Download Mack ASET AI, AMI Diesel Engine Service Manual 

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This manual contains mechanical removal, installation and overhaul procedures for Mack ASET AC Diesel Engine.

Topic List:

INTRODUCTION
SAFETY INFORMATION
Advisory Labels
Service Procedures and Tool Usage
EXPLANATION OF NUMERICAL CODE
CONVERSION CHART
ABOUT THE MACK ASET AI/AMI DIESEL ENGINE
AI/AMI Engine Changes for 2004
Heater Core Hose Connection Revision
Engine Configuration and Chassis Application for 2004/2005
VISUAL IDENTIFICATION
ENGINE MODEL IDENTIFICATION
Engine Information Plate
Engine Serial Number Identification
DESCRIPTION AND OPERATION
ENGINE DESIGN FEATURES
ASET™ AI/AMI (IEGR) Technology
ASET™ AI/AMI (IEGR) Engine Features and Components
MACK Fuel Filtration System
Electronic Unit Pumps (EUP)
Engine Brake
Camshaft
Valve Train
Low-Pressure Fuel System
High-Pressure Fuel System
High-Pressure Fuel Injection Lines
Fuel Injector Assemblies
Cylinder Block
Crankshaft
Block Heater
Cylinder Head
Cylinder Head Gasket
Gear Train
Air Compressor
Power Steering Pump
Vibration Damper Hub
Front Cover
Lubrication System
GLOSSARY OF TERMS
COMPONENT LOCATOR
COMPONENT LOCATION VIEW
TROUBLESHOOTING
ENGINE SYMPTOM DIAGNOSIS FOR MACK ASET™ ENGINES
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 (MACK POWERLEASH™)
Operational Tests
Electrical Troubleshooting
MACK PowerLeash™ Checks (Hydraulic/Mechanical)
MACK PowerLeash™ Troubleshooting Guide
Removal and Inspection of MACK PowerLeash™ Engine Brake Components
ENGINE BRAKE TESTS (J-TECH™)
Operational Tests
Electrical Troubleshooting
J-Tech™ Checks (Hydraulic/Mechanical)
J-Tech™ Troubleshooting Guide
MAINTENANCE
LUBRICATION SYSTEM MAINTENANCE FOR ASET™ ENGINES
Crankcase Breather Element Cleaning
Oil Level Check
Oil and Filter Change Procedure
FUEL FILTER ELEMENT REPLACEMENT FOR ASET™ AI/AMI ENGINES
Primary/Secondary Fuel Filter Change
Fuel/Water Separator
COOLANT CONDITIONER ELEMENT REPLACEMENT FOR ASET™ ENGINES
Coolant Conditioner Replacement
DRIVE BELT REPLACEMENT AND TENSIONING FOR ASET™ AI/AMI ENGINES
General Information
Manually Tensioned System
Automatically Tensioned System
REPAIR INSTRUCTIONS, PART 1
ENGINE REMOVAL
General Instructions
Removal from Vehicle
ENGINE DISASSEMBLY
General Instructions
Filter Element Removal
Dipstick Tube Removal (Front-Redesign)
Oil Cooler and Oil Filter Mounting Bracket Assembly Removal
Mounting Engine in Stand
Alternator Removal
Engine Electronic Control Unit (EECU) Removal
Thermostat Housing Removal
Water Pump Assembly Removal
Coolant Manifold Removal
Air Inlet Manifold Removal
Turbocharger Removal
Fuel Nozzle Inlet Tube Assembly Removal
Exhaust Manifold Removal
Engine Wiring Harness Removal
Electronic Unit Pump (EUP) Removal
Oil Fill Tube Removal
Air Compressor Removal
Cylinder Head Cover and Spacer Removal
Rocker Arm, Valve Yoke and Push Rod Removal
Revised Rocker Arm Shaft Mounting Bolts
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 Cleaning and 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
Inlet and Exhaust Valve Inspection
Inlet and Exhaust Valve Installation
VALVE ROCKER ARM SHAFT BENCH PROCEDURES
Rocker Arms
Valve Rocker Arm Shaft Disassembly (with/without Engine Brake)
Inspection
Valve Rocker Arm Shaft Reassembly (without Engine Brake)
Valve Rocker Arm Shaft Reassembly (with J-Tech™ Engine Brake)
Valve Rocker Arm Shaft Reassembly (with MACK PowerLeash™ 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 COMPONENT 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
5-110
Page viii
TABLE OF CONTENTS
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
Cylinder Head Cover and Spacer Installation
Dipstick Tube Installation
Oil Fill Tube/Turbo Drain
Air Compressor Installation
Electronic Unit Pump (EUP) Installation
Engine Wiring Harness Installation
Fuel Nozzle Inlet Tube Assembly Installation
Turbocharger Installation
Coolant Manifold Installation
Air Inlet Manifold Installation
Water Pump Installation
Thermostat Housing Installation
Coolant Conditioner Installation
Oil Cooler-to-Water Pump Inlet Line Installation (Engine with Standard-Type
Water Pump)
Fuel Filter Adapter Assembly Installation (Engine with Standard Front Configuration and
Fuel Filter Arrangement)
EECU Installation
Alternator Installation
Removing Engine from Engine Stand
Oil Cooler and Oil Filter Mounting Bracket Assembly Installation
Dipstick Tube Installation (AI/AMI with Front-Redesign)
ENGINE INSTALLATION
General Instructions
Engine Installation into Vehicle
REPAIR INSTRUCTIONS, PART 2
IN-CHASSIS PART/COMPONENT PROCEDURES
ELECTRONIC UNIT PUMP REPLACEMENT (IN-CHASSIS)
Unit Pump Removal
Tappet Guide Pin and Tappet Bore Inspection
Salvaging a Damaged EUP Tappet Bore
Tappet Installation
Unit Pump Installation
CAMSHAFT REPLACEMENT (IN-CHASSIS)
Preliminary Steps
Camshaft/Lifter Removal
Cleaning and Inspection of Cylinder Block
Camshaft Installation
Camshaft Idler Gear Installation
EXHAUST VALVE YOKE PIN AND VALVE ROTATOR INSPECTION AND REPLACEMENT CRITERIA (IN-CHASSIS)
VALVE LIFTER H-RING DISLODGEMENT AND ALIGNMENT INSPECTIONS (IN-CHASSIS)
H-Ring Dislodgement Inspection
H-Ring Alignment Inspection
H-Ring Dislodgement Check and Alignment Verification
COOLING SYSTEM SERVICE PROCEDURES (IN-CHASSIS)
AI/AMI Engines with Standard-Type Water Pump
AI/AMI Engines with Front-Redesign Water Pump
REPAIR INSTRUCTIONS, PART 3
ENGINE SETUP AND ADJUSTMENTS
Fuel Injection Timing
Valve Adjustment
Valve Adjustment Procedure
Electronic Unit Pump (EUP) Calibration
ENGINE SPEED AND POSITION SENSORS INSTALLATION AND ADJUSTMENT
Engine Speed Sensor
Engine Position Sensor
Other Engine-Mounted Sensors
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
ASET™ AI/AMI ENGINE MECHANICAL SPECIFICATIONS
Performance Specifications
Material and Dimensional Data
Engine Component Torque Specifications
SPECIFICATION FOOTNOTES
ASET™ ENGINE ASSEMBLY LUBRICANTS AND SEALANTS
ASET™ AI/AMI ENGINE DRIVE BELT SPECIFICATIONS (ENGINES WITH FRONT-REDESIGN
CONFIGURATION)
SCHEMATIC & ROUTING DIAGRAMS
ASET™ AI/AMI ENGINE SYSTEMS SCHEMATICS
Cooling System Flow Diagram
Lubrication System Flow Diagram
Fuel System Flow Diagrams
Accessory Drive Belt Routings
SPECIAL TOOLS & EQUIPMENT
ASET™ ENGINE SPECIAL TOOLS
Special Tools for Engine Overhaul
V-MAC III Special Tools
FASTENER IDENTIFICATION
Fastener Selection and Installation
Fastener Sizes and Types
TORQUE WRENCH USE
Using an Adapter in Combination with a Torque Wrench
TURBOCHARGER FAILURE AND ACTIONS REQUIRED TO AVOID REPEAT FAILURE
Cleaning Oil from the Charge Air Cooler
Cleaning the Intake Air System
Cleaning the Turbocharger Oil Supply Line, Changing the Engine Oil and Pre-Lubricating the
Turbocharger Following a Failure
Pre-Lubricating a Turbocharger After Sitting Idle for an Extended Period of Time
INDEX

Covers: Mack ASET AI/AMI Diesel Engine w/ EGR
Pages: 494
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File size: 43mb
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