Engine Mack MP8 (Euro 4), service e-manual

Content Introduction Safety information Advisory labels Service procedures and tool usage Explanation of numerical code Conversion chart About the mack MP8 euro 4 engine Service precautions summary Visual identification MP8 euro 4 engine model identification Engine information plate Engine serial number identification Description and operation Mack MP8 euro 4 engine design features Engine components Lubrication system Crankcase ventilation Fuel system Powerleash engine brake Exhaust gas recirculation system Air intake system Variable geometry turbocharger (VGT) Cooling system Engine management system Glossary of terms Component locator MP8 euro 4 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 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 EGR crossover piping removal EGR venturi tube removal Cylinder head (valve) cover removal Engine wiring harness removal Timing gear cover removal Camshaft gear and vibration damper removal Rocker arm shaft 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 and pump inlet housings removal Cooling duct cover and oil cooler removal Drive belts and fan hub removal EGR mixer removal Crankcase ventilation (CCV) separator removal Fuel lines and 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 Block stiffener plate removal Oil pump 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 Block cleaning and inspection 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 tools 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 Oil pump and block stiffener plate installation Oil pump pipes and strainer installation Front engine support installation Crankshaft front cover and seal installation Timing gear plate installation Cylinder head installation Camshaft installation Timing gear train installation Unit injector installation Valve yoke (bridge) installation Rocker arm shaft and engine brake installation Flywheel housing installation Crankshaft rear seal installation Flywheel and pilot bearing installation Oil pan installation Oil filler pipe and dipstick pipe installation Power take-off installation Timing gear cover installation Coolant pump installation Thermostat and cover installation Coolant pipe installation Oil cooler and cooling duct cover installation Oil filter housing installation Exhaust manifold installation EGR valve installation EGR cooler installation EGR hot pipe (cooler inlet) installation Turbocharger installation Starter installation Air compressor installation Tandem pump (fuel and power steering) installation Inlet manifold installation EGR mixer installation Eecu and cooler installation Fuel lines and filter housing installation Crankcase ventilation separator Crankshaft vibration damper and fan pulley installation Alternator and refrigerant compressor installation Wiring harness installation Cylinder head (valve) cover installation EGR venturi tube and crossover piping installation Fan hub and drive belt 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 Camshaft bearing brackets, replacement Preliminary steps General information Camshaft inspection Bracket replacement procedure Final steps Oil thermostat and pressure safety valve replacement Pressure safety valve removal Oil thermostat valve replacement Crankshaft front seal replacement Special tools Seal removal Seal installation Crankshaft rear seal replacement Special tools Neoprene seal removal Neoprene seal installation Teflon seal removal Teflon seal installation Crankcase ventilation (CCV) separator replacement CCV separator removal CCV separator installation Oil pump replacement (in chassis) Special tools Oil pump removal Oil pump installation Injector copper sleeve replacement Tools and equipment Preliminary steps Copper sleeve removal Copper sleeve installation Final steps 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 Valve stem height measurement procedure Valve stem seal replacement Special tools Preliminary steps Seal removal Seal installation Final steps Repair instructions, part 3 MP8 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 Turbocharger Cooling system Fuel system Engine operational check Rebuilt engine run-in procedures General Run-in check Specifications MP8 engine mechanical specifications Material and dimensional data Engine component torque specifications (critical fasteners) Standard bolt and nut torque values Engine gaskets, lubricants and sealants Gasket and seal reuse Lubricants and sealants Special tools and equipment MP8 engine service tools Special tools for engine overhaul Index

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