessive force can
damage the cap nut surface, making the injector
unacceptable for reuse.
Page 245
VALVE STEM HEIGHT
426
MEASUREMENT PROCEDURE
[213 FB]
On engines exhibiting poor performance, smoke
(at times) and a noticeable engine miss (with the
symptoms getting worse as the engine gets
hotter), may be an indication of valve seat
recession. A decrease in clearance (valve lash)
between the valve rocker and valve yoke (bridge)
can be measured at the valves to determine if
seat recession is occurring. If valve seat
recession is suspected, the following procedure
can be used to measure valve stem height. To
perform this measurement, a valve stem height
measurement gauge (tool No. 85112461) and a
depth micrometer are required.
Figure 426 — Engine Brake Piston Retained

For detailed information on rocker arm shaft
removal and installation procedures, refer to the 3. Remove the valve yokes (bridges).
applicable section of this service manual.
1. Remove components as necessary to gain

access to the cylinder head (valve) cover. The valve yokes must be installed on the same
2. Remove the cylinder head cover and rocker set of valves that they were removed from. Before
arm shaft assembly. removing the valve yokes, mark them to identify
their location and orientation. An incorrectly
installed valve yoke causes severe engine
damage due to a dropped valve. For proper valve
yoke removal and installation, refer to the
On engines equipped with an engine brake, use appropriate sections in this service manual.
suitable tie straps or mechanics wire to retain the
pistons in the rocker arms. The match between 427
the pistons and rocker arms must be maintained.

Failure to secure the engine brake pistons before
removing the rocker shaft assembly, allows the
pistons to drop from the bore of the rocker arms.
If a piston drops out, it might not be noticed, or it
may be difficult to push the piston fully back into
the bore of the rocker arm. Also, pistons are a
match-fit to the rocker arm, and so inadvertent
mix-up of components must be avoided.
Assembling the rocker arm shaft to the engine, or
operating an engine with the engine brake pistons
not fully retracted (or missing), results in
breakage of valve train components and
significant engine damage.
Figure 427 — Removing the Valve Yoke
1. Inlet Valve Stem Tips 2. Inlet Valve Yoke
Page 246
4. Remove the screws securing the unit 6. Place the valve stem height measurement
injector harness tie bar to the cylinder head. gauge (tool No. 85112461) over the valve
Slide the tie bar outward to provide sufficient spring of the valve to be measured. Make
clearance for the valve stem height sure the tool is fully seated on a clean
measurement gauge to be installed over the surface.
valve springs. Do not disconnect the
harness connectors from the unit injectors or
cut the tie straps that secure the harness to
the tie bar. Make sure there are no particles of any kind
428
between the bottom of the valve stem height
measurement gauge and the cylinder head
surface. Particles between the gauge and the
cylinder head surface results in an inaccurate
measurement.
430
Figure 428 — Move Harness Tie Bar Outward
1. Tie Straps 3. Wiring Harness

2. Tie Bar Notch
5. Set the depth micrometer to 8.10 mm

(0.319 inch) to measure stem protrusion.
429
Figure 430 — Place Measurement Gauge over Valve

Spring
Figure 429 — Set Depth Micrometer
Page 247
7. Place the depth micrometer on top of the 앫 If there is clearance between the tip of
valve stem height measurement gauge and the valve stem and the tip of the depth
note if there is clearance between the end of micrometer spindle, valve height is
the micrometer spindle and the tip of the within specification. Measure the next
valve stem. valve stem height using the same
431
method.
앫 If valve stem height is less than
8.10 mm (0.319 inch), as indicated by
the tip of the depth micrometer spindle
contacting the tip of the valve stem, the
valve seat is recessed. Replacement of
the cylinder head is necessary.
8. Position the unit injector harness tie bar to
the cylinder head, install the screws and
tighten according to specification.
9. Install the valve yokes to their original
location.
10. Install the rocker arm shaft assembly and
remove the retainers securing the engine
brake pistons. Adjust valve lash as
necessary.
11. Install the cylinder head cover.
12. Install the components that were removed to
Figure 431 — Measuring Valve Stem Height gain access to the cylinder head cover.
Page 248
VALVE STEM SEAL REPLACEMENT
[213 MV]
Special Tools


(Essential)
Page 249
Preliminary Steps
433
The following components need to be

removed for access to the valve stem seals
(see ENGINE DISASSEMBLY for procedures):
앫 Unit Injectors
Seal Removal
Figure 433 — Compressing Valve Springs
When replacing the valve stem seals, the pistons 1. Valve Spring Compressor 9990210
must be at TDC when the valves are released so
that the valves do not drop into the cylinder.
3. Remove and discard the valve stem seals.
1. Using the flywheel turning tool, 88800014, 4. Using a clean cloth, thoroughly clean all
rotate the crankshaft so that the pistons are engine oil off the valve stem and valve guide.
at TDC for the appropriate pair of cylinders
where stem seals are being replaced. Seal Installation
432
1. Apply a thin film of clean engine oil to the

outside diameter of the valve seal guide tool
and to the sealing lips of the new valve stem
seal to avoid damage to the seal as it is
installed.
Do NOT apply oil to the inner surfaces of the seal

that contact the valve guide. These surfaces must
be dry.
2. Place the seal guide tool, 88800011, in

Figure 432 — Rotating Crankshaft position on the valve stem.
2. Using the valve spring compressor tool, 3. Place a new valve stem seal in position over
9990210, press down on the springs (one at the guide tool and onto the valve stem.
a time) and remove the valve retainers and 4. Using the appropriate end of the seal
springs for the cylinder. installation tool, 85112460, seat the valve
stem seal on the valve guide by gently
tapping the installation tool with a light
plastic or rubber mallet. When the seal is
Use protective goggles or eye injury could fully seated, a normal “spring-back” of the
occur. seal will occur, leaving a maximum gap of
approximately 0.5 mm (0.02 inch) between
the bottom of the seal and the shoulder
surface on the valve guide.
Page 250
5. Using the valve spring compressor,
9990210, install the valve spring and valve
retainers. Carefully tap on the valve stem
Use only gentle taps with the hammer when with a plastic or rubber hammer to ensure
seating the seal to avoid damage to the seal that the valve keepers are positioned
casing as well as the top rubber portion of the correctly.
seal.
Use protective goggles or eye injury could

occur.
Seal installation tool, 85112460, is designed for
use on MP7, MP8 and MP10 engines. Use the
appropriate end of the tool for the engine being 6. Move the valve spring compressor to the
serviced. next cylinder of the cylinder pair and repeat
the procedure. Rotate the crankshaft so that
434
the pistons are at TDC for the next cylinder
pair and repeat the procedure. Continue on
and repeat the procedure for the final
cylinder pair.
Final Steps
Install the following components which were
removed for access to the valve stem seals
(see ENGINE REASSEMBLY for procedures):
앫 Unit Injectors
Figure 434 — Seating the Valve Stem Seal 앫 Cylinder Head Cover
Page 251
NOTES
Page 252
Page 253
MP8 EURO 3 ENGINE SETUP
AND ADJUSTMENT
[200 EA]
Due to the Engine Electronic Control Unit (EECU)

self-learning capability, it is necessary to reset
learned EECU parameters after servicing some
EECU to learn the new component's behavior.
After servicing is complete, perform the “Learned
Data Reset” located in VCADS.
Special Tools

9999696 Magnetic Base (Available)
85111377 Feeler Gauge Set
Page 254
85111422 Timing Gear Cover Alignment Tool
(A, B)
85111493 Angled Extension (Available)
88800014 Flywheel Turning Tool
Page 255
Valve and Unit Injector Adjustment
[213 NB, 222 KG]
— 4 Rocker — Marked as E1–E6.
— 3 Rocker — Marked as V1–V6.
GENERAL INFORMATION
435
INLET VALVE ADJUSTMENT
Apply the parking brake before barring the

engine over. Remove the EMS power supply
fuse to avoid starting the engine
unintentionally. Make sure that the
transmission is not in gear.
With the engine cold, 60°C (140°F) or less, check

and adjust the valves and injector as required for
each cylinder before moving to the next. Follow
this sequence of cylinders when adjusting
clearances: 5, 3, 6, 2, 4 and 1.
1. Using the flywheel turning tool, 88800014,
bar the engine over manually to the
Figure 435 — Camshaft Timing Marks — Front Bearing appropriate camshaft marking for
Cap (4 Rocker Shown) adjustment of the inlet valves and injector for
that cylinder.
Timing marks for basic camshaft timing and 2. Using a feeler gauge, check the clearance
adjustment of the valves and unit injectors are between the rocker arm adjusting screw and
located at the front of the camshaft just forward of the valve yoke (bridge) of the inlet valves.
the No. 1 front bearing journal. Two lines at the Refer to Figure 436.
top of the front bearing cap mark the alignment 436
point for positioning of the camshaft and making
the adjustments.
The top dead center (TDC) mark is used for basic

camshaft timing. The TDC mark must be between
the two lines on the front camshaft bearing cap
when the flywheel is at 0° (top dead center for
cylinder No. 1).
The engine must be cold, 60°C (140°F) or less,

before making these adjustments.
Camshaft markings for setting of valves and
unit injectors:
앫 Without PowerLeash™: Markings 1–6
apply to adjustment of inlet valves, exhaust
valves and injectors.
앫 With PowerLeash™: Markings 1–6 apply to
adjustment of inlet valves and injectors.
Markings E1–E6/V1–V6 apply to adjustment
of exhaust valves. Figure 436 — Checking Inlet Valve Clearance
Page 256
3. If the clearance is not within specification, EXHAUST VALVE ADJUSTMENT (WITHOUT
loosen the locknut and adjust the clearance POWERLEASH™)
as required.
1. At the current camshaft setting used for the
4. Hold the adjusting screw to prevent it from inlet valves, adjust the exhaust valves
turning and tighten the locknut to following the same procedure described for
specification. adjustment of the inlet valves. However, the
valve clearance specification is different.
5. Recheck the clearance after tightening the 438
locknut.
6. Mark the rocker arm when adjustment is
complete.
UNIT INJECTOR ADJUSTMENT

The unit injector adjustment is done with the
engine and camshaft in the same position as for
the inlet valve adjustment on each cylinder.
1. Loosen the injector rocker arm adjusting
screw jam nut and turn the adjusting screw
out (counterclockwise) to relieve the preload.
2. Turn the adjusting screw in (clockwise) until
it firmly contacts the injector. Do not
compress the spring.
3. Turn the adjusting screw in a further 240°
(four flats on the hex head).
437
Figure 438 — Checking Exhaust Valve Clearance

complete.
3. Using the flywheel turning tool, bar the
engine over manually to the appropriate
marking for the next cylinder. Adjust the inlet
valves, unit injector and exhaust valves at
that cylinder.
Figure 437 — Adjusting Unit Injector Clearance
4. Hold the adjusting screw to prevent it from

turning further and, using a torque wrench,
tighten the jam nut to specification.
complete.
Page 257
EXHAUST VALVE ADJUSTMENT (WITH
440
3-ROCKER POWERLEASH™)
The numbers on the camshaft preceded by a V

are used to adjust the exhaust valves when the
engine is equipped with PowerLeash™.

bar the engine over so that the appropriate V
number marking for the respective exhaust
valve is between the lines on the camshaft
bearing cap.
Figure 440 — Measuring Exhaust Valve Clearance
2. Press down on the rocker arm as shown in
Figure 439. If the rocker arm “springs,” the 4. If clearance is not within specification, adjust
brake piston spring should be pulled outward the clearance as required, using shims
at the same time as the rocker arm is (Figure 441) placed on top of the valve yoke
pressed down to make and ensure contact (bridge).
with the valve stem. Use a strong wire with a
hooked end to catch and compress the a. Remove the shim retaining screw and
spring. When the piston spring is loosened remove the shim(s).
from its seat, the residual oil film retaining b. Determine the thickness of the shim(s)
the spring is punctured, allowing the required to match the measured
adjustment setting to be more accurate. clearance.
439
c. Make sure that the valve yoke and
shim(s) are clean. Place the shim(s) in
position on the valve yoke.
DO NOT use more than two shims. Shims are

available in 0.05 mm (0.002 inch) increments with
the thickness marked on the surface. If two shims
are required to take up the clearance, the shims
should be of nearly equal thickness.
441
Figure 439 — Releasing Engine Brake Piston Pressure
3. Measure the clearance between the rocker

arm piston and the shim on top of the yoke
(bridge) as shown in Figure 440.
Figure 441 — Engine Compression Brake Adjustment

Shim
Page 258
5. With the required shim(s) in place, install the 1. Loosen the screws holding the plate springs
retainer screw securing the shim(s) to the to release the spring tension against the
valve yoke and tighten to specification. Hold engine brake rocker arms.
the yoke securely while tightening the 443
retaining screw.
6. Recheck the clearance between the exhaust
valve rocker arm and the valve yoke.
Mark the respective rocker arm as each valve

adjustment is completed.
EXHAUST VALVE ADJUSTMENT (WITH

4-ROCKER POWERLEASH™)
The numbers on the camshaft preceded by an E

are used to adjust the exhaust valves when the
engine is equipped with PowerLeash™.
442
Figure 443 — Plate Spring Attaching Screws

bar the engine over so that the appropriate E
number marking is between the lines on the
front camshaft bearing cap.
3. Measure the clearance between the exhaust
rocker arm piston and the shim on top of the
valve yoke (bridge) as shown in Figure 444.
444
Engines equipped with the PowerLeash™ engine

brake have two rocker arms working in
combination to control the exhaust valves. They
are the exhaust rocker arm and the brake
rocker arm which are adjusted separately as
described in the following procedure.
Figure 444 — Measuring Exhaust Valve Clearance
Page 259
4. If clearance is not within specification, adjust b. Using the dial indicator with angled
the clearance as follows, using shims extension and base (9989876,
(Figure 441) placed on top of the valve yoke 85111493 and 9999696), place the tip
(bridge). of the dial gauge on the yoke as close
as possible to the rocker arm yoke pad.
Adjusting Exhaust Rocker Arm Clearance
Zero the gauge.
a. Remove the shim retaining screw and 446
remove the shim(s).

b. Determine the thickness of the shim(s)
required to provide the specified
clearance.
c. Make sure that the valve yoke and
shim(s) are clean. Place the shim(s) in
position on the valve yoke and install
the retaining screw. Tighten the screw
to specification.
DO NOT use more than two shims. Shims are

available in 0.05 mm (0.002 inch) increments with
the thickness marked on the surface. If two shims
are required to take up the clearance, the shims
should be of nearly equal thickness.
445
Figure 446 — Brake Rocker Arm Adjustment with Dial

Indicator
A. Locknut B. Adjusting Screw
c. Tighten the rocker arm adjusting screw

B until the dial shows that the yoke has
been pushed downward to
specification.
d. Loosen the rocker arm adjusting screw
e. Hold the adjusting screw to prevent it
Figure 445 — Engine Compression Brake Adjustment
from turning further and, using a torque
Shim wrench, tighten the locknut to
specification.
5. Leave the feeler gauge in place between the
exhaust rocker arm piston and the valve 6. Remove the dial indicator and the feeler
yoke shim and adjust the brake rocker arm gauge.
clearance. 7. Using a feeler gauge, check the clearance
Adjusting Brake Rocker Arm Clearance between the brake rocker arm roller and the
cam lobe. If the clearance is incorrect,
a. Loosen the locknut A on the brake repeat the brake rocker arm clearance
rocker arm adjusting screw. adjustment.
Page 260
447 448
Figure 447 — Checking Brake Rocker Arm Roller to Cam Figure 448 — Plate Spring Attaching Screws
Lobe Clearance
8. Mark the respective rocker arm as each OPERATIONAL CHECK

valve adjustment is completed. After the valve and unit injector adjustments have
been completed, check engine operation as
CONTINUATION OF ADJUSTMENTS follows:
Continue the procedure by barring the engine to 1. Using the flywheel turning tool, bar the
the appropriate timing marks and adjusting the engine over manually two complete
valves and unit injectors at each of the remaining revolutions to ensure that no piston-to-valve
cylinders. Follow the steps described above to contact occurs. If contact does occur,
adjust the inlet and exhaust valves, and unit readjust the valves as needed BEFORE
injector at each cylinder. starting the engine.
2. Start the engine and bring it up to normal
For engines equipped with the 4-rocker operating temperature.
PowerLeash™ engine brake, tighten the plate
spring attaching screws to specification after the 3. Once normal operating temperature is
valve and unit injector adjustments have been attained, let the engine idle for an additional
completed. five minutes. During this time, the electronic
engine management system (EMS) will
perform its own cylinder balancing, resulting
in smooth engine idling.
DO NOT use any form of power consuming

equipment, such as PTO or air conditioning,
when cylinder balancing is being carried out.
Page 261
Checking and Adjusting Timing
450
Gear Backlash
(Camshaft Gear to Idler Gear)
Apply the parking brake before barring the

engine over. Remove the EMS power supply
fuse to avoid starting the engine
unintentionally. Make sure that the
transmission is not in gear.
1. Remove the 16 retaining screws and springs

and remove the valve cover from the cylinder
head.
2. Disconnect the wiring harness leads at the Figure 450 — Camshaft Positioning
unit injectors and camshaft sensor
connector. Pull the harness out through the 7. Loosen and remove the six screws securing
cover. the vibration damper and gear to the
camshaft. Remove the damper from the
3. Remove the compressor coolant lines. camshaft, but DO NOT remove the camshaft
4. Loosen and remove the capscrews securing gear.
the timing gear cover to the cylinder head. 8. Install the gauge plate tool, J 44514-1A.
451
5. Remove the timing gear cover from the
engine. Use care when removing the cover
to avoid the rubber seals falling into the
flywheel housing. Remove the rubber seals
from the cover and discard.
449
Figure 449 — Timing Gear Cover

Figure 451 — Camshaft Gear Timing Marks Alignment
6. Using the flywheel turning tool, bar the
engine over manually so that the camshaft is 9. Insert the alignment tool in the hole in the
positioned at top dead center (TDC) by timing gear plate to engage the camshaft
aligning the TDC mark on the camshaft with gear teeth with the rod of the tool in the slot
the timing marks on the No. 1 camshaft of the clamp tool. Rotate the camshaft until
bearing cap. this occurs.
Page 262
10. Tighten the bolts to specification. With the d. While holding the idler gear in against
camshaft set at TDC, the double timing the thickness gauge and camshaft
marks on the gear should be aligned with gear, tighten, but DO NOT torque, the
the marking hole in the gear plate. idler gear hub screws.
11. Install the clamp assembly tool, J 44514-5. e. Tighten the clamp assembly tool.
12. Install a dial gauge against a tooth on the f. Recheck the backlash. With the
camshaft gear (Figure 452). With the idler specified backlash attained, replace
gear locked in position, rotate the camshaft each adjustable idler gear hub screw
gear back and forth to measure backlash. with new and tighten the screws to
The backlash reading should be within specification.
specification. 453
452
Figure 453 — Idler Gear Flank Clearance Adjustment
1. Idler Gear 2. Hub Screws
14. Remove the gauge plate tool securing the

camshaft gear. Use care to ensure that the
gear remains in place and properly aligned
on the camshaft.
15. Reinstall the vibration damper on the gear
and camshaft. Install the six new mounting
screws and tighten to specification.
Figure 452 — Camshaft Gear Backlash Measurement
16. Apply a 2 mm (5/64 inch) bead of
1. Idler Gear 2. Camshaft Gear
MACK-approved sealant on the timing gear
cover mounting surface and install new
rubber seals (Figure 454).
13. If the backlash measurement is out of
specification, adjust the gear flank clearance
as follows:
a. Loosen the clamp assembly tool.
b. Loosen the camshaft idler gear hub
screws. Loosening the hub screws will
allow the idler gear to be moved slightly
in/out from the camshaft gear.
c. Insert a 0.1 mm (0.004 inch) thickness
gauge on the pressure side of the idler
and camshaft gear teeth (Figure 453).
Page 263
18. Using alignment tools, 85111422A and
454
85111422B, ensure that the upper and lower

seals are properly seated and that the upper
surface of the cover is flush with the top of
the cylinder head (points A in Figure 455).
19. Install the three remaining capscrews (item 2
in Figure 455) and tighten to specification.
20. Reconnect the wiring harness leads at the
unit injectors and camshaft sensor
connector.
21. Apply an even 2 mm (5/64 inch) bead of
sealant at the joint lines (point A) between
the cylinder head and the timing cover.
22. Install the valve cover and the 16 retaining
screws and springs. Tighten the screws to
specification.
Figure 454 — Timing Cover Seals and Sealant

Application
1. Rubber Seals 2. Sealant
17. Place the timing gear cover in position on

the engine. Install two capscrews (item 1 in
Figure 455) and hand tighten.
455
Figure 455 — Timing Gear Cover Installation
Page 264
ENGINE FINAL PREPARATION PRIMING THE LUBRICATION SYSTEM
AND OPERATIONAL CHECK 1. Fill the engine crankcase with the specified
quantity of the specified engine oil.
After Engine Overhaul 2. Using a pressure prelubricator filled with the
Procedures specified oil, prime the engine lubrication
system for a minimum of five minutes.
Filter Element Installation 3. Check the crankcase oil level.

4. If necessary, add oil to reach the FULL mark
All filters and coolant conditioners must meet on the dipstick.
MACK specifications.
1. Install a new air filter in the air filter housing.
2. Using a torque wrench, tighten the attaching Do NOT overfill.
screw to specification.
3. Lubricate the gaskets.
Oil Pressure
4. Using a filter wrench, tighten the filters to
specification.
Engine
5. Attach the filters to the valve housing. Speed/RPM Temperature Pressure
6. Using a filter wrench, tighten the filters to 600 90–110°C >250 kPa (36 psi)
specification. (195–230°F)
>1100 90–110°C 300–550 kPa
(195–230°F) (44–80 psi)
Engine Lubrication System >1100 Cold Engine 650 kPa (95 psi)
An oil film coats rotating parts and bearings of an

overhauled engine, but this may not provide Rocker Shaft Engine
sufficient lubrication when the engine is started Engine Brake Speed/RPM Oil Pressure
for the first time. Following is the recommended Inactive — 80–120 kPa
procedure for providing adequate lubrication. (12–17 psi)
Active 900–2300 220 kPa (32 psi)
Do not mix brands or types of lubricants.

Chemical additives may be incompatible and may
contribute to the formation of sludge, acid and
hardening.
engine damage.
Usually there are various points on the engine

where a pressure line may be opened, but if no
other is apparent, use the oil pressure sensor
port.
Page 265
Turbocharger Fuel System
It is necessary to perform the system Before working on or inspecting a vehicle, set

pre-lubrication procedure anytime the vehicle has the parking brake, place the transmission in
not been operated for a period exceeding 30 days neutral and block the wheels. Failure to heed
to avoid damage to the turbocharger. During this this warning can result in unexpected vehicle
extended period, all oil will have drained away movement and cause severe personal injury
from the bearing and shaft surfaces. or death.
1. Remove and flush the turbocharger oil

supply line with a suitable, clean,
non-flammable solvent.
To avoid potential fire hazard, do not service
any part of the fuel system while smoking or
in the presence of flames, sparks or hot
Allow solvent to run through the line to flush any surfaces, or when working on an operating
debris, then blow the line dry with clean engine. Failure to heed this warning can
compressed air. result in fire which can produce severe
A turbocharger failure can result in debris

contaminating the turbocharger oil supply line. It Wear adequate protective clothing (face
is EXTREMELY IMPORTANT to remove, flush shield, heavy gloves, apron, etc.) when
and thoroughly clean the line prior to starting the working on a hot engine to guard against
engine. Failure to heed this caution may result in burns from direct contact with hot fuel.
severe component and engine damage. Failure to heed this warning can result in
severe personal injury or death.
2. Reinstall the oil supply line.
3. Prime the lubrication system following the
procedure described earlier in this section.
4. Following engine overhaul, use the Do not work near the fan with the engine
diagnostic computer to calibrate the variable running. The engine fan can become active at
geometry turbocharger. any time without warning. Failure to heed this
warning can result in severe personal injury.
Cooling System
1. Check the cooling system. Make sure all
plugs and coolant drain quick disconnects
Before turning the ignition on, make sure no
are installed and are tight.
one is near the fan. Failure to heed this
2. Make sure the thermostat is installed. warning can result in severe personal injury.
3. Install a new coolant filter.
4. Fill the system with the recommended 1. Check the fuel system to make sure that all
coolant. connections are tight.
2. Start the engine and run it at idle for
approximately 5 minutes to remove air
trapped in the fuel system.
Make sure that all air is purged from the cooling
system.
Page 266
PRIMING THE FUEL SYSTEM 5. Check the fuel system to make sure that all
connections are tight.
Using the hand priming pump is usually only
necessary when the fuel system has air in it, or
when replacing filters. If hand priming is needed,
use the following procedure.
456 If the engine does not start following this
procedure, contact your local MACK Truck dealer.
Do not crank the engine continuously for more

than 30 seconds without allowing the starter to
cool for 2 minutes between cranks.
Some starters are equipped with starter
protection. If the starter temperature is too high,
starter engagement is inhibited to prevent starter
damage. Wait until the starter has cooled to crank
the engine.
The only acceptable method of priming the fuel

system is the hand primer pump. Applying air
pressure to the fuel tank or using an auxiliary
Figure 456 — Unlocking the Hand Primer Pump pump to prime the fuel system is PROHIBITED.
These priming techniques may cause fuel to leak
1. Unlock the hand primer pump by pushing past the supply pump seal into the crankcase.
the handle in and turning it Failure to heed this caution may result in severe
counterclockwise. engine damage.
2. Pump the hand primer until the force of
pumping increases.
After running for 5 minutes, the engine, all its

components and fluids will be hot. Contact
When the fuel system is completely empty, 200 or
with hot components and fluids can cause
more strokes may be needed to prime the system
severe burns. Failure to heed this warning can
properly.
result in severe personal injury.
There are NO bleed nipples to be opened in order

to prime the fuel system.
3. Lock the pump by pushing the handle into

the housing, turning it clockwise and
releasing it.
4. Start the engine and run it at an increased
idle for approximately 5 minutes to remove
air trapped in the fuel system.
Page 267
Engine Operational Check Run-in procedures vary depending on method
used (i.e., engine dynamometer, chassis
1. Remove all tools from the engine dynamometer or highway run-in). Regardless of
compartment. method, however, always prepare the engine
2. Connect the battery cables (negative cable properly before starting it for the first time.
last).
3. Clear the work area of debris and personnel. Run-In Check
The following step is important to proper break-in Install any additional instrumentation needed for
for all new parts at initial startup of the engine. the run-in method selected.
4. Start the engine and immediately increase

The operator should be familiar with the correct,
the speed to 1200–1600 rpm. During the
established procedure for checking chassis
break-in period, check for leaks and monitor
power before using the chassis dynamometer
gauges for satisfactory oil pressure, etc.
method for run-in. Refer to applicable chassis
5. Operate the engine within the dynamometer operating procedures.
1200–1600 rpm range for 15 minutes.
The operator must be observant throughout the
entire run-in procedure in order to detect any
problems.
DO NOT allow the engine to drop to idle speed
until the 15 minute break-in period at Constantly monitor the instrument display of
1200–1600 rpm has been completed. engine functions and support systems and record
all readings.
6. Shut down the engine.
If the engine develops any of the following
7. Check the fluid levels and fill to capacity abnormal characteristics during run-in, shut it
before restarting the engine. down immediately.
8. Refer to Rebuilt Engine Run-In Procedures
Discover and correct problems before continuing
for inspections to be sure of proper engine
the run-in procedure.
operation before releasing the vehicle for
service.
Always investigate the following conditions:
앫 Unusual noises, such as knocking, scraping,
REBUILT ENGINE RUN-IN etc.
PROCEDURES 앫 A significant drop in engine oil pressure
앫 A significant rise in coolant temperature,
General exceeding 116°C (240°F)
앫 A significant rise in oil temperature that
The durability and service life of a rebuilt engine exceeds 116°C (240°F)
is directly related to its initial run-in following
overhaul. After a complete overhaul or any major 앫 An exhaust temperature that exceeds
repair job involving installation of piston rings, maximum acceptable limits for the engine
pistons, cylinder liners or bearings, the engine involved, as measured by a pyrometer (if
must be run-in prior to release for service. applicable)
앫 Any oil, coolant, fuel or air inlet system leaks
Page 268
SPECIFICATIONS
SPECIFICATIONS
Page 269
SPECIFICATIONS
MP8 EURO 3 ENGINE MECHANICAL SPECIFICATIONS
Material and Dimensional Data
GENERAL DATA, WEIGHTS AND DIMENSIONS
Item Specification
Engine Type In-line, direct injection, diesel
Number of Cylinders 6
Displacement 12.8 L
Bore and Stroke 131 x 158 mm (5.16 x 6.22 in.)
Compression Ratio 18.1:1
Emissions Level Euro 3
Fuel System Electronic Unit Injector
Valve Actuation Single Overhead Cam, 4 valves per cylinder
Aspiration Turbocharger
Power Cylinder Wet sleeve; one-piece steel pistons
Electronic Controls Electronic Management System (EMS)
Peak Power Ratings 254–324 kW (346–440 hp)
Peak Torque Ratings 1800–2200 N•m (1328–1623 lb-ft)
Weight, Dry 1145 kg (2524 lb.)
Firing Order 1–5–3–6–2–4
Length Overall 1359 mm (53.5 in.)
Width Overall 813 mm (32.0 in.)
Height Overall 1171 mm (46.1 in.)
COMPONENT FEATURES AND MATERIALS
Item Description
Air Compressor Flange mounted, oil lubricated, coolant cooled
Camshaft Induction hardened, gear driven
Coolant Conditioner Spin-on type, disposable
Coolant Pump Centrifugal rotor impeller, belt driven
Connecting Rods Forged steel, cracked cap design
Crankshaft Drop forged steel, induction hardened, seven main bearings
Cylinder Block In-line six cylinder; wet, replaceable cylinder sleeves; cast
iron, machined with bearing caps, stiffener plate added at
bottom, timing gear train mounting plate added at rear
Cylinder Head One-piece cast iron alloy; supports overhead camshaft, four
valve system, unit injectors; replaceable cast iron valve
guides with oil seals; replaceable steel valve seats; copper
unit injector sleeves; integral fuel passages; integral
thermostat housing
Cylinder Head (Valve) Cover Plastic, 20 spring tension attaching screws
Cylinder Head — Valve Springs Double springs on exhaust valves, single on inlet
Page 270
SPECIFICATIONS
Item Description
Cylinder Head — Valve Guides Cast iron, replaceable; with oil seals
Cylinder Head Gasket One-piece steel stamping; elastomer seals added; one-time
bosses to aid head installation
Cylinder Head Bolts M16 (38)
Cylinder Liner Wet; replaceable; with EDPM rubber and Viton seals
Fasteners and Threads Metric
Flywheel Housing Die-cast aluminum
Fuel Filters Two: primary and pre-filter with water separator
Fuel Injection Individually programmed unit injectors (6): EMS module
controlled; common fuel gallery in head; constant supply
pressure; over-pressure return
Fuel Supply Pump Gear type pump integral with power steering pump;
crankshaft idler gear driven
Lubrication System Crankshaft gear driven lubrication pump; system integrated
within block and head; serves camshaft, rocker arm shaft,
pistons, crankshaft, air compressor; three filters, 1 bypass
and 2 full-flow; lubricant level and temperature sensor in oil
pan
Main Bearing Caps Nodular iron; machined with block; No. 7 mounts lubrication
pump; 1–3, 5 and 6 numbered for consistent reassembly;
cast and drilled for consistent reassembly; thrust washers at
No. 4 main bearing journal
Manifold — Exhaust Three-piece, six port
Pistons Steel; one-piece; 3 ring grooves
Piston Rings — Compression 2: 1 trapezoidal cross section, 1 rectangular cross section
Piston Ring — Oil 1 garter spring type; scraping
Oil Filters 2 full flow; 1 bypass
Filter capacity, 2 full flow:
앫 4.0–4.5 L (4.2–4.8 qts.)
Oil Pan Plastic or steel; 22 spring-tension screws
Sump capacity:
앫 25 L (26.4 qts.) minimum
앫 30 L (31.7 qts.) maximum
Thermostat, Coolant Piston-type; 82°C (180°F)
Thermostat Housing Integrated in head
Timing Gear Cover Die-cast aluminum, elastomer seals
Turbocharger Exhaust gas driven, radial flow, engine oil lubricated
Valve Rocker Arms Roller followers
Valve Seat Inserts Pressed in head, replaceable
Vibration Damper, Crankshaft Internal fluid-filled ring
Page 271
SPECIFICATIONS
FITS AND LIMITS
The specifications as listed are for new parts and,
therefore, maximum wear must be established by
good judgment, experience and sound shop
practice.
Tolerances Are Shown Low to High Standard Size or Fit

Component Metric English
CAMSHAFT
Camshaft Journal Diameter 70 mm 2.75 in.
Inlet Valve Lobe Nominal Lift 13.1 mm 0.516 in.
Exhaust Valve Lobe Nominal Lift (EPG) 12.3 mm 0.484 in.
Exhaust Valve Lobe Nominal Lift (3-Rocker) 13.1 mm 0.516 in.
Exhaust Valve Lobe Nominal Lift (4-Rocker) 12.3 mm 0.484 in.
Camshaft End Play 0.24 mm max. 0.0094 in. max.
CONNECTING ROD
Length between Centers 267.5 mm 10.5 in.
CRANKSHAFT
Crankpin Journal OD 99 mm 3.9 in.
(Inspection only: not for machining)
Main Journal OD 108 mm 4.25 in.
(Inspection only: not for machining)
CYLINDER BLOCK
Main Bearing Bore in Block 113 mm 4.449 in.
Cylinder Sleeve Flange Bead to Block Deck (Top of Bead to 0.15–0.21 mm 0.0059–0.0083 in.
Block Deck)
1. Cylinder Liner 2. Cylinder Block
Page 272
SPECIFICATIONS
CYLINDER HEAD
Do NOT machine the cylinder head. This will

change the extension of the injector/valves and
upset injector timing.
Do NOT grind copper injector sleeves.
Overall Height 135 mm 5.315 in.

Valve Guide Height Above Cylinder Head Spring Face — 24.5 mm 0.965 in.
Inlet
Valve Guide Height Above Cylinder Head Spring Face — 24.5 mm 0.965 in.
Exhaust
Valve Seat Insert (Inlet) 45 mm 1.77 in.
Valve Seat Insert (Exhaust) 43 mm 1.69 in.
Valve Seat Height (Inlet) 7.55 mm 0.2972 in.
Valve Seat Height (Exhaust) 7.5 mm 0.2953 in.
Valve Seat Counterbore Depth (Inlet) 11.8 mm 0.4646 in.
Valve Seat Counterbore Depth (Exhaust) 11.2 mm 0.4409 in.
INJECTORS
Preload 240° (4 flats on the hex head)
PISTON
Wrist Pin Diameter 58 mm 2.2835 in.
Wrist Pin Length 76 mm 2.9921 in.
PISTON RINGS
Compression Ring End Gap — Upper: Wear Tolerance 0.9 mm max. 0.0354 in. max.
Compression Ring End Gap — Lower: Wear Tolerance 1.3 mm max. 0.0512 in. max.
Oil Control Ring End Gap — Wear Tolerance 1.0 mm max. 0.0394 in.
OIL PUMP
Crankshaft Gear to Oil Pump Gear Backlash 0.1–0.4 mm 0.004–0.016 in.
TIMING GEARS
Adjustable Idler Gear to Camshaft Gear Backlash 0.05–0.15 mm 0.0020–0.0059 in.
VALVES
Head Diameter (Inlet Valve) 42 mm 1.654 in.
Head Diameter (Exhaust Valve) 40 mm 1.575 in.
Inlet Rocker Arm Clearance (cold engine) 0.2 ±0.05 mm 0.008 ±0.002 in.
Page 273
SPECIFICATIONS
Exhaust Rocker Arm Clearance (cold engine)
— without PowerLeash™ 0.8 ±0.05 mm 0.031 ±0.002 in.
— with PowerLeash™ 3-Rocker 1.6 ±0.05 mm 0.063 ±0.002 in.
— with PowerLeash™ 4-Rocker 0.8 ±0.05 mm 0.031 ±0.002 in.
Brake Rocker Arm Clearance, PowerLeash™ 4-Rocker (cold engine)
Note: After setting exhaust arm clearance
— Brake rocker press down using adjusting screw 0.25 ±0.05 mm 0.010 ±0.002 in.
— Brake rocker adjusting screw loosening 720° counterclockwise —
— Clearance check (camshaft to brake rocker arm roller) 3.8 ±0.1 mm 0.150 ±0.004 in.
Valve Face to Cylinder Head Deck (Inlet) 1.0 mm min. 0.0394 in. min.
1.6 mm max. 0.0630 in. max.
Valve Face to Cylinder Head Deck (Exhaust) 1.35 mm min. 0.0531 in. min.
2.0 mm max. 0.0787 in. max.
Note: Replacing valve seats requires replacing valves.
VALVE SEAT ANGLE
Inlet Valve Head 24.5°
Exhaust Valve Head 39.5°
Inlet Valve Seat 25.0°
Exhaust Valve Seat 40.0°
VALVE SPRINGS
Outer Spring:
Free Length (approximate) 73.8 mm 2.91 in.
Inner Spring:
Free Length (approximate) 70.5 mm 2.78 in.
Page 274
SPECIFICATIONS
Exhaust Pressure Governor
457
Figure 457 — Exhaust Pressure Governor
Stroke, shutter (A) 29 mm min. 1.14 in. min.
Page 275
SPECIFICATIONS
Engine Component Torque FASTENER REUSE
Specifications (Critical Fasteners)
Repeated tightening of fasteners and threaded

components reduces their capacity to function
All components are to be clean and free from adequately. The following table describes the
foreign material or corrosion. Assemblies are to various items and the limits of their reusability.
be made using suitable tools and procedures so Failure to conform to these limits may result in
that no permanent damage will occur as a result severe component damage.
of the assembly.
Threads, washers, under head of screw and
washer face of nuts should be lubricated with
clean engine oil unless otherwise specified.
The following listed fasteners require the use of a
calibrated manual torque wrench. If an adapter is
required in combination with a torque wrench, a
correction factor must be applied to the torque
wrench readings in order to obtain accurate
fastener torque values.
Fasteners noted by an asterisk (*) require
retorque after engine run-in.
Reusable
Fasteners Examples Limit Reuse Recommendations
Highly loaded screws Cylinder head 5 times Apply engine oil on threads and
(Phosphating plus oil) Cylinder block under screw head.
Injector yoke Mark bolt head with an
indentation.
Camshaft bearing housing
Dry mounting for new screws
Transmission (except adjustable (delivered with oil pre-applied and
idler gear) anti-rust treatment for spare
Flywheel parts).
If a part is replaced, e.g., cylinder
head, also replace the screws.
Connecting rods 5 times Apply clean engine oil.
Adjustable idler gear Do not reuse
Special screws (specific shape) Oil pan and valve cover No limit No limit if no cracks, corrosion or
damage to the flat surfaces.
Flange head screws Exhaust manifold 5 times If exhaust manifold is replaced,
also replace the screws.
Stainless steel fasteners and Turbocharger 5 times If turbocharger or the exhaust
spacers manifold is replaced, also replace
the fasteners and spacers and
apply anti-seize.
Prevailing torque feature screws Piston cooling jets Do not reuse
(Dri-Loc Plastic or Tuflock)
Standard screws Property class 8.8 No limit No limit if no cracks, corrosion or
Property class 10.9 damage to the flat surfaces.
Property class 12.9
Page 276
SPECIFICATIONS
Reusable
Fasteners Examples Limit Reuse Recommendations
V-nipples with taper thread With locking fluid pre-applied Do not reuse Before fitting the new nipple,
clean the hole with a nipple tap
and apply sealant on the nipple
thread, or use a new, coated
nipple.
Taper plugs or nipples With sealer fluid pre-applied Do not reuse Before fitting the new nipple,
clean the hole with a nipple tap
and apply sealant on the nipple
thread, or use a new, coated
nipple.
Bolts and screws that have limited reusability

458
specified in the table above must be marked with

a punch (A) each time they are installed in
service. Bolts and screws with four punch marks
when removed have been tightened five times
and must be discarded.
Do not reuse timing gear mounting plate bolts.

Do not reuse timing gear mounting bolts.
SENSORS AND WIRING HARNESS
Overtorquing a sensor or sensor mounting screw

can result in sensor breakage or thread damage.
Figure 458 — Usage Marks on Head of Fastener
Sensors
Camshaft Position (timing gear cover) 8 ±2 N•m (6 ±1 lb-ft)
Charge Air Pressure/Temperature (inlet manifold) 3.3 N•m (29 lb-in)
Coolant Level (surge tank) Plug-in
Coolant Temperature (front, right side cylinder head) 22 ±3 N•m (16 ±2 lb-ft)
Crankcase Pressure (block, front of air compressor) 30 ±5 N•m (22 ±3 lb-ft)
Flywheel Position/Speed (top of flywheel housing) 8 ±2 N•m (6 ±1 lb-ft)
Fuel Pressure (fuel filter housing) 25 ±3 N•m (18.5 ±2 lb-ft)
Humidity (fresh air pipe) 27 ±3 N•m (20 ±2 lb-ft)
Oil Level/Temperature (inside sump) Standard Torque
Oil Pressure (block, front of air compressor) 30 ±5 N•m (22 ±4 lb-ft)
Wiring Harness
Attaching Screws 24 ±4 N•m (18 ±3 lb-ft)
Page 277
SPECIFICATIONS
MP8 ENGINE COMPONENTS — TOP OF ENGINE
Valve (Cylinder Head) Cover
459
Figure 459 — Valve Cover Torque Sequence
Install two alignment pins and bushings in the head before assembling the valve cover.
Tighten screws in the order indicated to . . . 24 ±4 N•m (18 ±3 lb-ft)
Page 278
SPECIFICATIONS
Camshaft Bearing Caps and Rocker Arm
Shaft Assembly
The rocker arm shaft assembly is installed on top

of the camshaft bearing caps (inboard side) using
the long screws, numbers 8 through 21. The 460
rocker arm shaft and camshaft bearing cap

retaining screws are tightened to specification as
listed below in the table.
Figure 460 — Camshaft Cap Torque Sequence Screw Numbers
Preliminary steps:
앫 Discard screws with four punch marks when removed and replace with new screws.
앫 If not already loose, loosen screws 1–7 before proceeding with the tightening sequence.
Step 1. Screws 1–7 25 ±3 N•m (18 ±2 lb-ft)
In step 2, tighten the screws progressively beginning with screw No. 11.
In steps 3–7, tighten the screws progressively from the center to the outer ends.
Step 3. Screws 1–7, angle tighten 90 ±5°
Step 6. Screws 8–13 Loosen completely
Page 279
SPECIFICATIONS
Cylinder Head
461
Figure 461 — Sealant Application Pattern — Head to Plate
Remove all old sealant before attempting to apply new sealant.

Apply a 2 mm (0.079 inch) bead of sealant to the timing gear plate following the pattern shown.
Attach the head to the timing gear plate within 20 minutes of applying the sealant.
Page 280
SPECIFICATIONS
462
Figure 462 — Torque Sequence Screw Numbers — Head to Block
Discard screws with four marks when removed and substitute new screws.
Tighten the screws in the order indicated by the numbers in the graphic.
Step 1. 100 ±5 N•m (74 ±4 lb-ft)
Step 2. Verify 100 ±5 N•m (74 ±4 lb-ft)
Step 3. Angle tighten 120° ±5°
Page 281
SPECIFICATIONS
Additional Top of Engine Components
Cylinder Head Plugs
Plug, M10 x 1.00 25 ±3 N•m (18 ±2 lb-ft)
Plug, M10 x 1.00, coated 10 ±2 N•m (7.5 ±1.5 lb-ft)
Plug, M14 x 1.50, coated 30 ±3 N•m (22 ±2 lb-ft)
Plug, M16 x 1.50 50 ±3 N•m (37 ±2 lb-ft)
Cylinder Head Connectors
Right side, coated 10 N•m (7.5 lb-ft)
Rocker Arm Components
Locknut, Valve Adjustment (Inlet and Exhaust without Engine 38 ±4 N•m (28 ±3 lb-ft)
Brake)
Locknut, Valve Adjustment (Exhaust with Engine Brake) 52 ±4 N•m (38 ±3 lb-ft)
Locknuts, Injector Adjustment 52 ±4 N•m (38 ±3 lb-ft)
Retainer Screw, Shim (Exhaust Yoke) 38 ±4 N•m (28 ±3 lb-ft)
Engine Brake
Attaching Screws, Solenoid Valve 24 ±4 N•m (18 ±3 lb-ft)
See Engine Brake Valve under Rocker Arm Components.
Engine Brake Plate Spring (PowerLeash™, 4-Rocker) 25 ±3 N•m (18 ±2 lb-ft)
Injector Retainers
If the copper injector sleeve is new, injector yoke screws must be tightened in five steps.
Step 3 requires loosening after steps 1 and 2.
If the copper injector sleeve is reused, only steps 4 and 5 below apply.
Step 1. 20 +5/−0 N•m (15 +4/−0 lb-ft)
Step 3. Loosen the screws until the torque is 10–15 N•m (7–11 lb-ft).
Step 4. 20 +5/−0 N•m (15 +4/−0 lb-ft)
Step 5. Angle tighten
앫 With raised-bead design copper sleeve (no injector 60° ±5°
gasket)
앫 With flat-bottom design copper sleeve and injector 90° ±5°
gasket
Page 282
SPECIFICATIONS
MP8 ENGINE COMPONENTS — FRONT OF ENGINE
Crankshaft Damper
463
Figure 463 — Torque Sequence Screw Numbers — Damper to Crankshaft
Do NOT reuse screws. Use new screws in service and tighten in the order indicated.
Step 1. 35 ±5 N•m (26 ±4 lb-ft)
Step 2. 90 ±10 N•m (66 ±7 lb-ft)
Page 283
SPECIFICATIONS
Crankshaft Front Seal Cover
464
Figure 464 — Sealant Application Pattern — Cover to Block

Apply a 2 mm (5/64 inch) bead of 3092340 sealant to the seal cover following the pattern (A) shown.
Attach the cover to the cylinder block within 20 minutes of applying the sealant.
465
Figure 465 — Torque Sequence Screw Numbers — Cover to Block
Tighten screws in the order indicated according to the following torque specifications.
Step 1. Secure cover with screws 1 and 2 Hand tighten
Page 284
SPECIFICATIONS
Front Engine Support
466
Figure 466 — Torque Sequence Screw Numbers — Support to Brackets
Step 1. Tighten in order: 1, 2, 3, 4, 5 and 6 275 ±45 N•m (203 ±33 lb-ft)
Step 2. Verify in the same order 275 ±45 N•m (203 ±33 lb-ft)
Front Engine Support Mounting Brackets

467
Figure 467 — Engine Support Brackets to Block
Sequence Torque Angle Tighten

Step 1. Screw No. 1 80 ±15 N•m (59 ±11 lb-ft) —
Step 2. Screws No. 2, 3 and 4 105 ±15 N•m (77 ±11 lb-ft) 60 ±5°
Step 3. Screw No. 1 105 ±15 N•m (77 ±11 lb-ft) 60 ±5°
Step 4. Screw No. 5 Standard screw torque —
Page 285
SPECIFICATIONS
Additional Front of Engine Components
468
Figure 468 — Coolant Pump Housing
Coolant Pump Housing

Step 1. Tighten all 6 screws in the following sequence: 2, 5, 6, 48 ±8 N•m (35 ±6 lb-ft)
4, 3, 1.
Step 2. Retighten screws 2 and 5. 48 ±8 N•m (35 ±6 lb-ft)
Viscous Fan Drive
Attaching Nuts, Drive to Hub 24 ±4 N•m (18 ±3 lb-ft)
Attaching Nuts, Hub to Cylinder Head and Block 48 ±8 N•m (35 ±6 lb-ft)
Page 286
SPECIFICATIONS
MP8 ENGINE COMPONENTS — REAR OF ENGINE
Timing Gear Train Plate
469
Figure 469 — Sealant Application Patterns — Head and Block to Plate

Apply a 2 mm (0.079 inch) bead of sealant to the timing gear plate next to the groove following the patterns shown.
Attach the timing gear plate to the head and block within 20 minutes of applying the sealant.
470
Figure 470 — Torque Sequence — Plate to Cylinder Block and Cylinder Head
Do not reuse mounting plate screws.

Do NOT apply sealant to new, coated screws.
Tighten screws in the order indicated. 28 ±4 N•m (21 ±3 lb-ft)
Page 287
SPECIFICATIONS
Timing Gears
471
Figure 471 — Torque Sequence Screw Numbers — Gear Mounting
Component Torque Plus Angle Tighten

Loosen any screws used to pull the cylinder head into position before beginning this sequence.
Tighten screws in the order indicated on each gear.
(A) Crankshaft Gear (2 screws) 24 ±4 N•m (18 ±3 lb-ft)
(B) Intermediate Gear Hub (6 screws) 25 ±3 N•m (18 ±2 lb-ft) 110° ±5°
(C) Intermediate Adjustable Gear Hub 35 ±4 N•m (26 ±3 lb-ft) 120° ±5°
(5 screws)
(D) Camshaft Gear and Damper (6 45 ±5 N•m (33 ±4 lb-ft) 90° ±5°
screws)
Page 288
SPECIFICATIONS
Timing Gear Cover
472
Figure 472 — Sealant Application Pattern — Cover to Plate

Apply a 2 mm (0.079 inch) bead of sealant to the timing gear cover following the pattern shown.
Attach the cover to the timing gear plate within 20 minutes of applying the sealant.
473
Figure 473 — Torque Sequence Screw Numbers — Cover to Plate
Step 1. Align cover to cylinder head so that sealing surfaces are flush and install screws 1 and 2. Hand tighten screws 1 and
2 to hold alignment.
Step 2. Tighten screws in the order indicated. 24 ±4 N•m (18 ±3 lb-ft)
Page 289
SPECIFICATIONS
Flywheel
474
Figure 474 — Torque Sequence Numbers — Flywheel to Crankshaft
Mark the head of each screw after installation. Discard screws with four marks when removed and substitute new screws.
Lubricate the threads and under the heads of screws to be reused.
Do NOT lubricate new screws that are coated.
Step 1. Tighten screws in the order indicated. 60 ±5 N•m (44 ±4 lb-ft)
Step 2. In the order indicated: angle tighten. 120° ±10°
Page 290
SPECIFICATIONS
Flywheel Housing
475
Figure 475 — Sealant Application Pattern — Flywheel Housing to Plate

Apply a 2 mm (5/64 inch) bead of 3092340 sealant to the flywheel housing following the pattern shown.
Attach the housing to the timing gear mounting plate within 20 minutes of applying the sealant.
476
Figure 476 — Torque Sequence — M14 and M10 Screws (Housing to Plate and Block)
Page 291
SPECIFICATIONS
477
Figure 477 — Torque Sequence — M8 Screws (Plate to Housing)
Tighten the screws in the order indicated according to the following torque values.
Step 1. M14, M10 and M8 screws 24 ±4 N•m (18 ±3 lb-ft)
Step 2. M14 screws, 1–8 140 ±20 N•m (103 ±15 lb-ft)
Step 3. M10 screws, 9–12 48 ±8 N•m (35 ±6 lb-ft)
Step 4. M8 screws, 13–23 (front of timing gear 24 ±4 N•m (18 ±3 lb-ft)
plate-to-flywheel housing)
Additional Rear of Engine Components

Attaching Screws, Rear Engine Support Bracket to Flywheel 300 ±45 N•m (221 ±33 lb-ft)
Housing
Page 292
SPECIFICATIONS
MP8 ENGINE COMPONENTS — BOTTOM OF ENGINE
Oil Pan
478
Figure 478 — Torque Sequence Screw Numbers — Oil Pan to Block
Tighten screws in the order indicated to . . . 24 ±4 N•m (18 ±3 lb-ft)
479
Figure 479 — Torque Sequence — Block Stiffener Plate to Block
Do NOT reuse stiffener plate attaching screws. Always use new screws in service.
Tighten the screws in the order indicated according to the following torque specifications.
Step 1. All screws 45 ±5 N•m (33 ±4 lb-ft)
Step 2. Angle tighten 60 ±5°
Page 293
SPECIFICATIONS
480
Figure 480 — Oil Filter Support Assembly
Filter Support Attaching Screws 24 ±4 N•m (18 ±3 lb-ft)

Oil Filter 25 +5/−0 N•m (18 +3.5/−0 lb-ft)
1. Plug 55 ±5 N•m (40 ±4 lb-ft)
2. Plug 12 ±2 N•m (9 ±1.5 lb-ft)
3. Plug 55 ±5 N•m (40 ±4 lb-ft)
4. M6 Screws 10 ±2 N•m (7 ±1.5 lb-ft)
Additional Bottom of Engine Components

Lube Valve Housing
Attaching Screws (4) Hand start all, then tighten to 48 ±8 N•m (35 ±6 lb-ft).
Crankshaft Bearing Caps
Attaching Screws
Step 1. 150 ±20 N•m (111 ±15 lb-ft)
Connecting Rod Bearing Caps
Tighten screws in a cross pattern.
Attaching Screws
Step 1. 20 ±3 N•m (15 ±2 lb-ft)
Step 2. 60 ±3 N•m (44 ±2 lb-ft)
Step 3. Angle tighten 90 ±5°
Oil Pan Drain Plug 60 ±10 N•m (44 ±7 lb-ft)
Oil Pump Attaching Screws 24 ±4 N•m (18 ±3 lb-ft)
Nozzle Attaching Screws, Piston Cooling 24 ±4 N•m (18 ±3 lb-ft)
Do not reuse.
Page 294
SPECIFICATIONS
MP8 ENGINE COMPONENTS — RIGHT SIDE
Exhaust Manifold
481
Figure 481 — Torque Sequence Numbers — Manifold to Cylinder Head
Use anti-seize compound on contact surfaces of nuts, bolts and screws when reassembling exhaust system components.
Step 1. All screws 5 ±1.5 N•m (3.5 ±1 lb-ft)
Step 2. Screws 1, 4, 5, 8, 9 and 12 10 ±1.5 N•m (7.5 ±1 lb-ft)
Step 3. Screws 3, 2, 7, 6, 11, 10, 1, 4, 5, 8, 9 and 12 48 ±8 N•m (35 ±6 lb-ft)
Oil Cooler Cooling Duct Cover

482
Figure 482 — Oil Cooler to Cooling Duct Cover
Step 1. Screws 1, 2, 3 and 4 5 ±1 N•m (44 ±9 lb-inl)

Step 2. Screws 1, 2, 3, 4 and 1 27 ±4 N•m (20 ±3 lb-ft)
Page 295
SPECIFICATIONS
483
Figure 483 — Torque Sequence Numbers — Cooling Duct Cover to Block
Place the cover in position on the cylinder block and loosely install screw A.
Press the cover against the coolant pump housing using the assembly tool 88800022 and loosely install screw B.
Check that the duct cover is properly positioned and install the screws following the step sequence listed below.
Step 1. Screws C and D 24 ±4 N•m (18 ±3 lb-ft)
Step 2. Starting at the center and moving outward — all 24 ±4 N•m (18 ±3 lb-ft)
screws in sequence 1, followed by sequences 2 (including A),
3 (including B) and 4.
Step 3. Verify screws C and D. 24 ±4 N•m (18 ±3 lb-ft)
Turbocharger
484
Figure 484 — Torque Sequence — Turbocharger Mounting Fasteners
Fasteners, Turbocharger to Exhaust Manifold (use anti-seize compound at reassembly)

Step 1. 20 ±4 N•m (15 ±3 lb-ft)
Step 2. 48 ±8 N•m (35 ±6 lb-ft)
Page 296
SPECIFICATIONS
Turbocharger Lubrication Fittings
485
Figure 485 — Torque Sequence — Turbocharger Lubrication Fittings
Step 1. Screws 1 and 3 12 N•m (9 lb-ft)

Step 2. Screws 2, 4, 1 and 3 24 ±2.4 N•m (18 ±1.8 lb-ft)
Connector 5 30 ±5 N•m (22 ±4 lb-ft)
Oil Pressure Safety Valve

486
Figure 486 — Oil Pressure Safety Valve
Screws A 50 ±5 N•m (37 ±3 lb-ft)
Page 297
SPECIFICATIONS
Starter 487
Figure 487 — Starter Attaching Studs
Attaching Studs 24 ±4 N•m (18 ±3 lb-ft)

Screws A 18 ±2 N•m (13 ±1.5 lb-ft)
Screws B 3 ±0.5 N•m (27 ±4.4 lb-in)
Screws C 60 ±6 N•m (44 ±4 lb-ft)
Page 298
SPECIFICATIONS
Additional Right-Side Engine Components
Oil Filter
Bracket Attaching Screws 24 ±4 N•m (18 ±3 lb-ft)
Oil Cooler Cooling Duct Cover
Plug, Oil Cooler Cooling Duct Cover 55 ±8 N•m (40 ±6 lb-ft)
Water Drain Connector 40 ±4 N•m (30 ±3 lb-ft)
Fitting, 90° Elbow 30 ±5 N•m (22 ±4 lb-ft)
MP8 ENGINE COMPONENTS — LEFT SIDE

Inlet Manifold
488
Figure 488 — Torque Sequence — Manifold to Cylinder Head
Tighten screws in the order indicated. 24 ±4 N•m (18 ±3 lb-ft)
Page 299
SPECIFICATIONS
Inlet Air Heater
489
Figure 489 — Torque Sequence Screw Numbers — Inlet Air Heater
Tighten screws in the order indicated.

Step 1. 10 ±2 N•m (7 ±1.5 lb-ft)
Step 2. 24 ±3 N•m (18 ±2 lb-ft)
Page 300
SPECIFICATIONS
Low Pressure Fuel Circuit
490
Figure 490 — Screw Number Identification for Torquing — Fuel Circuit
Filter Bracket Attaching Screws, M8 x 1.25 24 ±4 N•m (18 ±3 lb-ft)

No. 1 18 ±3 N•m (13 ±2 lb-ft)
No. 3 30 ±4 N•m (22 ±3 lb-ft)
No. 4 35 ±5 N•m (26 ±4 lb-ft)
No. 5 40 ±5 N•m (29.5 ±4 lb-ft)
No. 6 48 ±5 N•m (35 ±4 lb-ft)
Page 301
SPECIFICATIONS
Fuel Filter Support
491
Figure 491 — Fuel Filter Support — Plugs and Valves
Tighten the plugs and valves according to the following specifications.

No. 1, 40 ±5 N•m (30 ±4 lb-ft) No. 4, 30 ±5 N•m (22 ±4 lb-ft)
No. 2, 10 ±1.5 N•m (7 ±1 lb-ft) No. 5, 2 ±0.5 N•m (18 ±4 lb-in) (Note lb-in)
No. 3, 25 ±1.5 N•m (18 ±1 lb-ft) No. 6, 40 ±1.5 N•m (30 ±1 lb-ft)
Page 302
SPECIFICATIONS
Tandem Pump (Fuel and Power Steering)
492
Figure 492 — Power Steering Pump Connectors
Tighten the connectors according to the following specifications.

Additional Left-Side Engine Components

Alternator
Mounting Bracket Attaching Screws, M10 48 ±8 N•m (35 ±6 lb-ft)
Pad Mount Attaching Screws, M12 85 ±15 N•m (63 ±11 lb-ft)
Attaching Screws, Tension Idler Roller 48 ±8 N•m (35 ±6 lb-ft)
Pulley Nut 101 ±6.5 N•m (75 ±5 lb-ft)
Inlet Manifold
Plug, Inlet Manifold 20 ±3 N•m (15 ±2 lb-ft)
Air Compressor, Brake System
Gear Attaching Nut 200 +50/−0 N•m (147 +37/−0 lb-ft)
Compressor Attaching Nuts 85 ±15 N•m (63 ±11 lb-ft)
Grease Connector 25 ±4 N•m (18 ±3 lb-ft)
Attaching Studs 24 ±4 N•m (18 ±3 lb-ft)
Fuel Pump
Attaching Screws (to Power Steering Pump) 8 +2/−0 N•m (6 +1/−0 lb-ft)
Banjo Bolts 40 ±5 N•m (30 ±4 lb-ft)
Power Steering Pump
Gear Attaching Nut 100 ±10 N•m (74 ±7 lb-ft)
Attaching Screws 24 ±4 N•m (18 ±3 lb-ft)
Refrigerant Compressor, Air Conditioning
M8 Attaching Screws 24 ±4 N•m (18 ±3 lb-ft)
Page 303
SPECIFICATIONS
Standard Bolt and Nut Torque
Values
The torque values in the table below conform to
standard STD 5511,15.
N•m (lb-ft)
Screw/Bolt
(Nut) Metric
Size Grade 8.8 Grade 10.9
M6 x 1.00 10 ±1.5 (7 ±1) 12 ±2 (9 ±1.5)
M8 x 1.25 24 ±4 (18 ±3) 30 ±5 (22 ±4)
M10 x 1.50 48 ±8 (35 ±6) 60 ±10 (44 ±7)
M12 x 1.75 85 ±15 (63 ±11) 105 ±20 (77 ±15)
M14 x 2.00 140 ±25 175 ±30
(103 ±18) (129 ±22)
M16 x 2.00 190 ±35 275 ±45
(140 ±26) (203 ±33)
M18 x 2.50 290 ±45 360 ±55
(214 ±33) (265 ±40)
M20 x 2.50 430 ±70 540 ±90
(317 ±52) (398 ±66)
M22 x 2.50 580 ±90 730 ±120
(428 ±66) (528 ±88)
M24 x 3.00 740 ±120 900 ±140
(546 ±88) (664 ±103)
Page 304
SPECIFICATIONS
ENGINE GASKETS,
LUBRICANTS AND SEALANTS
Gasket and Seal Reuse

Some gaskets and seals must be discarded if
removed during service. The following table
describes the components and their limits.
Reusable
Components Examples Limit Reuse Recommendations
Gaskets (steel) Cylinder head Do not reuse Discard the old gasket and
substitute new if the head is
removed.
Gaskets (hot) Exhaust manifold Do not reuse Discard old gaskets and
Turbocharger substitute new if associated
components are removed.
Rubber gaskets (special) Sealing strip (coolant duct cover, No limit if no Remove old silicone from the T
valve cover, oil pan, upper timing damage and no joints.
gear cover and inlet manifold) leaks Clean the surfaces.
Apply fresh silicone.
Rubber gaskets (standard) O-rings and sealing rings Do not reuse
Bonded seals, steel/rubber gasket Nipples, hollow screws and oil No limit if no
filter housing damage and no
leaks
Valve seals Valve stems No limit if no Discard old seals and substitute
damage and no new if the gasket is removed.
leaks
Crankshaft seals Do not reuse Discard old seals and substitute
new if removed. Do not apply oil
on the inside or outside diameters
of the seal during assembly.
SEALS MUST BE DRY
MOUNTED.
Sealant agent Sealing between: Do not reuse Remove the old sealant.
Timing Gear Plate and Cylinder Clean the surfaces.
Block Apply fresh sealant.
Flywheel Housing and Timing Important: Remove the old
Gear Plate silicone from the T joints and
Timing Gear Cover and Gear apply fresh.
Plate
Page 305
SPECIFICATIONS
Lubricants and Sealants
Use only the following recommended sealing All genuine MACK cylinder head gaskets are
compounds and lubricants. precoated and do not require any type of sealing
compound. Before installing new gaskets,
degrease both gasket sealing surfaces to avoid
leaks.
Location Sealant or Lubricant

Crankshaft front seal cover Part No. 342SX33 (or Dow Corning® 832)
Cup plugs/threaded plugs Loctite® 277 or equivalent/Teflon® thread sealer
Cylinder sleeve seats Part No. 342SX33 (or Dow Corning® 832)
Engine parts, fasteners (sides and threads), and washers Clean engine oil
Injector sleeve copper seals Clean coolant
Oil filter sealing gaskets (full-flow filters) Clean engine oil
O-rings Use the type of fluid that the O-ring contacts in use.
Sensors with O-ring seals Assemble dry
Valve stems and guides SAE 15-40 clean engine oil
Page 306
SPECIAL TOOLS & EQUIPMENT
Page 307
MP8 ENGINE SERVICE TOOLS
[200 EA]
Special Tools for Engine Overhaul

9809667 9 mm Tap, use with 9998252 (Available)
9809668 9 mm Bit, use with 9998253 (Available)
9809729 Hydraulic Ram (Available)
9990006 Two-Jaw Puller for Unit Injector Removal,

Page 308
9990008 Set of Test Pins
9990013 Slide Hammer for Unit Injector Removal,

9990106 Sealing Plate for MP7, MP8 and MP10

Cylinder Heads
9990107 Connection Disc for MP7, MP8, and MP10

Cylinder Heads
9990114 Main Bearing Cap Puller
Page 309
9990176 Tool Press for Valve/Valve Guide

Replacement (Available)
9990192 Crankshaft Seal Puller
9990262 Slide Hammer Adapter

9991821 Slide Hammer for Pilot Bearing Removal

and other various uses (Available)
Page 310
9992564 Driver for Installation of Pilot Bearing, use

9996049 Coolant Drain Hose (Available)
9996159 Adapter (Tool Press for Valve/Valve Guide

Replacement) (Available)
Page 311
9996222 Hydraulic Pump (Available)
9996454 Handle for Liner Installation Plate

(Available)
9996599 Liner Installation Plate (Available)
9996662 Pressure Gauge and Hoses (Available)
Page 312
9998170 Seal Spacer (Essential)
9998238 Rear Main Seal Remover/Installer, use with

9992000 (Essential)
Note: For Teflon® seals, use tools
9990166, 9990192 and 9996400.
9998246 Valve Spring Compressor Adapter

(Available)
9998250 Fuel Gallery Sealing Rings (Available)
Page 313
9998252 Unit Injector Sleeve Tap (to thread nose of

cup) (Essential)
This tool comes with both M8 x 1.25 (part
No. 9987009) and M9 x 1.25 (part No.
9809667) taps. Use the larger of the two
taps, M9 x 1.25 (part No. 9809667), when
servicing an MP8 engine.

This tool comes with both M8 (part No.
9809746) and M9 (part No. 9809668) bits.
Use the larger of the two bits, M9 (part No.
9809668), when servicing an MP8 engine.
9998263 Valve Guide Removal Tool (Available)
9998267 Dowels (Locating Tools for the Timing Gear

Mounting Plate)
9998333 Coupler, for use with EGR Cooler Leak

Test Kit 88800216.
Page 314
9998511 Lever
9998531 Piston Ring Compressor (Essential)
9998649 Block Stiffener Plate Installation Tool
9998691 Oil Filter Nipple (Spud) Installer Kit

(Essential)
Page 315
9999696 Magnetic Stand (Available)

Note: Alternate lifting tool —9998264
85109208 Bearing Cap Press Tool (Essential)

(Essential)
Note: Alternate lifting tool —9990185
85109980 Camshaft Bearing Cap Removal Tool, use

85111377 Feeler Gauge Set
Page 316
85111422 Timing Gear Cover Alignment Tool
(A, B) (Essential)
85111493 Angled Extension (Available)
85112461 Valve Stem Height Measurement Gauge

(Essential)

(Essential)
Page 317

(Essential)
88800022 Coolant Duct Cover Installation Tool
88800031 Camshaft Sensor Depth Gauge (Essential)
88800062 Inlet and Exhaust Valve Guide Installation

(Available)
Page 318
88800186 Charge Air System Leakage Tester
(Essential)
88800196 Swaging Tool for Installing Unit Injector

88800215 Sealing Plate
88800216 EGR Cooler Leak Test Kit (Essential)

Note: For alternate pressure test method,
use tools 9988288, 9996662 and 9998143.
88880010 Swaging Bit (Available)
Page 319
DBT 2V700 Coolant Extractor/Injector
(2815- 2V700)
J 5347-B Dial Bore Gauge
J 6692-B Cylinder Compression Gauge (Available)
J 26948 Cylinder Liner Height Measurement Tool

(Available)

Note: Alternate tool kit for cleaning —
9998599.
J 43051 Oil Valve Socket
Page 320
J 44392 Fan Belt Tensioner Tool (Available)
J 47038-3 Engine Lifting Tool (Essential)

J 47038-4
J 47038-6
J 47038-8
J 47363 Cylinder Compression Gauge Adapter

(Essential)
Note: Alternate tools — 9998248 with
9988539.
J 47364 Cylinder Head Adapter Plate
Page 321
J 48061 Coolant Conditioner Filter Wrench
(Available)
J 48062 Piston Ring Compressor (Available)
J 48662 Engine Stand Adapter Plate for use with

stand J 29109-A (Available)
Note: Alternate tools —88800117 with
stand 9986485.
J 48922 Heavy-Duty Unit Injector Puller (Essential)
Page 322
PT-2900 Chip Vacuum
PT-6435 or Cylinder Liner Puller (Available)

PT-6400-C Note: Alternate tools for liner removal –
9992955, 9996394, 9996395 and 9996645
in combination.
All of the above tools are available through the

MACK Parts System with the exception of those
beginning with the prefix J or PT-. J and PT- tools
are available from Kent-Moore at the following
address.
KENT-MOORE
O.E. TOOL AND EQUIPMENT GROUP
SPX CORPORATION
28635 MOUND ROAD
WARREN, MICHIGAN 48092-3499
TEL: 1-800-328-6657
FAX: 1-800-578-7375
Page 323
NOTES
Page 324
INDEX
INDEX
Page 325
INDEX
A COPPER SLEEVE REMOVAL. . . . . . . . . . . . . . . . 236
COUNTERBORE INSPECTION AND
ABOUT THE MACK MP8 (EURO 3) ENGINE . . . . . 9
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
ADVISORY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . 2
CRANKCASE VENTILATION . . . . . . . . . . . . . . . . . 25
AIR COMPRESSOR INSTALLATION. . . . . . . . . . 201
CRANKCASE VENTILATION (CCV)
AIR COMPRESSOR REMOVAL. . . . . . . . . . . . . . 100
SEPARATOR REMOVAL . . . . . . . . . . . . . . . . . . 96
AIR INTAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . 34
CRANKCASE VENTILATION (CCV)
ALTERNATOR AND REFRIGERANT
SEPARATOR REPLACEMENT . . . . . . . . . . . . 231
COMPRESSOR INSTALLATION . . . . . . . . . . 208
CRANKCASE VENTILATION SEPARATOR . . . . . 206
ALTERNATOR AND REFRIGERANT
CRANKCASE VENTILATION SYSTEM. . . . . . . . . . 65
COMPRESSOR REMOVAL . . . . . . . . . . . . . . 105
CRANKCASE VENTILATION, CHECK . . . . . . . . . . 50
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
CRANKSHAFT FRONT COVER AND SEAL
AUTOMATICALLY TENSIONED SYSTEM. . . . . . . 69
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 166
B CRANKSHAFT FRONT COVER REMOVAL . . . . . 110
CRANKSHAFT FRONT SEAL REMOVAL. . . . . . . 110
BLOCK CLEANING AND INSPECTION . . . . . . . . 118
CRANKSHAFT FRONT SEAL
BLOCK STIFFENER PLATE REMOVAL . . . . . . . 112
REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . 223
BRACKET REPLACEMENT PROCEDURE . . . . . 219
CRANKSHAFT INSTALLATION . . . . . . . . . . . . . . 158
C CRANKSHAFT REAR SEAL
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 184
CAMSHAFT BEARING BRACKETS,
CRANKSHAFT REAR SEAL REMOVAL . . . . . . . . 103
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 218
CRANKSHAFT REAR SEAL
CAMSHAFT BENCH PROCEDURES. . . . . . . . . . 146
REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . 226
CAMSHAFT GEAR AND VIBRATION DAMPER
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . 115
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
CRANKSHAFT VIBRATION DAMPER AND FAN
CAMSHAFT INSPECTION . . . . . . . . . . . . . . 146, 219
PULLEY INSTALLATION . . . . . . . . . . . . . . . . . 207
CAMSHAFT INSTALLATION . . . . . . . . . . . . . . . . 172
CRANKSHAFT VIBRATION DAMPER AND FAN
CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . 85
PULLEY REMOVAL . . . . . . . . . . . . . . . . . . . . . 109
CAMSHAFT SENSOR DEPTH, CHECK. . . . . . . . . 49
CYLINDER BLOCK RECONDITIONING . . . . . . . . 116
CAMSHAFT TIMING, CHECK . . . . . . . . . . . . . . . . 50
CYLINDER HEAD (VALVE) COVER
CCV SEPARATOR INSTALLATION . . . . . . . . . . . 231
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 210
CCV SEPARATOR REMOVAL . . . . . . . . . . . . . . . 231
CYLINDER HEAD (VALVE) COVER
CHECKING AND ADJUSTING TIMING GEAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
BACKLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
CYLINDER HEAD CLEANING AND
CLEANING AND INSPECTION . . . . . . . . . . . . . . 244
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 132
CONNECTING ROD — PISTON
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . 169
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
CYLINDER HEAD OVERHAUL . . . . . . . . . . . . . . . 127
CONNECTING ROD — PISTON
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . 107
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 122
CYLINDER HEAD, PRESSURE TEST . . . . . . . . . . 51
CONNECTING ROD AND PISTON BENCH
CYLINDER LINER AND PISTON WEAR,
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . 122
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
CONVERSION CHART. . . . . . . . . . . . . . . . . . . . . . . 6
CYLINDER LINER INSTALLATION . . . . . . . . . . . . 120
COOLANT AND PUMP INLET HOUSINGS
CYLINDER LINER REMOVAL . . . . . . . . . . . . . . . . 117
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
COOLANT DRAIN OUTLETS . . . . . . . . . . . . . . . . . 68 D
COOLANT FILTER . . . . . . . . . . . . . . . . . . . . . . . . . 68
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
COOLANT PIPE INSTALLATION . . . . . . . . . . . . . 193
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
COOLANT PUMP INSTALLATION . . . . . . . . . . . . 192
DRIVE BELT REPLACEMENT AND
COOLANT PUMP REMOVAL . . . . . . . . . . . . . . . . 106
TENSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
COOLING DUCT COVER AND OIL COOLER
DRIVE BELTS AND FAN HUB REMOVAL . . . . . . . 95
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . 35, 266 E
COOLING SYSTEM COMPONENTS BENCH
EECU AND COOLER INSTALLATION . . . . . . . . . 204
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . 152
EECU AND COOLING PLATE REMOVAL . . . . . . . 98
COOLING SYSTEM MAINTENANCE. . . . . . . . . . . 68
EGR COOLER, PRESSURE TEST . . . . . . . . . . . . . 54
COPPER SLEEVE INSTALLATION . . . . . . . . . . . 240
Page 326
INDEX
ENGINE CHECKS AND TESTS . . . . . . . . . . . . . . . .46 FRONT ENGINE SUPPORT REMOVAL. . . . . . . . 112
ENGINE COMPONENT TORQUE FUEL FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . 66
SPECIFICATIONS (CRITICAL FUEL FILTER REPLACEMENT . . . . . . . . . . . . . . . 66
FASTENERS) . . . . . . . . . . . . . . . . . . . . . . . . . .276 FUEL LINES AND FILTER HOUSING
ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . .14 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 205
ENGINE COMPRESSION, TEST . . . . . . . . . . . . . . .55 FUEL LINES AND FILTER VALVE HOUSING
ENGINE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . .76 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
ENGINE FINAL PREPARATION AND FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 26, 266
OPERATIONAL CHECK . . . . . . . . . . . . . . . . . .265
ENGINE GASKETS, LUBRICANTS AND G
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .305 GASKET AND SEAL REUSE . . . . . . . . . . . . . . . . 305
ENGINE INFORMATION PLATE . . . . . . . . . . . . . . .12 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . .214 GENERAL INFORMATION . . . . . . . . . . . . . . . 69, 218
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . .265 GENERAL INSTRUCTIONS . . . . . . . 73, 79, 158, 214
ENGINE MANAGEMENT SYSTEM . . . . . . . . . . . . .36 GLOSSARY OF TERMS . . . . . . . . . . . . . . . . . . . . . 38
ENGINE OPERATIONAL CHECK . . . . . . . . . . . . .268
ENGINE PREHEATER/SPACER I
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . .204 IN-CHASSIS PART/COMPONENT
ENGINE REASSEMBLY. . . . . . . . . . . . . . . . . . . . .153 PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . 218
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .72 INJECTOR COPPER SLEEVE
ENGINE SERIAL NUMBER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 234
IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . .12 INJECTOR SLEEVE REPLACEMENT . . . . . . . . . 135
ENGINE SYMPTOM DIAGNOSIS . . . . . . . . . . . . . .44 INLET AIR PREHEATER/SPACER
ENGINE WIRING HARNESS REMOVAL. . . . . . . . .81 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
EXHAUST MANIFOLD INSTALLATION. . . . . . . . .197 INLET AND EXHAUST VALVE REMOVAL . . . . . . 131
EXHAUST MANIFOLD REMOVAL. . . . . . . . . . . . . .92 INLET MANIFOLD INSTALLATION . . . . . . . . . . . 203
EXHAUST PRESSURE GOVERNOR (EPG) INLET MANIFOLD REMOVAL . . . . . . . . . . . . . . . . 99
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . .199 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
EXHAUST PRESSURE GOVERNOR (EPG) INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
EXHAUST PRESSURE GOVERNOR (EPG) L
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 LINER HEIGHT MEASUREMENT. . . . . . . . . . . . . 119
EXHAUST PRESSURE GOVERNOR, LUBRICANTS AND SEALANTS . . . . . . . . . . . . . . 306
OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . .148 LUBRICATION SYSTEM. . . . . . . . . . . . . . . . . . . . . 22
EXPANSION PLUG REPLACEMENT . . . . . . . . . .142 LUBRICATION SYSTEM MAINTENANCE . . . . . . . 64
EXPLANATION OF NUMERICAL CODE . . . . . . . . . .5
M
F MACK MP8 EURO 3 ENGINE DESIGN
FAN HUB AND DRIVE BELT FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . .211 MAIN BEARING CAP INSTALLATION . . . . . . . . . 159
FILTER ELEMENT INSTALLATION. . . . . . . . . . . .265 MAIN BEARING CAP REMOVAL . . . . . . . . . . . . . 114
FILTERS AND MISCELLANEOUS MATERIAL AND DIMENSIONAL DATA . . . . . . . . 270
COMPONENTS INSTALLATION . . . . . . . . . . .213 MOUNTING THE ENGINE ON A REPAIR
FINAL STEPS. . . . . . . . . . . . . . . . .220, 243, 245, 251 STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
FLYWHEEL AND PILOT BEARING MP8 ENGINE SERVICE TOOLS. . . . . . . . . . . . . . 308
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . .185 MP8 EURO 3 ENGINE COMPONENT LOCATION
FLYWHEEL AND PILOT BEARING VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 MP8 EURO 3 ENGINE MECHANICAL
FLYWHEEL BENCH PROCEDURES . . . . . . . . . .121 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 270
FLYWHEEL HOUSING INSTALLATION . . . . . . . .182 MP8 EURO 3 ENGINE MODEL
FLYWHEEL HOUSING REMOVAL . . . . . . . . . . . .102 IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . 12
FLYWHEEL HOUSING RUNOUT, CHECK . . . . . . .57 MP8 EURO 3 ENGINE SETUP AND
FLYWHEEL RING GEAR REPLACEMENT . . . . . .121 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 254
FRONT ENGINE SUPPORT
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . .166
Page 327
INDEX
N R
NEOPRENE SEAL INSTALLATION . . . . . . . . . . . 227 REBUILT ENGINE RUN-IN PROCEDURES . . . . . 268
NEOPRENE SEAL REMOVAL . . . . . . . . . . . . . . . 226 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
NOISE AND VIBRATION . . . . . . . . . . . . . . . . . . . . 44 REMOVING ENGINE FROM ENGINE STAND . . . 212
ROCKER ARM SHAFT AND ENGINE BRAKE
O INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 179
OIL AND FILTER CHANGE PROCEDURE . . . . . . 65 ROCKER ARM SHAFT ASSEMBLY . . . . . . . . . . . 145
OIL COOLER AND COOLING DUCT COVER ROCKER ARM SHAFT BENCH
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 194 PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . 144
OIL COOLER RECONDITIONING . . . . . . . . . . . . 152 ROCKER ARM SHAFT DISASSEMBLY . . . . . . . . 144
OIL COOLER, PRESSURE TEST . . . . . . . . . . . . . 58 ROCKER ARM SHAFT REMOVAL . . . . . . . . . . . . . 83
OIL FILL PIPE AND DIPSTICK RETAINER ROCKER ARM, CHECK . . . . . . . . . . . . . . . . . . . . . 59
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 RUN-IN CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
OIL FILLER PIPE AND DIPSTICK PIPE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 189 S
OIL FILTER HOUSING INSTALLATION. . . . . . . . 196 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . 2
OIL FILTER VALVE HOUSING REMOVAL . . . . . . 93 SEAL INSTALLATION . . . . . . . . . . . . . . . . . . 224, 250
OIL LEVEL CHECK. . . . . . . . . . . . . . . . . . . . . . . . . 64 SEAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . 223, 250
OIL PAN INSTALLATION . . . . . . . . . . . . . . . . . . . 187 SERVICE PRECAUTIONS SUMMARY . . . . . . . . . . 10
OIL PAN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 111 SERVICE PROCEDURES AND TOOL USAGE . . . . 3
OIL PUMP AND BLOCK STIFFENER PLATE SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 64, 68
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 164 SPECIAL TOOLS . . . . . . . . 46, 72, 76, 148, 153, 214,
OIL PUMP INSTALLATION. . . . . . . . . . . . . . . . . . 232 223, 226, 231, 249, 254
OIL PUMP PIPES AND STRAINER SPECIAL TOOLS FOR ENGINE OVERHAUL. . . . 308
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 165 STANDARD BOLT AND NUT TORQUE
OIL PUMP REMOVAL. . . . . . . . . . . . . . . . . . 113, 232 VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
OIL PUMP REPLACEMENT (IN CHASSIS) . . . . . 231 STARTER INSTALLATION . . . . . . . . . . . . . . . . . . 200
OIL THERMOSTAT AND PRESSURE SAFETY STARTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 89
VALVE REPLACEMENT . . . . . . . . . . . . . . . . . 221
OIL THERMOSTAT VALVE T
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 222 TANDEM PUMP (FUEL AND POWER
STEERING) INSTALLATION . . . . . . . . . . . . . . 202
P TANDEM PUMP (FUEL AND POWER
PISTON AND CONNECTING ROD STEERING) REMOVAL . . . . . . . . . . . . . . . . . . 100
ASSEMBLY INSTALLATION. . . . . . . . . . . . . . 161 TEFLON® SEAL INSTALLATION . . . . . . . . . . . . . 228
PISTON AND CONNECTING ROD TEFLON® SEAL REMOVAL . . . . . . . . . . . . . . . . . 228
ASSEMBLY REMOVAL. . . . . . . . . . . . . . . . . . 113 THERMOSTAT AND COVER
PISTON COOLING SPRAY NOZZLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 193
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 THERMOSTAT AND COVER REMOVAL . . . . . . . 106
PISTON INSPECTION AND CLEANING . . . . . . . 123 THERMOSTAT, CHECK . . . . . . . . . . . . . . . . . . . . . 61
PISTON RING INSPECTION AND TIMING GEAR COVER INSTALLATION . . . . . . . . 190
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 124 TIMING GEAR COVER REMOVAL . . . . . . . . . . . . . 82
POWER TAKE-OFF (PTO) ASSEMBLY TIMING GEAR PLATE INSTALLATION. . . . . . . . . 168
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 TIMING GEAR PLATE REMOVAL. . . . . . . . . . . . . 104
POWER TAKE-OFF INSTALLATION . . . . . . . . . . 189 TIMING GEAR TRAIN INSTALLATION . . . . . . . . . 173
POWERLEASH™ ENGINE BRAKE . . . . . . . . . . . . 32 TIMING GEAR TRAIN REMOVAL . . . . . . . . . . . . . 103
PRELIMINARY STEPS . . . . . . . . . 218, 236, 244, 250 TOOLS AND EQUIPMENT . . . . . . . . . . 116, 127, 234
PRESSURE SAFETY VALVE REMOVAL . . . . . . 221 TROUBLESHOOTING TECHNIQUE . . . . . . . . . . . . 44
TURBOCHARGER. . . . . . . . . . . . . . . . . . . . . . 35, 266
TURBOCHARGER INSTALLATION . . . . . . . . . . . 198
TURBOCHARGER REMOVAL . . . . . . . . . . . . . . . . 91
Page 328
INDEX
U VALVE INSTALLATION. . . . . . . . . . . . . . . . . . . . . 143
VALVE SPRING INSPECTION . . . . . . . . . . . . . . . 134
UNIT INJECTOR CLEANING . . . . . . . . . . . . . . . . .244
VALVE STEM HEIGHT MEASUREMENT
UNIT INJECTOR INSTALLATION . . . . . . . . . . . . .176
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 246
UNIT INJECTOR REMOVAL . . . . . . . . . . . . . . . . . .87
VALVE STEM SEAL REPLACEMENT . . . . . . . . . 249
V VALVE YOKE (BRIDGE) INSTALLATION . . . . . . 179
VALVE YOKE (BRIDGE) REMOVAL . . . . . . . . . . . 85
VALVE AND UNIT INJECTOR
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . .256 W
VALVE GUIDE REPLACEMENT . . . . . . . . . . . . . .133
VALVE GUIDE WEAR, CHECK . . . . . . . . . . . . . . . .62 WIRING HARNESS INSTALLATION . . . . . . . . . . 209
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . .142
Page 329
NOTES
Page 330
MACK® MP8 DIESEL ENGINE
SERVICE MANUAL
(EURO 3 EMISSIONS REGULATIONS)
PRINTED IN U.S.A.
5-116 © MACK TRUCKS, INC. 2009

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MACK MP8 ®

(EURO 3 EMISSIONS REGULATIONS)

JULY 2009 © MACK TRUCKS, INC. 2009

The information, specifications, and illustrations in this publication are

No part of this publication may be reproduced, stored in a retrieval

Danger indicates an unsafe practice that could result in death or serious

Warning indicates an unsafe practice that could result in personal injury.

Two optional fan drives are available: On/Off and

Timing gears mount on the rear of the MP8

Another feature of the MP8 is the rear engine

Repair instructions in this manual deal with

Figure 2 — Engine Information Plate

Engine Serial Number Identification

DESCRIPTION AND OPERATION

Separate chambers for exhaust and inlet at each

CAMSHAFT AND VALVE TRAIN

If the engine is equipped with EPG exhaust brake

Figure 5 — PowerLeash™ 3-Rocker Valve Train

1. Inlet Valve Yoke (Bridge) 3. Adjustment Shim

adjustment. Replaceable valve guides and seats

Rollers in the ends of the rocker arms contact the

The camshaft is induction-hardened. Timing

Camshaft thrust washers are integral on the No. 7

Figure 7 — Camshaft Assembly Components

1. Spacer 5. Upper Bearing Cap

and injector adjustment. PowerLeash™ includes

Figure 9 — Cylinder Block and Stiffener Plate

The screws and washers at the side guide the

Figure 10 — Head to Block Alignment Screws and

1. Cylinder Head 3. Cylinder Block

Three screws and washers installed at the side

The head is aligned with the timing gear plate by

The lower seals are fitted in grooves in the

Figure 13 — Oil Pan and Stiffener Plate

1. Block Stiffener Plate 2. Oil Pan with Gasket

The oil pan includes an oil level/temperature

Figure 14 — Crankshaft, Bearings, Thrust Washers and Cap Alignment Tabs

1. Alignment Tab, Block 3. Thrust Washers

A Teflon® seal bearing directly on the crankshaft

Whenever the lower main bearing caps are

Figure 15 — Piston and Connecting Rod

1. Piston Ring Set 6. Connecting Rod Bolts

Connecting rods are forged steel and are used in

combination with one-piece Monosteel™ steel

The piston is fitted with three rings. In the top

Figure 16 — Piston Cooling

1. Piston Cooling Nozzle 3. Opening Valve

Figure 17 — Timing Gears and Plate

1. Crankshaft Gear 6. Power Steering/Fuel Pump Gear

The double idler drives the adjustable idler and

Two full-flow filters and a by-pass filter maintain

Figure 18 — Drive Belt Routings — Conventional and

1. Conventional Chassis 2. LCF Chassis

Figure 19 — Lubrication System Diagram

A strainer and pickup tube lead the lubricant into