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Service Bulletin Trucks Service Bulletin Mack Trucks, Inc. Greensboro, NC USA Trucks Date Group No. Release Page 5.2010 214 87 01 1(11) Valves and Unit Injectors Adjustment MP7 EPA2007, MP7 EPA2010 Valves and Unit Injectors, Adjustment T2022275 This information covers the correct procedure for adjusting the valves and unit injectors on MP7 EPA2007 and MP7 EPA2010 engines. Contents • “Special Tools”, page 2 • “Valves and Injectors, Adjustment”, page 3 Note: Information is subject to change without notice. Illustrations are used for reference only and may differ slightly from the actual vehicle being serviced. However, key components addressed in this information are represented as accurately as possible. PV776-88948798 USA39019 Mack Trucks, Inc. Date Group No. Release Page Service Bulletin 5.2010 214 87 01 2(11) Tools Special Tools For special tools ordering instructions, refer to Tool Information, group 08. 85111158 9996956 85111377 VEB Shim Kit Flywheel Turning Tool Feeler Gauge Set Mack Trucks, Inc. Date Group No. Release Page Service Bulletin 5.2010 214 87 01 3(11) Service Procedures 2140-05-02-03 Valves and Injectors, Adjustment You must read and understand the precautions and guidelines in Service Information, group 20, "General Safety Practices, Engine" before performing this procedure. If you are not properly trained and certified in this procedure, ask your supervisor for training before you perform it. Special tools: 85111158, 9996956, 85111377 Valve and Unit Injector, Adjustment 1 1 Apply the parking brake and place the shift lever in neutral. 2 2 Remove all cables from ground (negative) battery terminals to prevent personal injury from electrical shock. 3 3 Remove the valve cover. Refer to Group 21 for procedure. W2005496 Mack Trucks, Inc. Date Group No. Release Page Service Bulletin 5.2010 214 87 01 4(11) 4 4 Remove the cover at the bottom of the flywheel housing and install the flywheel turning tool 9996956. T2024401 Mack Trucks, Inc. Date Group No. Release Page Service Bulletin 5.2010 214 87 01 5(11) Inlet Valve Adjustment Timing marks for basic camshaft timing and adjustment of the valves and unit injectors are located at the rear of the camshaft just forward of the No. 7 rear bearing journal. Some engines also have the timing markings located on the front face of the camshaft at the No. 1 front bearing journal. Two lines at the top of the bearing cap mark the alignment point for positioning of the camshaft and making the adjustment. Engines without engine brake — Adjust the inlet valves, exhaust valves and injectors using the timing marks 1–6 on the camshaft. Engine with engine brake — Adjust the inlet valves and the injectors using the timing marks 1–6. Adjust the exhaust valves using the timing marks identified with a V in front of the number, i.e., V1 or V6. Camshaft settings for adjustment of the valves and unit injectors are shown in the following chart. Camshaft Markings Exhaust Exhaust (without (with Cam Engine Engine Position Injector Intake Brake) Brake) 5 X X X V6 X 3 X X X V2 X 6 X X X V4 X 2 X X X V1 X 4 X X X V5 X 1 X X X V3 X Mack Trucks, Inc. Date Group No. Release Page Service Bulletin 5.2010 214 87 01 6(11) W2006251 Rear of Cam Shaft Showing Timing Marks W2034980 Front of Cam Shaft Showing Timing Marks 1 1 Using the flywheel turning tool 9996956, turn the engine over manually in the normal direction of rotation to the appropriate camshaft marking for adjustment of the inlet valves and unit injector of that cylinder. T2024401 Mack Trucks, Inc. Date Group No. Release Page Service Bulletin 5.2010 214 87 01 7(11) 2 2 Using a feeler gauge, check the clearance between the rocker arm adjustment screw and the valve bridge of the inlet valves. The inlet valve clearance should be 0.20 ± 0.05 mm (0.008 ± 0.002 inch). W2005486 3 3 If the clearance is not within specification, loosen the locknut and adjust the clearance as required. Hold the adjustment screw to prevent it from turning and tighten the locknut to 38 ± 4 Nm (28 ± 3 ft-lb). Unit Injector Adjustment 1 1 To adjust the unit injector at the same cylinder location, loosen the locknut and back off the adjusting screw until it no longer makes contact. 2 2 Turn the adjusting screw in until it contacts the unit injector (zero clearance). Then, tighten the adjusting screw an additional 4 flats or 240 degrees of clockwise rotation. Zero clearance, Plus, 4 flats or 240 degrees of clockwise rotation W2005488 3 3 Hold the adjusting screw and tighten the locknut to 52 ± 4 Nm (38 ± 3 ft-lb). Mack Trucks, Inc. Date Group No. Release Page Service Bulletin 5.2010 214 87 01 8(11) Exhaust Valve Adjustment (without Engine Brake) 1 1 At the current camshaft setting, adjust the exhaust valves following the same procedure described above for adjustment of the inlet valves. However, the valve clearance specification is different, at 0.80 ± 0.05 mm (0.031 ± 0.002 inch). T2022277 2 2 Using the flywheel turning tool, turn the engine over manually to the appropriate marking for the next cylinder. Adjust the inlet valves, unit injector and exhaust valves at that cylinder. Exhaust Valve Adjustment (with Engine Brake) 1 1 Using the flywheel turning tool, turn the engine over so that the appropriate V number marking for the respective exhaust valves is between the lines on the rear and/or front camshaft bearing cap. W2006251 Image Shows Rear Cam Shaft Timing Marks Mack Trucks, Inc. Date Group No. Release Page Service Bulletin 5.2010 214 87 01 9(11) 2 2 Press down on the exhaust rocker arm to release the pressure from the engine brake rocker arm piston. W2006238 3 3 Measure the clearance between the rocker arm piston and the shim on top of the bridge as shown in the figure. The clearance should be 2.00 ± 0.05 mm (0.079 ± 0.002 inch). W2005490 4 4 If clearance is not within specification, adjust the clearance as required, using shims placed on top of the valve bridge. 1 Remove the shim retaining screw and remove the shim(s). 2 Determine the thickness of the shim(s) required to match the measured clearance. Note: DO NOT use more than two shims. Shims are T2009008 available (shim kit No. 85111158) in 0.05 mm (0.002 inch) increments with the thickness marked on the surface. If two shims are required to take up the clearance, the shims should be of nearly equal thickness. Mack Trucks, Inc. Date Group No. Release Page Service Bulletin 5.2010 214 87 01 10(11) 3 Clean the valve bridge and shim(s). Place the shim(s) in position on the bridge, install the retaining screw and tighten to 38 ± 4 Nm (28 ± 3 ft-lb). Hold the bridge securely while tightening the retaining screw. 5 5 With the required shim(s) in place and secured, recheck the clearance between the exhaust valve rocker arm and the valve bridge. Note: Mark the respective rocker arm as each valve adjustment is completed. Continuation of Adjustments 1 1 Continue the procedure by turning the engine to the appropriate timing marks and adjusting the valves and unit injectors at each of the remaining cylinders. Follow the steps described in the preceding procedure to adjust the inlet and exhaust valves, and unit injector at each cylinder. Note: Ensure that the turning tool is well greased before attempting to turn the flywheel. 2 2 After all adjustments have been made, use the flywheel turning tool to turn the engine over manually two complete revolutions. This is done to ensure that no piston-to-valve contact occurs. If contact does occur, readjust the valves as needed. 3 3 Remove the flywheel turning tool, 9996956, and reinstall the cover. T2024401 Mack Trucks, Inc. Date Group No. Release Page Service Bulletin 5.2010 214 87 01 11(11) Final Steps 1 1 Clean the valve cover mounting surface on the cylinder head and inspect the valve cover gasket for damage. The gasket must be replaced if any damage is found, All old sealant must be removed from the gasket prior to re-use. 2 2 Apply 2 mm (0.079 inch) of approved sealant to the parting lines between the cylinder head and the timing cover on both sides of the cylinder head. 3 3 Install valve cover. Refer to Group 21 for procedure. W2005523 4 4 Install all previously removed cables to the ground (negative) battery terminals. 5 5 Start the engine and check for leaks. Once normal operating temperature is attained, let the engine idle for an additional five minutes. During this time, the Engine Control Module (ECM) will perform its own cylinder balancing, resulting in smooth engine idling. Note: During cylinder balancing, do not use any form of power consuming equipment, such as power take-off or air conditioning. 6 6 After engine shutdown, replenish fluids as necessary..
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