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

Topic List:

INTRODUCTION
REMOVAL FROM VEHICLE
Cleaning
CYLINDER BLOCK
Inspection
Cylinder Sleeve Counterbore
Machining
Crankshaft Main Bearing Bore
Camshaft Bushing
CYLINDER BLOCK ASSEMBLY
Cylinder Sleeve
Measuring Sleeve Bore
Honing Sleeve Bore
Installing Cylinder Sleeve
Removing Cylinder Sleeve
Main Oil Gallery Plugs
CRANKSHAFT AND MAIN BEARINGS
Crankshaft
Crankshaft Gear and Counterweight
Crankshaft Gear
Crankshaft External Counterweight
Main Bearings
Main Bearing Thrust Washer
CRANKSHAFT REAR OIL SEAL
Crankshaft Rear Flange
Rear Oil Seal
FLYWHEEL HOUSING AND FLYWHEEL
Flywheel Housing
Flywheel
VALVE LIFTER AND CAMSHAFT
Camshaft Thrust Washer
Valve Lifters
Camshaft
CONNECTING ROD AND PISTON
Connecting Rod
Piston
Connecting Rod and Piston Assembly
Piston Rings
Connecting Rod Bearings
Piston and Connecting Rod Installation
PISTON COOLING OIL SPRAY NOZZLE
Piston Cooling Oil Spray
Nozzle Arrangement
Piston Cooling Oil Spray
Nozzle Installation
Piston Cooling Oil Spray
Nozzle Removed
Piston Cooling Oil Spray
Nozzle Sleeve Installation
OIL PUMP DRIVE IDLER GEAR
Oil Pump Drive Idler Gear
Parts Identification
Oil Pump Drive Idler Gear Removal
Page IV
OIL PUMP
Oil Pump Parts Identification
Oil Pump Disassembly
Oil Pump Assembly
Gear to Cover End Clearance Check
Low Limit
High Limit
Side Clearance Check
High Limit
Backlash Check
Low Limit
High Limit
OIL PRESSURE RELIEF VALVE
Operation of Oil Pressure Relief Valve
Removal of Oil Pressure Relief Valve
Assembly of Oil Pressure Relief Valve
OIL PUMP INLET AND OUTLET TUBES
AND PISTON COOLING TUBES
Oil Pump Inlet Tube
Oil Pump Outlet Tube
Piston Cooling Tubes
TIMING GEAR COVER AND OIL PAN
Inspection
Timing Gear Cover Installation
Seal Installation
Camshaft Thrust Screw Adjustment
Oil Pan
WATER PUMP
Description
Removal
Pump Disassembly
Inspection
Assembly
AUXILIARY DRIVE
Description
Removal
Disassembly
Inspection
Bushing Removal
Assembly
Installation on Engine
VALVE LIFTER COVER AND ENGINE
BREATHER
Description
Valve Lifter Cover
Engine Breather
Oil Filler Tube (or Cover Plate)
FAN DRIVE
Inspection
Installation
VIBRATION DAMPER AND HUB
Inspection
Installation
Vibration Damper Hub Removal

INJECTION PUMP (BOSCH)
Injection Pump Removal
Gear and Hub Removal
Gear and Hub Installation
Mounting Adapter
Timing Procedure for Setting
Injection Pump to Engine Timing
Checking Pump to Engine Timing
INJECTION PUMP (AMBAC)
Description
Gear and Hub Removal
Checking Timing Indicator and Top
Dead Center Marking
Gear and Hub Installation
Injection Pump Installation
Injection Pump Timing
Timing Check Procedure
Injection Pump Oil Feed Line
VALVE ROCKER ARM SHAFT ASSEMBLY
Inspection
Assembly Procedure
Engine Brake Solenoid
CYLINDER HEAD ASSEMBLY
Description
Disassembly
CYLINDER HEAD
Inspection
Fire Ring Groove
Valve Guides
Valve Seat Insert Counterbore
Inlet Valve Seat Insert
Exhaust Valve Seat Insert
Cup Plug Installation
Injection Nozzle Holder Insert
Injection Nozzle Holder Insert Removal
Valve Yoke Guide Pin
Valve Spring
Inlet and Exhaust Valve Assembly
Inlet Valve Assembly Dimension
Exhaust Valve Assembly Dimension
Engine Brake Terminal Installation
Cylinder Head Gasket Installation
Cylinder Head Installation
Push Rod Installation
Valve Yoke Installation
Valve Rocker Arm Shaft
Assembly Installation
INLET, EXHAUST AND WATER MANIFOLDS
Water Manifold Crossover Tube
Thermostat Housing and Thermostat
Inspection
Seal Assembly
Thermostat Assembly
Water By-Pass Fitting 129
Water Pump Outlet Fitting
Coolant Conditioner
Conditioner Installation and Removal
EXHAUST MANIFOLD/SEAL RINGS
VALVE LASH ADJUSTMENT
Inlet Valve Adjustment
Exhaust Valve Adjustment
INJECTION NOZZLE, HOLDER AND
NOZZLE FUEL, INLET TUBES
Description
Nozzle Holder Installation
Nozzle Fuel Inlet Tube Installation
Cylinder Head Cover
Nozzle Holder Removal
CYLINDER COMPRESSION TEST
TURBOCHARGER
Description
Turbocharger
OIL COOLER AND OIL FILTERS
Description
Oil Cooler
Oil Filter Pressure Relief Valve
AIR COMPRESSOR
Inspection
Assembly
Air Filter
SECONDARY FUEL FILTER
MACK PUFF LIMITER
Assembly
OIL FLOW DIAGRAM
Main Oil System Engine
Sectioned From Front
Main Oil System and Turbocharger
Engine Sectioned From Left Side
Piston Cooling System Engine
Sectioned From Front
Piston Cooling System Engine
Sectioned From Left
External Left Side Detail
AIR FLOW DIAGRAM
Air Induction System
LUBRICATION OIL FLOW
FITS AND LIMITS CHART
TORQUE SPECIFICATIONS
FASTENER TORQUE

Covers: Mack E9 V8-998 Series Diesel Engine (w/ Bosch or AMBAC fuel injection pump)
Pages: 193
Format: PDF file
Compatibility: Windows/Mac/Tablet
Note: Instant digital download only – no printed copy or CD-ROM media.