WELCOME

M1 - MP7/ MP8 ENGINE REBUILD

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 COURSE OBJECTIVES

Upon successfully completing the engine overhaul class the student

will be able to remove, inspect, rebuild, and install components as they
relate to the overhaul of the 700 and 800 cubic inch Mack engines. In
order for the student to complete the 5 day course, an understanding of
the items mentioned in each of the modules must be achieved through
class room instruction as well as hands on training.

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 MODULE 1 Service information review, Engine I.D.
Component location

MODULE 2 Engine removal procedures and tools.

MODULE 3 Disassembly of the 700 and 800 cubic inch

engine along with the use of information found
on the Dealer portal or a service CD.
Inspection of components as they are removed.
Inspection and review of critical areas.
The on-line e-learning tool measurement training
should have been completed as a pre-requisite.

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 MODULE 4 Block prep, liner installation, main bearing and
crankshaft installation.

MODULE 5 Piston and rod preparation and installation.

MODULE 6 Installation of the gear train mounting plate, gear

train, flywheel, flywheel housing and the cylinder
head.

MODULE 7 Camshaft and Camshaft timing gear installation.

MODULE 8 Installation of the injectors, rocker shaft and

overhead adjustments.

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 MODULE 9 Install the manifolds, EGR system, AHI, turbo,
oil cooler, balancer, oil filter housing, fuel and
p/s pumps, compressor, all wiring harness,
brackets, tensioners.

MODULE 10 Review engine installation, the tools needed

and clutch installation. The engine run in
procedures.

MODULE 11 Review of maintenance procedures.

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 MODULE 1 ENGINE IDENTIFICATION
REVIEW AND USE OF THE ELECTRONIC INFORMATION SYSTEM (EIS)
HANDS ON IN THE CLASS ROOM WILL REQUIRE
USE OF EIS ON THE DEALERPORTAL OR A CD DURING
DISASSEMBLY AND RE-ASSEMBLY.

ENGINE IDENTIFICATION WILL COVER:

I.D. LOCATIONS ON THE ENGINE
WHAT THE INFORMATION MEANS

SYSTEM COMPONENTS WILL COVER:

SYSTEMS LOCATIONS
BRIEF DISCRIPTIONS OF THE OIL, FUEL, and COOLANT FLOW.
COMPONENTS WITHIN THESE SYSTEMS

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There are two locations, that the Technician needs to be aware of when
seeking information directly from the engine. One is the sticker attached to the
valve cover. This information plate includes information concerning engine model,
serial number and part number. It will display advertised horsepower at rated
rpm, emission regulations and other pertinent emissions information, inlet
valve, exhaust valve and engine brake lash settings.

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In addition to the information plate on the valve cover, the engine is also
identified by the engine serial number stamped into the cylinder block

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 Search the CD or the dealer portal and
look up VISUAL IDENTIFICATION

This Visual Identification chapter will explain each item on the

engine information plate located on the valve cover

Be sure you examine the information plate during your shop hands
on time in the coming week.

The following 9 pages in the Student handout contain pictures of

an MP-7 and a MP-8 in a Vocational and Conventional application.
Fill in the blanks as a Component Identification exercise and feel free
to use the CDs or the Dealer portal to aid in the identification.

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 US07 MP-7 Conventional Application Component
Identification on right side
10.

12. 11. 9.
1

8.

7.

3.

6.
5.
4.

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 US07 MP-7 Conventional Application Component
Identification on left side
8.
9.

1. 7.

2.

3.

4.
6.
5.
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 US07 MP-7 Conventional Application component
Identification on front view
1.

4.

5.

2.

3.

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US07 MP-7 Vocational Application component
Identification Left Side View
This intake configuration
is used on MRU and the
LEU chassis

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 US07 MP-8 Conventional Application Component
Identification on right side
12.

1.

11.
2.

10.

3.
9.

4.

5. 8.

7
6.
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 US07 MP8 Conventional Application Component
Identification left side view
1. 12.

2. 11.

10.

3.

4.

9.

5. 8.
7.

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US07 MP8 Vocational Application Component
Identification on left side view
This intake configuration
is used on MRU and LEU

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 US07 MP8 Conventional Application Component
Identification front view
1.

2.

3.

8.

4.

5.

6.
7.

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 US07 MP8 Vocational Application Component
Identification front view

1.

5.

4.

2. 3.

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 MP-7 2006 04 Emissions Right Side Engine
Component Identification
1. 8.

2.

3.

4.

5.

7.

6.

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 MP-7 2006 04 Emissions Left Side Engine Component
Identification
11.
1.

10.

2.

3.

4. 9.

5.

6. 8.
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MP-7 2006 04 Emissions Front Side Engine
Component Identification

4.

1.

5.
2.

3.

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 MP-7 LUBRICATION SYSTEM (04 EMISSION 2006
ENGINE

1. EGR valve
2. Turbocharger
3. Main oil Galley
4. Oil cooler
5. Full flow filter over flow valve
6. Piston cooler oil control valve
7. Centri - max oil filter
8. Piston cooler spray nozzles
9. Pressure reduction valve
10. Full flow filters
11. Oil cooler by-pass valve
12. Oil high pressure control valve
13. Oil pump
14. Oil pan

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MP-7 LUBRICATION SYSTEM (04 EMISSION ENGINE)

Piston cooler galley

REAR Oil passage

Main oil galley

Oil flow to
intermediate gear

Select

Pressure regulator
located here.

Select

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 MP-7 LUBRICATION SYSTEM (07 EMISSION
ENGINE

By pass Full flow Full flow

Drains into
rear timing
cover of engine

1. Oil pump
2. Oil pump pick up tube 7. Full flow filters over flow valve
3. Oil pressure regulator 8. Piston cooling opening valve 13. Crankcase ventilation
4. Oil filter base 9. Piston cooling control valve 14. Oil pressure sensor
5. Pressure relief valve 10.Oil cooler bypass valve 15. EGR valve feed
6. By pass filter over flow valve 11.Oil cooler 16.Turbo feed
12.Air compressor

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MP-7 LUBRICATION SYSTEM (07 EMISSION ENGINE

Piston cooler galley

Rear oil passage
Main oil galley

Flow to
intermediate gear

Select
Pressure regulator
located here.

Select

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 MP8 LUBRICATION & OIL SYSTEM
Select
Click
1. Strainer
2. Pickup tube
3. Oil pump
4. Pressure pipe
6. Filter housing
7. Full-flow filters
8. Main oil galley
9. CCV separator
10. Exhaust brake control valve
11. Air compressor
12. Turbocharger
13. Bypass filter
14. Piston cooling nozzles
15. Oil pressure check port
16. EGR valve
This is an internal passage in
the oil filter base
Full flow Full flow
Bypass
Drains into
rear timing
cover of
engine
A. Reducing Valve
B. Safety Valve
C. Oil cooler thermostat valve
D. Overflow valve for the full flow filters
E.. Opening valve for the piston cooling
F. Control valve to regulate the oil coming from the valve E
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Flow to Main oil galley (oil pressure gauge
intermediate reads off this galley on left rear.)
gear

Piston cooling galley

t
Selec

Select

Cross over pipe Select

Select

Oil Pickup tube

B
Oil pump Reducing valve

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 MP-7 04 Emission engine fuel flow

1. Fuel pump
2. Fuel tank and Inlet
tube
3. EECU cooler
4. Fuel filter housing
5. Fuel pre-heater (optional)
6. Water separator
7. Secondary filter
8. Fuel galley
9. Unit injector
10. Pressure regulator
valve
11. Pump safety valve
(pressure regulator)
12. One way valve
13. Hand priming pump
14. Water level sensor
15, Manual water drain valve (shown)
16. Air bleed valve (closes when filter is
removed to prevent fuel siphoning out of the 21. Check valve for#13
system) 17. Service port pressure check 22. Automatic air bleed
18. Fuel supply pressure sensor valve
19. Fuel heater (optional) 23. Fuel tank breather
20. Bleeder check valve
(same purpose as #17)

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 MP-7/8 07 Emission engine
Fuel flow
1. Fuel pump
2. Fuel tank and Inlet
tube After treatment injector
3. EECU cooler
4. Fuel filter housing
5. Fuel pre-heater (optional)
6. Water separator
7. Secondary filter
8. Fuel galley
9. Unit injector
10. Pressure regulator
valve
11. Pump safety valve
(pressure regulator)
12. One way valve
13. Hand priming pump
14. Water level sensor
15. After treatment fuel shutoff valve
16. Electrical (optional) or manual water drain
valve (shown) 18. Service port (pressure gauge)
17. Air bleed valve (closes when filter is 19. Fuel supply pressure sensor 22. Check valve for #13
removed to prevent fuel siphoning out of the 20. Fuel heater (optional) 23. Automatic air bleed
system) 21. Bleeder check valve valve
(same purpose as #17) 24. Fuel tank breather
25. Deaeration valve
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 COOLING SYSTEM
The cooling system is closed and pressurized to eliminate air and raise
the boiling point of the coolant. When the thermostat is below 180
degrees the following components flow coolant:
EGR cooler
Smart Remote Actuator
Turbocharger
Oil cooler
Coolant conditioner
Coolant pump
Air compressor
Fuel heater (if so equipped)
Cab heater
Sleeper heater (if so equipped)
Expansion tank

When the thermostat opens the following components flow coolant:

Radiator
Transmission cooler (if equipped)
Expansion tank

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Expansion tank

Cylinder head and block

Route of Thermostat
Coolant when
the thermostat
is open. Route of
Coolant EGR
Radiator when the Turbocharger
thermostat
cooler
is closed.

Cab heater

SRA (Smart
Remote Actuator

Sleeper heater Oil cooler

Coolant conditioner
(if equipped)

Coolant pump

Transmission cooler
(if equipped)

Fuel heater (if so equipped)

Air compressor

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 MODULE 2 ENGINE REMOVAL PROCEDURES
AND THE TOOLS NEEDED
Using the computer, locate the publications which contain the procedures needed
to remove the engine.

Insert the CD provided or log on to the Dealer portal now.

Depending on which engine you have been assigned you will need to look
up ENGINE REMOVAL and look at what tools will be needed, general
instructions and the removal instructions. It is a good idea to review the
NOTES, CAUTIONS and DANGERS ASSOCIATED WITH THE REMOVAL
PROCESS.
The following slides shows the proper use of the required tools.

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 COOLANT EXTRACTOR/INJECTOR
This tool allows the cooling system to be drained and refilled through a special factory
installed fitting. This fitting has been installed beginning with the introduction of the US
07 Mack CXU,CHU,GU7 and GU8. The MRU and LEU will have them beginning
June/July 2007 time frame. The tool reduces the amount of time it takes to drain and
refill the cooling system by 70% and helps prevent coolant spills. When the tool is
used to fill the cooling system it will fill from the bottom effectively purging the system
of air.

The tool can also be used

to pressurize a cooling
system to check for leaks.

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MP-7 04 Emission
2006 engine front Tool J-47038-5
hook-up

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 FRONT VIEW

Tool J-47038-5 is to be
used on the MP704
Emission engines.
Tool J-47038-7 is to be
used on MP-707 and
can be used on MP704
engines as well.

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The rear plate when used on the
MP-7 and MP-8 must be installed
with the bend at the bottom in the
position shown for the short
flywheel housing.
For the long flywheel housing,
the plate must be turned around
so that the bend is in the
opposite direction.

P/ N J-47038-4

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With the MP-7
this area may create
a restriction. Be aware in
order that the valve cover
is not damaged.

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Properly installed and ready to be lifted.

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 MODULE 3 ENGINE DISASSEMBLY

Using the CD or the Computer locate the publication which contains the
procedures needed to disassemble the engine.

When dismantling the engine pay close attention to critical areas that
could possibly cause the overhaul cost to exceed the cost of using an
exchange engine.

The following slides show some areas and procedures that should be
reviewed when disassembling the engine.

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THIS IS NOT A VERY PRODUCTIVE WAY TO
ORGANIZE YOUR REMOVED PARTS

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Wire ties should be installed in their original locations
to prevent future wire chaffing and the possibility of
shorts shorts.

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The rocker arm bolts need to be loosen in increments.

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The use of a rocker shaft lifting tool
will prevent injury and parts damage
and will keep the parts in order until
MP-7 P/N 85109050
they are ready to be cleaned and MP-8 P/N 85109250
inspected.

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 These 6 areas should
be inspected for
cracks, bent or
crushed sleeves.
Oil is fed to the cam
bushings from
the rocker shaft at low
PSI.

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 Shown is the proper
use of the injector
puller ( P/N 9990006
and slide hammer
P/N 9990013

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 Install the injector
bore protection tool
P/N 9998251

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Store for proper reassembly in original positions and for possible future
diagnostics. The unit protectors shown are P/N 9998249

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 Slide hammer P/N 9990013

Cam cap removal tool P/N 85109980

This tool correctly

separates the cam
bearing supports
to minimize damage
which can happen
by forcing or prying
with the wrong tool.

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Use of a cam lifting tool insures there
Cam lifting tool for
will be no injuries from lifting or
MP-7 and MP-8 cams
cuts from sharp edges. P/N 85108034

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 Store the cam and
crank properly by
standing them on end
and securing them in
this position.

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 During disassembly, keep parts in order or mark them for the original installation
positions. In particular, any mating parts (those that are in contact with others)
must be stored in this way. An inspection of the wear patterns on the mating parts
may be helpful if diagnosing a problem.

Front of engine to Back of engine

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 Potential wear areas should not have any
noticeable indentations, deep scratches or
discolorations from heat or abrasions.

The oblong hole faces

away from the camshaft

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Potential wear areas should not have any
noticeable indentations, deep scratches or
discolorations from heat or abrasions.

Shim size

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Inspect for chafing, broken guide pins, spun bearings or dark spots
indicating overheating of the metal.

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 Again, keep parts in order or mark them for the original installation positions .
If they are not stamped, make sure you identify them, as they are position
specific.

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 MP-7 and MP-8

The crankshaft gear can be pulled very easily with this set up. The next
slide will show the area to inspect.

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This area should be
inspected for excessive
wear or corrosion along
with gear teeth wear.

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MP-7

The two
lower bolts
thread into
the block
and the
three upper
bolts thread
into the head.

All five are

not to be
reused.

Arrows shown
indicate lube
oil flow

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 Take notice as to how
the sealant spreads out.
A 2mm bead will keep
excess sealant from
entering the engine.

This side
faces block

Oil passage
MP-7 engine
hole for
Intermediate
idler gear
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 MP-7 Flywheel side of the
gear train mounting plate.

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 Double idler gear

MP-8
When removing the gear
train mounting plate, and
the plate and the gears are
to be reused, the dial pins
need to be installed in order
that the correct gear lash
Idler gear
will be maintained between
the crankshaft gear, idler
gear and the double idler
gear.
Failure to install the dials
before removing the plate
Crankshaft gear will result in the correct
lash being lost and it will be
necessary to reestablish
gear lash between all three
Timing gear mounting plate dial pin kit P/N 9998267 (used on MP-8 gears mentioned.
only)
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MP-7 ENGINE Make sure the eyelet is positioned
so as to lift the head evenly.
Tool P/N 85109049

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 MP-7 ENGINE

The piston is notched for the oil spray tube.

Putting the piston in backwards will cause the
tube to break off and a piston failure will occur.
The MP-8 is not notched. N

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The head has a slotted area so the dowel pin can slide front and back.
This arrangement is only on the MP-7 engine.

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MP-7 Engine

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 Bolt and washer
attached to the
head. MP-8 Engine

Bolt and
washer Bolt and washer
attached attached to the
to the block
block

Confirm that the bolts and washers are in place in the positions shown.
If they are not, install new bolts and washers. These are needed to align the
cylinder head during assembly

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If the head is to be MP-7 and MP-8 Engine
removed from the
block, the adjustable idler
gear must be rotated
far enough to remove
3 bolts that are hidden
behind the gear. A total of 7
bolts must be removed
from the timing plate and 3
from the adjustable idler
gear before removing the
cylinder head.
The MP-8 has 6 timing
gear mounting plate bolts
and 4 adjustable idler gear
mounting bolts that need to
be removed before the
head can be removed.

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 On MP7 engines, the
double idler gear must be
loosened enough to allow
the adjustable idler gear
to clear the dowel pin. To
do this, the flywheel
housing must be
removed.

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 On the MP-8 engine
The double idler gear
does not need to be
loosen or removed when
removing the adjustable
idler gear. Therefore, the
flywheel housing does
not require removal.

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Head and rocker assembly with the proper lifting tools in place.
Make sure the head is stored so as to protect the head gasket side.

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 Make sure the main caps
are marked and the caps go
back into the correct locations

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 MP-7

Protrusions cast into the main bearing caps and the block prevent
assembling the caps incorrectly front to back.
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 As mentioned before, keep removed parts
in order and/or marked for reassembly in
their original locations. For instance,
the main bearing caps are matched to
their original block locations.

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The MP-7 04 and 07 Emission engines have a lower sealing area in the
block which should be examined closely for erosion, cracks, out of
round and cavitation marks due to poor coolant maintenance.
The upper ledge area should be carefully inspected for cavitation,
erosion, rust and fretting caused by liner vibrations.

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 The MP-7 04 and 07 Emission engines have two lower
O-rings and one upper. Reinstall with a grease free new o-ring
and a .08 mm bead of silicone. If a shim is used reference the
Service manual for instructions to reseal.

MP-7 liner o-ring placement

EPDM (Black) Viton (Purple)

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The blocks of an MP-7 engine
should be inspected very carefully
for uneven, corroded, cracked and
fretted surfaces, main web areas
and liner sealing areas. Plugs,
pipe thread areas and mating
surfaces must be checked for
gouges, deep scratches and
stripped threads.
This should be done before
sending the block and cylinder
head out for any kind of
reconditioning.

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 The MP8 has the lower liner sealing
rings installed in the block. 3 o-rings are
used as shown.

Viton(Purple)

Inspect this EPDM(Black)

area for pits
or fretting.

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The MP-8 uses an O-ring at the top of the liner.

EPDM (Black)

Sealing area of O-rings

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 MP-8
Oil flow from
filter base to
the cross Check
over tube. block deck
Oil flows
for fretting,
from the
cracks,
crossover
heat spots
tube to main
and rust.
oil galley at
Oil flow Also check
this port.
from the the block
oil pump to deck for
the oil filter flatness.
base. Check for
cracks or
fretting at all
7 main bearing
supports

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 MODULE 4 BLOCK PREP, AND LINER, MAIN
BEARINGS AND CRANK INSTALLATION

Using the service CD or Dealer portal, look up CYLINDER BLOCK

RECONDITIONING, paying close attention to the service hints, notes and
cautions.

Using the CD or Dealer portal, look up CRANKSHAFT INSTALLATION

UNDER ENGINE REASSEMBLY

In this module, you must complete a worksheet before beginning the

assembly of the engine. The worksheet requires that you look up and
fill in a number of standard size and fit specifications, then measure
components and fill in the actual measurements.

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 CYLINDER BLOCK AND CRANKSHAFT
FITS AND LIMITS METRIC ENGLISH ACTUAL

Cylinder Block
Deck Flatness
Main Bearing Bore in Block
Cylinder Sleeve Flange
Bead to Block Deck (Liner
Protrusion)
CRANKSHAFT
End play
Crankpin Journal O. D.
Main Journal O. D.
Journal Out-of-round
(maximum)

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 CRANKSHAFT
FITS AND LIMITS METRIC ENGLISH ACTUAL
Journal Taper (Maximum)
Main Journal to Bearing
Clearance
Maximum run out at No. 4
Journal with the shaft
supported at No. 1 and
No. 7 main journals.

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 ENGINE COMPONENT TORQUE
SPECIFICATIONS (CRITICAL FASTENERS)
Repeated tightening of fasteners and threaded components reduces their capacity to function
adequately. The following table describes the various items and the limits of their reusability.
Failure to conform to these limits may result in severe component damage.

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 ENGINE COMPONENT TORQUE
SPECIFICATIONS (CRITICAL FASTENERS)
(continued)

Connecting rods for 5 times

MP-8 engines

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 GASKET AND SEAL REUSE
Some gaskets and seals must be discarded if removed during service. The
following tables describes the components and their limits.

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GASKET AND SEAL REUSE
(continued)

Do not reuse Remove the old sealant

Clean the surfaces.

Apply fresh sealant.

IMPORTANT: Remove the old

silicone from the T joints and
apply fresh.

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 LUBRICATES AND SEALANTS
All cylinder head gaskets are precoated and do not require any type of
sealing compound. Before installing new gaskets, degrease both
sealing surfaces to avoid leaks.

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 MODULE 5 PISTON AND ROD PREP
AND INSTALLATION

Using the CD or Dealer portal, look up CONNECTING ROD

AND PISTON BENCH PROCEDURES, paying close
attention to the service hints, notes and cautions.

Using the CD or dealer portal, look up under ENGINE REASSEMBLY

PISTON AND CONNECTING ROD ASSEMBLY INSTALLATION

When installing the pistons, make sure the piston cooler nozzles are installed
according to the instructions, which can be found under the piston and
connecting rod installation chapter.

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Ring compressor for MP-7 is 9990044, the piston is 120 mm diameter
Ring compressor for MP-8 is 9998531, the piston is 130 mm diameter
The ring compressor for the MP-8 is the same as the D12D Volvo
piston ring compressor (Dual Dealer Info)

Proceed to the shop and install the ring and piston assemblies.

Install the oil pump and the block stiffener.

The valve housing assembly along with the front engine

support, crankshaft front cover and seal can be installed at this time.

In this module, you must complete a worksheet before beginning the

assembly of the engine. The worksheet requires that you look up and
fill in a number of standard size and fit specifications, then measure
components and fill in the actual measurements.

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 PISTON AND CONNECTING ROD

FITS AND LIMITS METRIC ENGLISH ACTUAL

Piston
Upper compression ring
end gap
Upper compression ring
end gap wear tolerance
Lower compression ring
end gap
Lower compression ring
end gap wear tolerance
Oil control ring end gap
Oil control ring end gap
Wear tolerance

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 PISTON AND CONNECTING ROD
FITS AND LIMITS METRIC ENGLISH ACTUAL

Piston
Compression ring lower
groove clearance
Oil ring clearance lower
groove
Top extension above
cylinder block deck at TDC
Wrist pin bore diameter
Wrist pin OD
Connecting rod
Connecting rod journal to
bearing clearance
Side clearance

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 MODULE 6 INSTALLATION OF THE GEAR TRAIN
MOUNTING PLATE, GEAR TRAIN, FLYWHEEL
HOUSING, FLYWHEEL AND CYLINDER HEAD.

Using the CD, or Dealer portal, look up TIMING GEAR

MOUNTING PLATE INSTALLATION under ENGINE
REASSEMBLY, paying close attention to the service hints,
notes and cautions.
Using the CD, or Dealer portal, look up CYLINDER HEAD Select
OVERHAUL, paying close attention to the service hints, Adjusting timing
notes and cautions. plate instructions

Using the CD, or Dealer portal, look up CYLINDER HEAD

INSTALLATION, paying close attention to the service hints,
notes and cautions.
In this module, you must complete a worksheet before continuing with the
assembly of the engine. The worksheet requires that you look up and fill in a
number of standard size and fit specifications, then measure components
and fill in the actual measurements. N

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 MP-8

The dial indicator is setup to measure

gear lash on the DOUBLER IDLER gear
set. This procedure should be used to
verify that you have set the correct gear
lash.

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MP-8

This procedure
checks the
AUXILLARY IDLER
gear lash and should
be used to verify that
you have set the
correct gear lash.

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MP-8 The dial indicator has been set up to measure oil pump drive gear back lash.

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The flywheel has a replaceable ring gear. The ring gear can
be removed with an air chisel. A new replacement gear
should be heated in an oven to 180C to 200C or 356F to
392F. Use of a torch is acceptable, but not preferred. Once
in position on the flywheel, the gear should be allowed to
air cool.

Inspect the flywheel to determine if it requires resurfacing. The wear areas should be
measured using a straightedge across the friction face and a thickness gauge. If the wear
measurement is 0.508 mm(0.020 inch) or less, the flywheel does NOT need to be
machined when operated against ceramic clutch facings.

Resurface the flywheel as required. To ensure satisfactory service life, the maximum
amount of material that may be removed from the flywheel surface is 1.78 mm (0.070
inch).

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 Overhauling the cylinder head should include
the replacement of the injector copper sleeves.
Shown are the new sleeves with the additional
Gasket (21014323). The copper sleeve kit is used
on the MP-7 04 and 07 emission engines
and the MP-8.

Proper location
for the injector
o-rings

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The tools that will be needed to remove and install injector copper kit 85111855
are shown. They can be used on the MP-7 04 emission engines MP-7 07
emission engines and the MP-8 engines.

Swaging bit P/N 8880010

Unit injector copper sleeve installation tool P/N 8880196

Unit injector copper sleeve remover P/N 9998253

Unit injector copper sleeve tap P/N 9998252

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GEAR TRAIN TIMING SPECIFICATIONS

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 CYLINDER HEAD
FITS AND LIMITS METRIC ENGLISH ACTUAL
Cylinder head
Overall height
Valve guide height above
cylinder head spring face
Inlet

Valve guide height above

cylinder head spring face
exhaust

Valve seat insert face angle Exhaust Inlet

( both inlet/exhaust)

Valve seat insert counter

bore diameter (inlet)

Valve seat insert counter

bore diameter (exhaust)
N

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 CYLINDER HEAD

FITS AND LIMITS METRIC ENGLISH ACTUAL

Valve seat insert diameter
(inlet, press fit in head)
Valve seat insert diameter
(exhaust, press fit in head)

Valve seat height (inlet)

Valve seat height
(exhaust)
Valve seat counterbore
depth (inlet)
Valve seat counterbore
depth (exhaust)

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 CYLINDER HEAD

FITS AND LIMITS METRIC ENGLISH ACTUAL

Valve face to deck (inlet)
Valve face to deck
(exhaust)
Valve stem OD (inlet)
Valve stem OD (exhaust)
Valve angle (inlet/exhaust) Exhaust Inlet
Outer spring free length
Outer spring length under
590 Newton (60 kilogram
force) ( (133lbf) load
Outer spring length under
1150 Newton ( 117
kilograms force) ( (259lbf)
load
Length when solid

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 CYLINDER HEAD

FITS AND LIMITS METRIC ENGLISH ACTUAL

Inner spring free length
Inner spring length under
243 Newtons
(117kilograms) (55lbf) of
load
Inner spring length under
447 Newtons (117
kilograms force), (100lbf)
of load
Length when solid

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 MODULE 7 CAMSHAFT AND
CAMSHAFT TIMING GEAR
INSTALLATION
Using the CD or Dealer portal look up CAM SHAFT
AND CAMSHAFT TIMING GEARS INSTALLATION
under ENGINE REASSEMBLY paying close attention to
the service hints, notes and cautions.

In this module, you must complete a worksheet before beginning the

assembly of the engine. The worksheet requires that you look up and
fill in a number of standard size and fit specifications, then measure
components and fill in the actual measurements.

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 CAMSHAFT and CAMSHAFT TIMING GEARS

FITS AND LIMITS METRIC ENGLISH ACTUAL

Camshaft
Camshaft journal diameter
Inlet valve lobe nominal lift
Exhaust valve lobe
nominal lift (with an engine
brake)
Cam to roller clearance
exhaust valve (with an
engine brake) MP-8 only
Camshaft end play
Cam gear
Adjustable idler gear to
camshaft gear backlash

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MODULE 8 INSTALLATION OF THE
INJECTORS, ROCKERSHAFT AND
OVERHEAD ADJUSTMENTS.

Using the CD or Dealer portal, look up INJECTORS,

ROCKERSHAFT, VALVE ADJUSTMENT AND VALVE COVER
INSTALLATION under ENGINE REASSEMBLY, paying close
attention to the service hints, notes and cautions.

In this module, you must complete a worksheet before beginning the

assembly of the engine. The worksheet requires that you look up and
fill in a number of standard size and fit specifications, then measure
components and fill in the actual measurements.

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Make sure that the rocker arms have cleared the pedestals when installing.
Tightening the rocker shaft mounting bolts with the rocker arms set on top
of the pedestals will bend the shaft or break the rocker arm. Make sure the
elongated recess in the valve bridge is installed away from the cam.
Tighten rocker shaft bolts in increments from the center on out.

DO NOT USE
AIR TOOLS TO
INSTALL THE
ROCKER SHAFT

N
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 N

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 INJECTOR and ROCKER SHAFT

FITS AND LIMITS METRIC ENGLISH ACTUAL

Inlet (cold engine)
Exhaust (cold engine)
MP-8 only
Exhaust clearance without
engine brake (cold
Exhaust clearance with
engine brake (cold)
Preload (for new injectors
or new copper sleeves)
Injector
Injector tip protrusion
Preload (for new injectors
or new copper sleeves)
Preload ( for used injectors
or used copper sleeves)

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 MODULE 9
INSTALL THE MANIFOLDS,EGR
SYSTEM, AHI, TURBO, OIL COOLER,
BALANCER, OIL FILTER HOUSING,
FUEL AND P/S PUMPS,
COMPRESSOR, ALL WIRING
HARNESS, BRACKETS AND
TENSIONERS
Using the CD or Dealer portal, look up the installation procedures for
the items noted above under ENGINE REASSEMBLY, paying close
attention to the service hints, notes and cautions.

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MODULE 10 ENGINE INSTALLATION
ENGINE BREAK-IN PROCEDURES

Review engine installation, the tools needed and clutch installation.

Review rebuilt engine run-in procedures, under repair instructions

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 MODULE 11 REVIEW OF
MAINTENANCE PROCEDURES.

The maintenance and lubrication recommendations can also be

found in the TS494 manual.

Select

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Return

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 NOTES

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 NOTES

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