E-TECH™ ENGINE OCTOBER 2000

(REVISED)

SERVICE MANUAL 5-106

(Includes Left-Side Redesign)

front.fm Page -ii Friday, August 4, 2000 11:16 AM

-ii
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PLEASE LET US KNOW!

Your comments and suggestions will help
us improve this manual!
Please complete and mail this form or FAX
your comments to: (610) 709-3800.
Manual: _______________________________ Publication Number: _______
Vehicle Model: _________________________ Model Year: ______________
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Thank You For Your Assistance

Mack Trucks, Inc.
(ATTENTION: RTS STAFF, 6S3)

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10_125erb.fm Page 2 Tuesday, April 18, 2006 11:43 AM

ERRATA SHEET — ENGINE

Crankshaft Center Main Bearing

Specification Update

Effective January 2006, Mack Powertrain Engineering has

widened the crankshaft center main bearing runout
specification. The maximum allowable crankshaft runout
specification was changed from 0.005 in. (0.127 mm) to
0.007 in. (0.178 mm). The manuals listed below are affected
by this change.

Reference: Engine Manuals

5-101 E7

5-106 E-Tech™

5-107 E7G

5-110 ASET™ AI/AMI

5-111 ASET™ AC

JANUARY 2006 © MACK TRUCKS, INC. 2006

(NEW ISSUE) MACK ENGINE SERIES
 SERVICE BULLETIN
NUMBER: SB-210-034
DATE: 5/14/02
MODEL: E-Tech™
(Also applies to Mack Trucks Australia)

MISCELLANEOUS FASTENER CHANGES — E-TECH™ ENGINES

The following fastener changes were made on E-Tech™ engines:
Injection Nozzle Hold-Down Screws — Beginning 3/00, the injection nozzle hold-
down screws having the 15 mm external hex head have been changed to a new screw
(part No. 421GC2116M) that has a 16 mm internal hex head.
Rocker Shaft Mounting Bracket Bolts — Beginning 4/00, the bolts and washers
used to secure the rocker shaft mounting brackets to the cylinder head have been
changed to a flange-head bolt (part No. 65AM5010). Tightening torque value for this
new fastener remains the same at 40 lb-ft (50 N•m).
Air Compressor Mounting Screw — Beginning 8/00, the original hex-head screw has
been changed to a flange-head screw (part No. 27AM16). This change was made so
that the mounting screw clamp load is distributed over a wider area of the flat washer.
Camshaft Thrust Washer — Beginning 10/00, the two screws and washers used to
secure the camshaft thrust washer to the block were changed to a flange-head screw
(part No. 66AM44). Tightening torque value for this fastener remains the same at 15 lb-
ft (20 N•m).
Cylinder Head Capscrews — Beginning 6/01, the cylinder head capscrews and the
separate hardened flat washer were replaced in production with capscrews having
captured washers (part number series 400GC317M). This change was implemented to
prevent the possibility of omitting or installing more than one washer during assembly.
Additionally, the outside diameter of the captured washer was reduced slightly
(approximately 0.030″) to accommodate the redesigned cylinder head cover that was
phased into production 7/01. Cylinder head capscrew torque remains the same at 205
lb-ft (278 N•m).
Flywheel-to-crankshaft mounting bolts — Beginning 9/01, bolts having captured
washers (part Nos. 419GC31M and 419GC31M2) were released into production to
replace the previously used bolts and separate hardened flat washer used to secure
the flywheel to the crankshaft. Flywheel-to-crankshaft mounting bolt torque remains the
same at 185 lb-ft (250 N•m).
Electronic Unit Pump (EUP) hold-down screws — Beginning 11/01, new hold-down
screws (part No. 421GC2123M) were released into production for the electronic unit
pumps. These screws are dimensionally the same as the previously used screws, but
conform to a more stringent specification that controls minor surface forming defects to
a greater degree than for common fasteners.Torque of the EUP hold-down bolts has
been changed from 42 lb-ft (57 N·m) to 60 lb-ft (81 N·m).
Turbocharger Mounting Nuts — Beginning 5/02, new turbocharger mounting nuts
were released into production. These nuts (part No. 142GC247M) are composed of
silver-plated stainless steel to provide greater resistance to heat than the previous nuts.
Additionally, these nuts have the Spiralock™ self-locking thread feature to prevent
loosening in service.

SB-210-034 — Page 1 of 1
SERVICE P UBLICATIONS , ALLE NTOWN , PA 18105 ©MACK TRUCKS, INC. 2002
 E-TECH ENGINE ™

SERVICE MANUAL
(Includes Left-Side Redesign)

MAY 2006 REPRINTED 2.5M

SEPTEMBER 2004 REPRINTED 2.5M
APRIL 2003 REPRINTED 2.5M
JUNE 2002 REPRINTED 2.5M
OCTOBER 2001 REPRINTED 2.5M
OCTOBER 2000 © MACK TRUCKS, INC. 2000
(REVISED – SUPERSEDED ISSUE JULY 1999) 5-106
front.fm Page ii Friday, August 4, 2000 11:16 AM

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.
No part of this publication may be reproduced, stored in a
retrieval system, or be transmitted in any form by any
means including electronic, mechanical, photocopying,
recording, or otherwise without prior written permission
of Mack Trucks, Inc.

ii
front.fm Page iii Friday, August 4, 2000 11:16 AM

TABLE OF CONTENTS

TABLE OF CONTENTS

iii
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TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Advisory Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Service Procedures and Tool Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EXPLANATION OF NUMERICAL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Changes from the Existing E-Tech™ Service Procedures Manual . . . . . . . . . . . . . . . . . . . . . . . 6
ABOUT THE E-TECH™ ENGINE AND ITS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ENGINE MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine Information Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine Serial Number Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DESCRIPTION & OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
E-TECH™ ENGINE DESIGN FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electronic Unit Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
V-MAC III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Belt Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
J-Tech™ Engine Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Valve Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Low-Pressure Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fuel Filtration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
High-Pressure Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
High-Pressure Fuel Injection Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Fuel Injector Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Block Heater for Front (Water Pump) Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Cylinder Head Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Vibration Damper Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Centri-Max® Oil Filter Breather Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
GLOSSARY OF TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
ENGINE SYMPTOM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
V-MAC III Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
CAMSHAFT TIMING AND LOBE LIFT CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Camshaft Timing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Camshaft Lobe Lift Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
CHASSIS-MOUNTED CHARGE AIR COOLING TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Special Tool Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
CMCAC Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
CMCAC Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Restriction Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

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TABLE OF CONTENTS
Core Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
CMCAC Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
CYLINDER HEAD AND CYLINDER BLOCK LEAK TEST PROCEDURE . . . . . . . . . . . . . . . . . . . 71
Cylinder Head and Head Gasket Check — In Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Cylinder Head Fuel Passages Leak Check — In Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Cylinder Block/Cylinder Head Coolant Passages Leak Check — In Chassis . . . . . . . . . . . . . . 72
Cylinder Head Oil Passage Leak Check — Out of Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Cylinder Head Coolant Passage Leak Check — Out of Chassis . . . . . . . . . . . . . . . . . . . . . . . . 75
Cylinder Block Coolant Passage Leak Check — Out of Chassis . . . . . . . . . . . . . . . . . . . . . . . . 76
ENGINE BRAKE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Operational Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Hydraulic/Mechanical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Final Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
BELT DRIVE SYSTEM TENSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Manually Tensioned System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Automatically Tensioned System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
FILTER ELEMENT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Crankcase Breather Filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Coolant Conditioner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Removal from Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
ENGINE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Filter Element Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Oil Cooler and Oil Filter Mounting Bracket Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . 101
Mounting Engine in Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Alternator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Engine Electronic Control Unit (EECU) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Fuel Filter Adapter Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Coolant Conditioner Element Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Oil Cooler-to-Water Pump Inlet Line Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Thermostat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Coolant Manifold Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Air Inlet Manifold Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Water Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Turbocharger Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Fuel Nozzle Inlet Tube Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Exhaust Manifold Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Engine Wiring Harness Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Engine Electronic Control Unit (EECU) and Cooling Plate Removal . . . . . . . . . . . . . . . . . . . . 115
Electronic Unit Pump (EUP) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Oil Fill Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

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Air Compressor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Valve Cover and Spacer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Rocker Arm, Valve Yoke and Push Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Nozzle Holder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Cylinder Head Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Vibration Damper and Crankshaft Hub Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Oil Pan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Auxiliary Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Camshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Piston and Connecting Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Flywheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Flywheel Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Main Bearing Cap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Crankshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
CYLINDER BLOCK RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Piston Cooling Spray Nozzle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Cylinder Sleeve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Cylinder Sleeve Counterbore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Cup Plug Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Pipe Plug Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
H-Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Camshaft Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Auxiliary Shaft Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Cylinder Sleeve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Piston Cooling Spray Nozzle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Cylinder Block Dowel Pin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
CRANKSHAFT AND FLYWHEEL BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Crankshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Crankshaft Dowel Pin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Crankshaft Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Crankshaft Wear Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Flywheel Inspection and Resurfacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
AUXILIARY SHAFT AND CAMSHAFT BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . 168
Auxiliary Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Camshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
CONNECTING ROD AND PISTON BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Connecting Rod Inspection and Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Piston Inspection and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 76
Piston Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Assembling Connecting Rod to Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
CYLINDER HEAD OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Inlet and Exhaust Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Cylinder Head Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Fire Ring Groove Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Valve Guide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

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Valve Seat Insert Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Valve Spring Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Injection Nozzle Holder Insert Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Valve Yoke Guide Pin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Cylinder Head Cup Plug Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Cylinder Head Pipe Plug Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
VALVE ROCKER ARM SHAFT BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Valve Rocker Arm Shaft Disassembly (without/with Engine Brake) . . . . . . . . . . . . . . . . . . . . . 206
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Valve Rocker Arm Shaft Reassembly (without Engine Brake) . . . . . . . . . . . . . . . . . . . . . . . . . 207
Valve Rocker Arm Shaft Reassembly (with J-Tech™ Engine Brake) . . . . . . . . . . . . . . . . . . . 209
LUBRICATION SYSTEM BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Oil Cooler Assembly Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Oil Pump Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
COOLING SYSTEM COMPONENTS BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Oil Cooler Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Water Pump Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
FUEL SYSTEM COMPONENTS BENCH PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Electronic Unit Pump (EUP) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Installation of Electronic Unit Pump Plunger Spring and Seat . . . . . . . . . . . . . . . . . . . . . . . . . 219
Fuel Injector Nozzle Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Crankshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Main Bearing Cap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Piston and Connecting Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Flywheel Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Crankshaft Rear Oil Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Valve Lifter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Camshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Camshaft Core Plug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Camshaft Idler Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Auxiliary Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Front Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Crankshaft Front Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Crankshaft Hub Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Vibration Damper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Oil Pan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Exhaust Manifold Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Nozzle Holder Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Push Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Valve Yoke Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Rocker Arm and Engine Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Valve Cover and Spacer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Oil Fill Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Engine ECU/Cooling Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

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Air Compressor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Electronic Unit Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Engine Wiring Harness Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Fuel Nozzle Inlet Tube Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Turbocharger Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Water Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Oil Cooler and Oil Filter Mounting Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Coolant Manifold Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Air Inlet Manifold Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Thermostat, Housing and Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Coolant Conditioner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Fuel Filter Adapter Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Engine ECU Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Oil Cooler-to-Water Pump Inlet Line Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Alternator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Removing Engine from Engine Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Plate-Type Oil Cooler and Oil Filter Mounting Bracket Assembly Installation . . . . . . . . . . . . . 282
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Engine Installation into Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
IN-CHASSIS PART/COMPONENT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Electronic Unit Pump (EUP) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Camshaft Replacement (Engine in Chassis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Engine Brake Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Valve Lifter H-Ring Installation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
ENGINE SETUP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
Fuel Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
Valve Yoke, Valve Lash and Engine Brake Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
Engine Speed and Position Sensors Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . 304
Electronic Unit Pump (EUP) Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
ENGINE FINAL PREPARATION AND OPERATIONAL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . 306
Filter Element Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Engine Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
REBUILT ENGINE RUN-IN PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Run-In Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
E-TECH™ ENGINE MECHANICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Material and Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
E-Tech™ Component Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
SPECIFICATION FOOTNOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
E-TECH™ ENGINE LUBRICANT AND SEALANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 329
FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Fastener Selection and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Fastener Sizes and Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

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TABLE OF CONTENTS
SCHEMATICS & DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
ENGINE SYSTEM SCHEMATICS (FLUIDS FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
Cooling System Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
Lubrication System Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Fuel System Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
SPECIAL TOOLS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
E-TECH™ ENGINE SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
Special Tools for Engine Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
V-MAC III Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

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NOTES

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INTRODUCTION

INTRODUCTION

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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:

Activities associated with Danger indicate that death or serious personal

injury may result from failing to heed the advisory. Serious personal injury
may be equated to career-ending injury.

Activities associated with Warning indicate that personal injury may result
from failing to heed the advisory. In this case, personal injury is not equated to
career-ending injury, but results in possible change in quality of life.

Activities associated with Caution indicate that product damage may result from
failing to heed the advisory. Caution is not used for personal injury.

A procedure, practice, or condition that is essential to emphasize.

A helpful suggestion that will make it quicker and/or easier to perform a procedure,
while possibly reducing service cost.

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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, be sure that parking brakes are set, and
disengage the clutch.
2. Before working on a vehicle, place the transmission in neutral, set the
parking brakes, and block the wheels.
3. 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.

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.

REMEMBER,
SAFETY . . . IS NO ACCIDENT!

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INTRODUCTION
Mack Trucks, Inc. cannot anticipate every r Use hoists or jacks to lift or move heavy
possible occurrence that may involve a potential objects.
hazard. Accidents can be avoided by recognizing
r 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 r 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
r 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 r 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
r 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
r DO NOT wear loose-fitting or torn clothing. the manner described in the instructions.
Remove any jewelry before servicing
r Do not store natural gas powered vehicles
vehicle.
indoors for an extended period of time
r ALWAYS wear safety glasses and protective (overnight) without first removing the fuel.
shoes. Avoid injury by being aware of sharp
r Never smoke around a natural gas powered
corners and jagged edges.
vehicle.

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INTRODUCTION
EXPLANATION OF NUMERICAL GROUP 400 — STEERING, AXLES, WHEELS
AND TIRES, DRIVELINE
CODE
The organization of MACK service manuals has GROUP 500 — BRAKES, AUXILIARY
been upgraded to standardize manual content SYSTEMS
according to a reference system based on
component identification. The new reference GROUP 600 — CAB, TRUCK BODY
system will help link the information contained in
this publication with related information included GROUP 700 — ELECTRICAL
in other MACK service/warranty publications,
such as associated service bulletins, warranty The second two digits of the three-digit code are
manuals, and MACK Service Labor Time used to identify the system, assembly or
Standards. subassembly, as appropriate, within each of the
groupings. The codes applicable to this
The system is based on a numerical code, the publication are shown at the beginning of each
first digit of which identifies the general procedure, as necessary, to guide you to specific
component grouping as listed here: component information.

GROUP 000 — GENERAL DATA Additionally, a two-character alpha code (i.e.,

[NV] RINGS, PISTON) may be referenced with
GROUP 100 — CHASSIS each procedure. This alpha code, in combination
with the three-digit Group number, identifies the
GROUP 200 — ENGINE specific assembly, sub-assembly or part, and
directly relates to the first five positions of the
GROUP 300 — CLUTCH, TRANSMISSION, operation code listed in MACK Service Labor
TRANSFER CASE AND PTO Time Standards.

Examples:

Numerical Code

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INTRODUCTION
ABOUT THIS MANUAL The engine reassembly procedure includes step-
by-step instructions for reassembling the engine.
This helps to ensure proper installation and
Changes from the Existing E-Tech™ longer service life.
Service Procedures Manual
Under Engine Setup and Adjustments, the latest
Mack Trucks, Inc. has made many major setup information is provided for adjusting all
improvements to this E-Tech™ Service E-Tech™ engine models. Engines perform best
Procedures Manual, with changes to both content and conserve fuel most efficiently when adjusted
and organization. This is a complete manual, properly.
describing engine features and the operation of
major systems as well as providing Two additional procedures are included as guides
comprehensive overhaul procedures, for removing and reinstalling the engine. Both
specifications and adjustments. sections are generic in nature since E-Tech™
engine installation procedures vary from one
All specifications and torque values are given in vehicle style to another. As such, the procedures
English and metric measurements. Critical torque are intended as a checklist to remind the
values are also included in the text, eliminating technician of all necessary tasks.
the need to refer to SPECIFICATIONS section
each time a specified torque value is required. While troubleshooting procedures are similar for
The Special Tools list has been revised to include most diesel engines, this manual includes only
all special tools required for a complete overhaul. those that pertain to the E-Tech™ engine. The
Warnings, cautions, notes and service hints help TROUBLESHOOTING section contains
the technician service the engine safely and symptom-related questions as well as tests to
efficiently. help the technician consider all possible problem
sources.
The engine disassembly procedures show how to
remove components in an order that requires the This service manual also includes applicable
least amount of handling. Where appropriate, it information from active service bulletins and
includes general information needed to properly service letters since publication of the E-Tech™
service that component. Service Procedures Manual dated July 1999.
Various component bench procedures guide the
technician in disassembly, cleaning, inspection
and assembly of each component. Each bench
procedure helps in determining if the part is
serviceable or should be replaced.

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INTRODUCTION
ABOUT THE E-TECH™ ENGINE Development of the E-Tech™ engine has been
driven by three basic requirements. It was
AND ITS SERVICE designed to:
This publication is intended to provide technicians r Meet projected exhaust and noise emissions
with a working knowledge of the E-Tech™ regulations.
engine, including both early-production and
current-production versions. r Meet customer demands for improved fuel
economy, driveability and engine braking.
The E-Tech™ engine has undergone a left-side r Compete in a world market.
redesign. Changes include a new plate-type oil
cooler and a new oil filter mounting arrangement. Although the drive to reduce emissions and noise
This new oil filter arrangement includes a new levels is primarily the result of government
centrifugal oil filter assembly, where the mandates, the E-Tech™ engine is designed to
centrifugal filter assembly is now mounted upside provide customers with an improved engine over
down, and the external oil drain is eliminated. the existing E7 engine it replaces. Specific
This new centrifugal oil filter is called Centri-Max® improvements include:
PLUS.
r Improved fuel economy.
The engine electronic control unit (EECU) has r Increased throttle response (time to
been relocated to the left side of the engine and 90 percent torque is faster with the
is mounted on a new one-piece inlet manifold. E-Tech™).
Relocating the EECU has eliminated the need for
the EECU cooling plate, and has also brought r More retarding horsepower through a newly
about a design change to the unit pump front designed J-Tech™ Engine Brake from
outboard heat shield. Additionally, with the Jacobs.
change to the one-piece inlet manifold, the fuel
filter mounting adapter is new and is located Mack Trucks, Inc. is looking beyond the borders
slightly forward of the previous location. of North America to increase its market and bring
the quality, toughness and technology associated
Descriptions of these design changes and the with the MACK name to a worldwide audience.
other features are provided in the DESCRIPTION The current environment of global regulations
& OPERATION section. Additionally, the service concerning exhaust emissions, noise and other
effects of these changes on removal, installation, factors has leveled the playing field on an
disassembly, assembly, setup and adjustment international basis. This means that the
procedures, etc., are included in the respective improvements made to meet the North American
sections of this publication. environmental regulations can now be applied
worldwide.

The E-Tech™ engine is used in MACK trucks and

European Renault VI trucks.

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NOTES

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IDENTIFICATION

IDENTIFICATION

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IDENTIFICATION
ENGINE MODEL Block 3 — ADR Regulations
IDENTIFICATION r An “X” in block three means the engine has
been certified to meet Australian emissions
Engine Information Plate regulations.
r Two dashes in block three mean the engine
The E-Tech™ engine information plate is located does not meet Australian emissions
on the top of the front cylinder head cover (back regulations.
cover for LE and MR chassis). This plate includes
information concerning: Block 4 — Model Year
r Engine model, serial number and 11GBA r The four-digit number stamped in block four
part number. represents the year in which the engine was
r Advertised horsepower at rated speed rpm. certified.
r Emissions regulations to which the engine Block 5 — Federal Family
conforms and other pertinent information
required by emissions regulations. r A 12-digit number stamped in block five
denotes the Federal Family to which the
r Inlet and exhaust valve lash settings and engine belongs for emissions certification
engine brake slave piston lash setting. purposes.
The following explanations are provided to aid in r All domestic engines will have a 12-digit
interpreting some of the key information found on Federal Family number in block five.
the engine information plate.
Block 6 — California Family
Block 1 — U.S. EPA Regulations r If the engine meets California emissions
r An “X” in block one means the engine meets regulations, the same 12-digit number
United States EPA regulations for the year stamped in the Federal Family block is
stamped in block four. stamped in block six.
r Two dashes in block one indicate the engine r If the engine does not meet California
does not meet United States EPA emissions regulations, there will be two
regulations for the year stamped in block dashes in block six.
four. This is only permissible with certain
export engines. All domestic engines will Block 7 — Initial Injection Timing
have an “X” in block one. r E-Tech™ engines do not have an initial
injection timing, as this is controlled
Block 2 — California Regulations electronically.
r An “X” in block two indicates the engine r E-Tech™ engines will have “NA” stamped in
meets California emissions regulations for block seven.
the year stamped in block four. This engine
is referred to as a “50-state” engine and can Block 8 — Engine Brake
be sold in any state throughout the U.S.
r This block is only used when the engine is
r Two dashes stamped in block two mean the equipped with an engine brake. The
engine does not meet California emissions stamping in this block indicates the engine
regulations. If an engine has an “X” in block brake slave-piston lash setting.
one and two dashes in block two, it is
referred to as a “49-state” engine, meaning it Figure 1 illustrates the location of the information
is not certified for sale in California. plate and Figure 2 illustrates its content.

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IDENTIFICATION
1

Figure 1 — Engine Information Plate Location

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IDENTIFICATION
2

Figure 2 — Engine Information Plate

Engine Serial Number Identification

In addition to the engine information plate on the
front 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 right side just below the
turbo oil drain tube flange as shown in Figure 3.
3

Figure 3 — Engine Serial Number

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DESCRIPTION & OPERATION

DESCRIPTION & OPERATION

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DESCRIPTION & OPERATION

E-TECH™ ENGINE DESIGN The EUP is very similar to a unit injector. The
primary difference is that the EUP delivers fuel
FEATURES through a fuel injection line to a conventional-
The E-Tech™ engine evolved from the E7 PLN style nozzle-holder assembly, whereas a unit
(commonly referred to as the E7). The four injector has a nozzle mounted directly on it.
primary design features that differentiate the
E-Tech™ engine from the E7 engine are as The EUP is capable of providing very high fuel-
follows: injection pressures. The pump is controlled by a
high-speed solenoid valve (see Figure 4)
r Electronic Unit Pump (EUP) fuel injection responding to electronic signals from the
system V-MAC III engine control module. This electronic
r V-MAC® III electronic control system control provides a greater timing range. The
combination of higher pressures and greater
r Poly-v belt drive system timing control improves the combustion process
r J-Tech™ engine brake system from Jacobs and optimizes engine performance. This enables
the E-Tech™ engine to conform to more stringent
These major changes resulted in subsequent emissions regulations while providing
improvements and redesign of related performance and fuel economy improvements.
4
components within the engine.

Electronic Unit Pumps

Electronic Unit Pump (EUP) technology, which
has been utilized in the heavy-duty industry for
many years, has been adapted for the E-Tech™
engine to achieve:
r Optimum performance
r Lower emissions
r Simplified service
r More effective pump/engine diagnostics
(individual cylinders can be isolated)
Figure 4 — EUP Components
An EUP is a single-plunger fuel-injection pump,
one per cylinder, driven by a third lobe on the
engine camshaft. The pump roller follower
(tappet) is in contact with the engine cam lobe.
Electronic unit pumps for engines produced
through approximately late 3rd quarter 2000 were
fitted with three O-rings on the pump housings.
Pumps on engines produced later than 3rd
quarter 2000 are fitted with two O-rings in the top
and bottom grooves. The O-ring in the center
groove has been eliminated.

Page 14
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