Mack MP7 EPA07 Diesel Engine Shop Service Repair Manual Download

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This manual contains mechanical removal, installation and overhaul procedures for Mack MP7 Diesel Engine (2007 standards).

Topic List:

INTRODUCTION
SAFETY INFORMATION
Advisory Labels
Service Procedures and Tool Usage
EXPLANATION OF NUMERICAL CODE
CONVERSION CHART
ABOUT THE MACK MP7 ENGINE
Service Precautions Summary
VISUAL IDENTIFICATION
MP7 ENGINE MODEL IDENTIFICATION
Engine Information Plate
Engine Serial Number Identification
DESCRIPTION AND OPERATION
MP7 ENGINE DESIGN FEATURES
Engine Variants
Engine Components
Lubrication System
Crankcase Ventilation
Fuel System
PowerLeash™ Engine Brake
Exhaust Gas Recirculation System
Exhaust Aftertreatment System
Variable Geometry Turbocharger
Cooling System
Engine Management System
GLOSSARY OF TERMS
COMPONENT LOCATOR
MP7 ENGINE COMPONENT LOCATION VIEWS
TROUBLESHOOTING
ENGINE SYMPTOM DIAGNOSIS
Troubleshooting Technique
Noise and Vibration
ENGINE CHECKS AND TESTS
Special Tools
Camshaft Sensor Depth, Check
Camshaft Timing, Check
Crankcase Ventilation, Check
Cylinder Head, Pressure Test
Cylinder Liner and Piston Wear, Check
EGR Cooler, Pressure Test
Engine Compression, Test
Flywheel Housing Runout, Check
Oil Cooler, Pressure Test
Rocker Arm, Check
Thermostat, Check
Valve Guide Wear, Check
MAINTENANCE
LUBRICATION SYSTEM MAINTENANCE
Special Tool
Oil Level Check
Oil and Filter Change Procedure
Crankcase Ventilation System
FUEL FILTER REPLACEMENT
Fuel Filter Change
COOLING SYSTEM MAINTENANCE
Special Tool
Coolant Drain Outlets
Coolant Filter
EXHAUST AFTERTREATMENT SYSTEM MAINTENANCE
Special Tools
Diesel Particulate Filter
Aftertreatment Fuel Injector (AFI)
DRIVE BELT REPLACEMENT AND TENSIONING
General Information
Automatically Tensioned System
REPAIR INSTRUCTIONS, PART 1
ENGINE REMOVAL
Special Tools
General Instructions
Removal
ENGINE DISASSEMBLY
Special Tools
General Instructions
Mounting the Engine on a Repair Stand
Cylinder Head (Valve) Cover Removal
Engine Wiring Harness Removal — External
Engine Wiring Harness Removal — Internal
Timing Gear Cover Removal
Camshaft Gear and Vibration Damper Removal
Rocker Arm Shaft and Engine Brake Removal
Valve Yoke (Bridge) Removal
Camshaft Removal
Unit Injector Removal
Starter Removal
Turbocharger Removal
EGR Hot Pipe (Cooler Inlet) Removal
EGR Valve Removal
EGR Cooler Removal
Exhaust Manifold Removal
Oil Filter Housing Removal
Coolant Pipe Removal
Cooling Duct Cover and Oil Cooler Removal
Fan Drive, Idler and Fan Bracket Removal
EGR Crossover (Cooler Outlet) Pipe Removal
EGR Venturi Housing Removal
EGR Mixer Removal
Fuel Lines and Fuel Filter Housing Removal
EECU and Cooling Plate Removal
Inlet Manifold Removal
Tandem Pump (Fuel and Power Steering) Removal
Air Compressor Removal
Flywheel and Pilot Bearing Removal
Power Take-Off (PTO) Assembly Removal
Flywheel Housing Removal
Crankshaft Rear Seal Removal
Timing Gear Train Removal
Timing Gear Plate Removal
Alternator and Refrigerant Compressor Removal
Thermostat and Cover Removal
Coolant Pump Removal
Cylinder Head Removal
Crankshaft Vibration Damper and Fan Pulley Removal
Crankshaft Front Cover Removal
Crankshaft Front Seal Removal
Oil Fill Pipe and Dipstick Retainer Removal
Oil Pan Removal
Front Engine Support Removal
Oil Pump and Valve Housing Removal
Block Stiffener Plate Removal
Piston and Connecting Rod Assembly Removal
Main Bearing Cap Removal
Crankshaft Removal
CYLINDER BLOCK RECONDITIONING
Tools and Equipment
Piston Cooling Spray Nozzle Removal
Cylinder Liner Removal
Cylinder Block Cleaning and Inspection
Cylinder Liner Height Measurement
Cylinder Liner Installation
FLYWHEEL BENCH PROCEDURES
Flywheel Ring Gear Replacement
CONNECTING ROD AND PISTON BENCH PROCEDURES
Connecting Rod — Piston Disassembly
Piston Inspection and Cleaning
Piston Ring Inspection and Replacement
Connecting Rod — Piston Assembly
CYLINDER HEAD OVERHAUL
Tools and Equipment
Inlet and Exhaust Valve Removal
Cylinder Head Cleaning and Inspection
Valve Guide Replacement
Valve Spring Inspection
Injector Sleeve Replacement
Expansion Plug Replacement
Valve Inspection
Valve Installation
ROCKER ARM SHAFT BENCH PROCEDURES
Description
Rocker Arm Shaft Disassembly
Inspection
Rocker Arm Shaft Assembly
CAMSHAFT BENCH PROCEDURES
Camshaft Inspection
COOLING SYSTEM COMPONENTS BENCH PROCEDURES
Special Tool
Oil Cooler Reconditioning
EGR Cooler Cleaning
EGR Cooler Pressure Test
ENGINE REASSEMBLY
Special Tools
General Instructions
Crankshaft Installation
Main Bearing Cap Installation
Piston and Connecting Rod Assembly Installation
Block Stiffener Plate Installation
Oil Pump and Valve Housing Installation
Front Engine Support Installation
Crankshaft Front Cover Installation
Crankshaft Front Seal Installation
Timing Gear Mounting Plate Installation
Cylinder Head Installation
Camshaft Installation
Unit Injector Installation
Valve Yoke (Bridge) Installation
Rocker Arm Shaft and Engine Brake Installation
Timing Gear Train Installation
Flywheel Housing Installation
Oil Pan Installation
Oil Filler Pipe and Dipstick Pipe Installation
Power Take-Off Installation
Timing Gear Cover Installation
Crankshaft Rear Seal Installation
Flywheel and Pilot Bearing Installation
EGR Crossover (Cooler Outlet) Pipe Installation
Fan Bracket Installation
Coolant Pump Installation
Thermostat and Cover Installation
Oil Cooler and Cooling Duct Cover Installation
Coolant Pipe Installation
Oil Filter Housing Installation
Exhaust Manifold Installation
EGR Valve Installation
EGR Cooler Installation
EGR Cooler Inlet Pipe Installation
Turbocharger Installation
Starter Installation
Air Compressor Installation
Tandem Pump (Fuel and Power Steering) Installation
Inlet Manifold Installation
EGR Mixer Installation
EGR Venturi Housing Installation
Intermediate and Mixer Inlet Piping Installation
EECU and Cooler Installation
Fuel Lines and Fuel Filter Housing Installation
Crankcase Ventilation Separator
Alternator and Refrigerant Compressor Installation
Crankshaft Vibration Damper and Fan Pulley Installation
Wiring Harness Installation
Cylinder Head (Valve) Cover Installation
Removing Engine from Engine Stand
Filters and Miscellaneous Components Installation
ENGINE INSTALLATION
Special Tools
General Instructions
Installation
REPAIR INSTRUCTIONS, PART 2
IN-CHASSIS PART/COMPONENT PROCEDURES
OIL PUMP REPLACEMENT (IN CHASSIS)
Oil Pump Removal
Oil Pump Installation
CRANKCASE VENTILATION (CCV) SEPARATOR REPLACEMENT
CCV Separator Removal
CCV Separator Installation
TURBOCHARGER SMART REMOTE ACTUATOR (SRA) REPLACEMENT
Preliminary Steps
Turbocharger SRA Removal
Turbocharger SRA Inspection and Installation
Final Assembly
UNIT INJECTOR CLEANING
Preliminary Steps
Cleaning and Inspection
Final Steps
INJECTOR COPPER SLEEVE REPLACEMENT
Tools and Equipment
Preliminary Steps
Copper Sleeve Removal
Copper Sleeve Installation
Final Steps
VALVE STEM HEIGHT MEASUREMENT PROCEDURE
VALVE STEM SEAL REPLACEMENT
Special Tools
Preliminary Steps
Seal Removal
Seal Installation
Final Steps
REPAIR INSTRUCTIONS, PART 3
MP7 ENGINE SETUP AND ADJUSTMENT
Special Tools
Valve and Unit Injector Adjustment
Checking and Adjusting Timing Gear Backlash
ENGINE FINAL PREPARATION AND OPERATIONAL CHECK
Filter Element Installation
Engine Lubrication System
Fuel System
Engine Operational Check
REBUILT ENGINE RUN-IN PROCEDURES
General
Run-In Check
SPECIFICATIONS
MP7 ENGINE MECHANICAL SPECIFICATIONS
Material and Dimensional Data
Engine Component Torque Specifications (Standard Fasteners)
Engine Component Torque Specifications (Critical Fasteners)
ENGINE GASKETS, LUBRICANTS AND SEALANTS
Gasket and Seal Reuse
Lubricants and Sealants
SPECIAL TOOLS & EQUIPMENT
MP7 ENGINE SERVICE TOOLS
Special Tools for the MP7 Engine

Covers: Mack MP7 EPA07 Diesel Engine
Pages: 364
Format: PDF file
Compatibility: Windows/Mac/Tablet
Note: Instant digital download only – no printed copy or CD-ROM media.

Mack MP7 EPA07 Diesel Engine Shop Service Repair Manual PDF