2007 Mack Emissions Standard Fault Code V-MAC IV Manual PDF

2007 Mack Emissions Standard Fault Code V-MAC IV Manual Download

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This repair manual contains mechanical removal, installation and overhaul procedures for Mack E7 E-Tech Diesel Engine.

Topics in the Mack E7 E-Tech Diesel Engine Shop Repair Manual:

INTRODUCTION
IDENTIFICATION
ENGINE MODEL IDENTIFICATION
Engine Information Plate
Engine Serial Number Identification
DESCRIPTION & OPERATION
E-TECH™ ENGINE DESIGN FEATURES
Electronic Unit Pumps
V-MAC III
Belt Drive System
J-Tech™ Engine Brake
Camshaft
Valve Train
Low-Pressure Fuel System
Fuel Filtration System
High-Pressure Fuel System
High-Pressure Fuel Injection Lines
Fuel Injector Assemblies
Cylinder Block
Crankshaft
Block Heater for Front (Water Pump) Location
Cylinder Head
Cylinder Head Gasket
Gear Train
Air Compressor
Power Steering Pump
Vibration Damper Hub
Front Cover
Centri-Max® Oil Filter Breather Vent
Lubrication System
GLOSSARY OF TERMS
TROUBLESHOOTING
ENGINE SYMPTOM DIAGNOSIS
V-MAC III Diagnostics
CAMSHAFT TIMING AND LOBE LIFT CHECKS
Camshaft Timing Check
Camshaft Lobe Lift Check
CHASSIS-MOUNTED CHARGE AIR COOLING TESTS
General Information
Special Tool Required
CMCAC Troubleshooting
CMCAC Pressure Test
Restriction Pressure Test
Core Inspection
CMCAC Preventive Maintenance
CYLINDER HEAD AND CYLINDER BLOCK LEAK TEST PROCEDURE
Cylinder Head and Head Gasket Check — In Chassis
Cylinder Head Fuel Passages Leak Check — In Chassis
Cylinder Block/Cylinder Head Coolant Passages Leak Check — In Chassis
Cylinder Head Oil Passage Leak Check — Out of Chassis
Cylinder Head Coolant Passage Leak Check — Out of Chassis
Cylinder Block Coolant Passage Leak Check — Out of Chassis
ENGINE BRAKE TESTS
Operational Tests
Electrical Troubleshooting
Hydraulic/Mechanical Troubleshooting
Final Test
Troubleshooting Guide
MAINTENANCE
BELT DRIVE SYSTEM TENSIONING
Manually Tensioned System
Automatically Tensioned System
FILTER ELEMENT REPLACEMENT
General Information
Crankcase Breather Filter Cleaning
Oil Filter Element Replacement
Fuel Filter Replacement
Coolant Conditioner Replacement
REPAIR INSTRUCTIONS
ENGINE REMOVAL
General Instructions
Removal from Vehicle
ENGINE DISASSEMBLY
General Instructions
Filter Element Removal
Oil Cooler and Oil Filter Mounting Bracket Assembly Removal
Mounting Engine in Stand
Alternator Removal
Engine Electronic Control Unit (EECU) Removal
Fuel Filter Adapter Assembly Removal
Coolant Conditioner Element Removal
Oil Cooler-to-Water Pump Inlet Line Removal
Thermostat Removal
Coolant Manifold Removal
Air Inlet Manifold Removal
Water Pump Removal
Turbocharger Removal
Fuel Nozzle Inlet Tube Assembly Removal
Exhaust Manifold Removal
Engine Wiring Harness Removal
Engine Electronic Control Unit (EECU) and Cooling Plate Removal
Electronic Unit Pump (EUP) Removal
Oil Fill Tube Removal
Air Compressor Removal
Valve Cover and Spacer Removal
Rocker Arm, Valve Yoke and Push Rod Removal
Nozzle Holder Removal
Cylinder Head Assembly Removal
Vibration Damper and Crankshaft Hub Removal
Oil Pan Removal
Oil Pump Removal
Front Cover Removal
Auxiliary Shaft Removal
Camshaft Removal
Piston and Connecting Rod Assembly Removal
Flywheel Removal
Flywheel Housing Removal
Main Bearing Cap Removal
Crankshaft Removal
CYLINDER BLOCK RECONDITIONING
Special Tools Required
Piston Cooling Spray Nozzle Removal
Cylinder Sleeve Removal
Cleaning and Inspection
Cylinder Sleeve Counterbore
Cup Plug Replacement
Pipe Plug Replacement
H-Ring Replacement
Camshaft Bushing Replacement
Auxiliary Shaft Bushing Replacement
Cylinder Sleeve Installation
Piston Cooling Spray Nozzle Installation
Cylinder Block Dowel Pin Replacement
CRANKSHAFT AND FLYWHEEL BENCH PROCEDURES
General Information
Crankshaft Inspection
Crankshaft Dowel Pin Replacement
Crankshaft Gear Replacement
Crankshaft Wear Ring Installation
Flywheel Inspection and Resurfacing
AUXILIARY SHAFT AND CAMSHAFT BENCH PROCEDURES
Auxiliary Shaft Inspection
Camshaft Inspection
CONNECTING ROD AND PISTON BENCH PROCEDURES
Connecting Rod Inspection and Reconditioning
Piston Inspection and Cleaning
Piston Ring Replacement
Assembling Connecting Rod to Piston
CYLINDER HEAD OVERHAUL
Special Tools Required
Inlet and Exhaust Valve Removal
Cylinder Head Inspection
Fire Ring Groove Cutting
Valve Guide Replacement
Valve Seat Insert Replacement
Valve Spring Inspection
Injection Nozzle Holder Insert Replacement
Valve Yoke Guide Pin Replacement
Cylinder Head Cup Plug Replacement
Cylinder Head Pipe Plug Replacement
Valve Replacement
VALVE ROCKER ARM SHAFT BENCH PROCEDURES
Rocker Arms
Valve Rocker Arm Shaft Disassembly (without/with Engine Brake)
Inspection
Valve Rocker Arm Shaft Reassembly (without Engine Brake)
Valve Rocker Arm Shaft Reassembly (with J-Tech™ Engine Brake)
LUBRICATION SYSTEM BENCH PROCEDURES
Oil Cooler Assembly Reconditioning
Oil Pump Reconditioning
COOLING SYSTEM COMPONENTS BENCH PROCEDURES
Oil Cooler Reconditioning
Water Pump Reconditioning
FUEL SYSTEM COMPONENTS BENCH PROCEDURES
Electronic Unit Pump (EUP) Inspection
Installation of Electronic Unit Pump Plunger Spring and Seat
Fuel Injector Nozzle Cleaning
ENGINE REASSEMBLY
General Instructions
Crankshaft Installation
Main Bearing Cap Installation
Piston and Connecting Rod Installation
Flywheel Housing Installation
Crankshaft Rear Oil Seal Installation
Flywheel Installation
Valve Lifter Installation
Camshaft Installation
Camshaft Core Plug Installation
Camshaft Idler Gear Installation
Auxiliary Shaft Installation
Oil Pump Installation
Front Cover Installation
Crankshaft Front Seal Installation
Crankshaft Hub Installation
Vibration Damper Installation
Oil Pan Installation
Cylinder Head Installation
Exhaust Manifold Installation
Nozzle Holder Assembly Installation
Push Rod Installation
Valve Yoke Installation
Rocker Arm and Engine Brake Installation
Valve Cover and Spacer Installation
Oil Fill Tube Installation
Engine ECU/Cooling Plate Installation
Air Compressor Installation
Electronic Unit Pump Installation
Engine Wiring Harness Installation
Fuel Nozzle Inlet Tube Assembly Installation
Turbocharger Installation
Water Pump Installation
Oil Cooler and Oil Filter Mounting Bracket Installation
Coolant Manifold Installation
Air Inlet Manifold Installation
Thermostat, Housing and Seal Installation
Coolant Conditioner Installation
Fuel Filter Adapter Assembly Installation
Engine ECU Installation
Oil Cooler-to-Water Pump Inlet Line Installation
Alternator Installation
Removing Engine from Engine Stand
Plate-Type Oil Cooler and Oil Filter Mounting Bracket Assembly Installation
ENGINE INSTALLATION
General Instructions
Engine Installation into Vehicle
IN-CHASSIS PART/COMPONENT PROCEDURES
Electronic Unit Pump (EUP) Replacement
Camshaft Replacement (Engine in Chassis)
Engine Brake Control Valve Replacement
Valve Lifter H-Ring Installation Check
ENGINE SETUP AND ADJUSTMENTS
Fuel Injection Timing
Valve Yoke, Valve Lash and Engine Brake Adjustments
Engine Speed and Position Sensors Installation and Adjustment
Electronic Unit Pump (EUP) Calibration
ENGINE FINAL PREPARATION AND OPERATIONAL CHECK
Filter Element Installation
Engine Lubrication System
Turbocharger
Cooling System
Fuel System
Engine Operational Check
REBUILT ENGINE RUN-IN PROCEDURES
General Instructions
Run-In Check
SPECIFICATIONS
E-TECH™ ENGINE MECHANICAL SPECIFICATIONS
Performance Specifications
Material and Dimensional Data
E-Tech™ Component Torque Specs
SPECIFICATION FOOTNOTES
E-TECH™ ENGINE LUBRICANT AND SEALANT SPECIFICATIONS
FASTENER TORQUE
Fastener Selection and Installation
Fastener Sizes and Types
SCHEMATICS & DIAGRAMS
ENGINE SYSTEM SCHEMATICS (FLUIDS FLOW)
Cooling System Flow Diagram
Lubrication System Flow Diagram
Fuel System Flow Diagram
SPECIAL TOOLS & EQUIPMENT
E-TECH™ ENGINE SPECIAL TOOLS
Special Tools for Engine Overhaul
V-MAC III Special Tools
INDEX

Covers: Mack E-Tech Engines with electronic unit pump & V-MAC III

• EM7-275 E-TECH
• EM7-300 E-TECH
• E7-300 E-TECH
• E7-310/330 E-TECH
• E7-330/350 E-TECH
• E7-350 E-TECH
• E7-355/380 E-TECH
• E7-400 E-TECH
• E7-427 E-TECH
• E7-460 E-TECH

Pages: 365
Format: PDF file
Compatibility: Windows/Mac/Tablet
Note: Instant digital download only – no printed copy or CD-ROM media.