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MP7 Piston Cooling Jet Replacement

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The document provides instructions for replacing piston cooling nozzles on a Mack MP7 engine.

It covers the replacement procedure for piston cooling nozzles.

A flywheel turning tool (9996956) and stiffening frame tool (9998649) are required as special tools.

Service Bulletin

Mack Trucks, Inc.


Greensboro, NC USA Trucks
Date Group No. Release Page

1.2010 221 53 01 1(16)

Piston Cooling Nozzle


Replacement
MP7

Piston Cooling Nozzle, Replacement

W2005758

This information covers the replacement procedure for the piston cooling nozzles on MACK
MP7 engines.

Contents
• “Special Tools”, page 2
• “Piston Cooling Nozzle, Replacement”, page 3

Note: Information is subject to change without notice. Illustrations are used for reference
only, and may differ slightly from the actual engine version. However, key components
addressed in this information are represented as accurately as possible.

PV776-88954152 USA39761
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2010 221 53 01 2(16)

Tools
Special Tools
For Special Tools ordering instructions, refer to Tools Information, Group 08.

9996956 9998649
Flywheel Turning Tool Stiffening Frame Tool
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2010 221 53 01 3(16)

Service Procedures
2219-03-02-02
Piston Cooling Nozzle, Replacement

You must read and understand the precautions and


guidelines in Service Information, Group 20, "General
Safety Practices, Engine" before performing this
procedure. If you are not properly trained and certified
in this procedure, ask your supervisor for training before
you perform it.

Note: To prevent the piston cooling nozzles from being


damaged, always remove them before removing pistons
and cylinder liners.

Special tools: 9996956, 9998649

Removal
1
1
Apply the parking brake and place the shift lever in
neutral.
2
2
Remove all cables from ground (negative) battery
terminals to prevent personal injury from electrical shock.
3
3
Using a hydraulic jack, lift the front axle until the front
wheels are off the ground. Position jack stands of a
suitable capacity under the frame in a position which will
allow the front axle to hang free.
4
4
If required, remove the skid plate to allow access for oil
pan removal.
5
5
Place a suitable container under the oil pan and remove
the oil drain plug. Drain the engine oil, then reinstall the
drain plug.

Note: Use only hand tools when removing and tightening


the drain plug. Do not use air tools to service the drain
plug.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2010 221 53 01 4(16)

6
6
If the vehicle is equipped with a transmission oil cooler,
remove the transmission cooler line bracket nuts and
separate the brackets from the oil pan fasteners. Position
the cooler lines and brackets to the side.

Note: Mark the transmission oil cooler bracket stud


locations to aid in reassembly.

W2004874

7
7
Pull the dipstick partially out of the dipstick tube, then
remove the dipstick tube fastener and tube from the oil
pan. Remove and discard the O-ring.

W2005086

8
8
Remove the oil fill tube fasteners and tube from the oil
pan. Remove and discard the tube O-ring.

W2004884
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2010 221 53 01 5(16)

9
9
Disconnect the oil level/temperature sensor connector.

W2004876

10
10
Support the oil pan. Loosen and remove the side
mounting bolts.

W2005831

11
11
With the aid of an assistant, support the oil pan and
remove the remaining bolts on the ends of the oil pan.
Carefully lower the pan to avoid contact with the oil pump
pickup tube and the oil pump gear.
12
12
Remove the rubber gasket from the oil pan for inspection.
The gasket may be reused with the original oil pan as
long as it does not exhibit any damage which could cause
it to leak. Carefully inspect the sealing surfaces and
sides of the gasket for any signs of deterioration such
as cracks or ruptures. The gasket must be replaced if
any discrepancies are found. All old sealant must be
removed from the gasket prior to reuse.

Note: A new gasket should be used if a replacement oil


pan (plastic or steel) is being installed.

W2004878
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2010 221 53 01 6(16)

13
13
Remove the oil pump inlet pipe. Remove the inlet pipe
O-ring and discard.

Note: The oil pump inlet pipe in an axle back oil pan is
longer than the oil pump inlet pipe in an axle forward oil
pan. The shorter pipe attaches to a bracket mounted on
the valve housing assembly. A clamp holds the longer
pipe directly on the valve housing assembly.

W2005476

1 Oil Pump
2 Pump Outlet (Pressure) Pipe
3 Valve Housing
4 Valve Housing-to-Block Seals
5 Pump Outlet Pipe O-Ring
6 Pump Inlet (Suction) Pipe
7 Pump Inlet Pipe O-Ring
14
14
Remove the fasteners securing the valve housing and
remove the valve housing. Disconnect and remove the
pump outlet pipe from the valve housing.

Note: The pump outlet pipe is held in place because it


slips into openings in the pump and valve housing.
15
15
Remove and discard the valve housing seals.
16
16
Remove and discard the O-rings on the oil pump inlet
and outlet pipes.
17
17
Remove a fastener from the center area of each side
of the engine stiffening frame and install the stiffening
frame tool. The tool supports the stiffening frame during
removal and installation.

9998649
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2010 221 53 01 7(16)

18
18
Remove the engine stiffening frame attaching bolts and
remove the frame.

W2005477

1 Plate Attaching Screws


2 Engine Stiffening Frame
3 Plate Orientation Holes
19
19
Remove the inspection cover from the bottom of the
flywheel housing and install the flywheel turning tool.

9996956

T2006702
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2010 221 53 01 8(16)

20
20
Turn the flywheel until the piston cooling nozzle to be
removed is easily accessible.

W2005545

1 Piston Cooling Duct


2 Attaching Screw
3 Spray Nozzle
21
21
Remove the piston cooling nozzle retaining screw.
22
22
Carefully pull the piston cooling nozzle from the cylinder
block.
23
23
Remove all other piston cooling nozzles as required.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2010 221 53 01 9(16)

Installation
1
1
Install the piston cooling nozzle, using a new retaining
screw. Tighten to specification. Refer to Function Group
20, Specifications.

Note: The piston cooling nozzle retaining screw is coated


with a friction-inducing compound. Do not reuse.

Note: Any piston cooling nozzle suspected of damage


must be replaced (this also applies to a new replacement
nozzle). Always make sure the piston cooling nozzle fits
correctly in its hole and the nozzle attachment plate is
flush with the cylinder block.

W2005545

1 Piston Cooling Duct


2 Attaching Screw
3 Spray Nozzle
2
2
Install other piston cooling nozzles as required.
3
3
Remove the flywheel turning tool and reinstall the
flywheel housing inspection cover.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2010 221 53 01 10(16)

4
4
Place the engine stiffening frame in position on the
cylinder block and install the fasteners. Use the stiffening
frame tool to support the frame while installing the
fasteners.

Note: Align the engine stiffening frame so that the


sequence of four mounting holes and one large hole are
toward the front of the cylinder block.

9998649

W2005477

1 Frame Attaching Screws


2 Engine Stiffening Frame
3 Frame Orientation Holes
5
5
Remove the stiffening frame tool and install the remaining
two (2) bolts.
6
6
Tighten the stiffening frame fasteners in sequence to
specification.
7
7
Lubricate and install a new O-ring on each end of the oil
pump outlet (pressure) pipe and insert one end of the
pipe into the oil pump housing.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2010 221 53 01 11(16)

8
8
Install new seals in the valve housing assembly. Place
the housing in position over the engine stiffening frame
and engine block while inserting the other end of the
pump outlet (pressure) pipe into the valve housing.

W2005476

1 Oil Pump
2 Pump Outlet (Pressure) Pipe
3 Valve Housing
4 Valve Housing-to-Block Seals
5 Pump Outlet O-Ring
6 Pump Inlet (Suction) Pipe
7 Pump Inlet Pipe O-Ring
9
9
Install the valve housing fasteners and tighten to
specification.
10
10
Lubricate and install an O-ring on the end of the oil pump
inlet (suction) pipe and insert the pipe in the oil pump
housing.
11
11
Secure the oil pump inlet (suction) pipe with the clamp
and fastener to the bracket or to the valve housing.
Tighten the fasteners to specification.
12
12
Clean the oil pan gasket sealing surface on the cylinder
block, flywheel housing, and front seal cover. All surfaces
must be completely free of dirt and debris such as old
sealant, and any grease or oil residue.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2010 221 53 01 12(16)

13
13
For plastic oil pan applications, install the oil pan seal into
the groove of the oil pan. Check that the seal is properly
aligned and seated in the groove.

W2004878

14
14
For steel oil pan applications, install the oil pan gasket on
the oil pan flange. Check that the gasket locating tabs
are properly aligned and inserted in the correct holes on
the mounting flange.

W2035141

1 Metal Tabs (Front of Engine)


2 Single Tab (Left Rear of Engine)
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2010 221 53 01 13(16)

15
15
Apply a 2 mm (0.079 inch) bead of approved sealant
to the seam between the flywheel housing and the
timing gear mounting plate, and between the timing gear
mounting plate and the engine block.

Note: Make sure that the block flange is flush with the
flywheel housing to prevent leaking. If not flush, flywheel
housing must be realigned.

W2006078

16
16
Apply a 2 mm (0.079 inch) bead of approved sealant to
the seam between the front seal cover and the engine
block.

Note: Make sure that the block flange is flush with the
crankshaft front cover to prevent leaking. If not flush,
front cover must be realigned.

W2006079

17
17
With assistance, position the oil pan to the engine block
and loosely install the mounting bolts.

Note: It is recommended that two guide pins be used


while the oil pan is being installed (one at each end of
the cylinder block) in order to properly align the oil pan
prior to installing the bolts.

Note: Use care to prevent damage to the oil pickup.

Note: Install transmission oil cooler bracket studs in


locations marked previously.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2010 221 53 01 14(16)

18
18
Tighten the bolts to specification following the numbered
sequence.

W2005831

19
19

Secure the oil drain plug and tighten to specification.

CAUTION
Do not use a copper washer with the oil drain plug.
Always use the steel washer.

Note: Do not use air tools when installing the oil drain
plug.

20
20
Reconnect the oil level/temperature sensor connector.

W2004876
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2010 221 53 01 15(16)

21
21
Install a new O-ring on the oil fill tube and install the tube
on the side of the oil pan. Install the oil fill tube fasteners
and tighten to secure.

W2004884

22
22
Install a new O-ring on the dipstick tube, then install the
tube and secure with the fastener. Install the dipstick.

W2005086

23
23
Position the transmission cooler line brackets onto the oil
pan fastener studs, install the bracket nuts and tighten
to secure.

W2004874

24
24
Install the skid plate if removed for access.
Mack Trucks, Inc. Date Group No. Release Page
Service Bulletin 1.2010 221 53 01 16(16)

25
25
Using a hydraulic jack, raise the front axle and remove
the jack stands. Lower the vehicle and remove the
hydraulic jack.
26
26
Fill the engine with the specified amount of approved
engine oil. Do not overfill.
27
27
Install all previously removed cables to the ground
(negative) battery terminals.
28
28
Start the engine, check for leaks and proper operation.
After shutdown, replenish fluids as necessary.

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