Version #1 – 9/23/2020

Revision #1 – 6/18/2021

MACK
MP7, MP8 & MP10

REMOVE AND REPLACE PROCEDURES

ENGINE INJECTOR AND SLEEVE

 Engine Injector and Sleeve (Conical)
Remove
1. Secure the vehicle for service by parking it on a flat level surface, applying the parking
brake, chocking the rear wheels, and placing the transmission in neutral or park.

2. Disconnect all cables from the negative (ground) battery terminals to prevent personal
injury from electrical shock and prevent damage to electrical components.

3. Drain the coolant from the radiator and engine using the coolant extractor.

NOTE: An alternate method is to connect the drain hose to the drain fitting and drain the
coolant.

4. Clean around the fuel supply line fitting on the filter housing. Loosen the fuel line at the
filter housing to allow fuel to drain from the cylinder head. Allow the fuel to drain into a
suitable container.

5. Remove the valve cover from the engine.

NOTE: Rotate the valve cover as needed, to clear the camshaft gear and damper.

NOTE: Dependent upon chassis, engine cover may need to be removed for clearance to
remove valve cover.

6. Remove the rocker arm shaft.

7. Make sure the alignment sleeves remain in position on each bearing cap.

8. Mark the valve bridges so they can be installed in the same location during reassembly.
Remove the valve bridges.

NOTE: Mark the location of the injectors for reinstallation. Injectors must be installed in the
same cylinder as they were removed.

9. Thoroughly clean around the injectors that are to be removed. Remove the injector hold
down bolt.

10. Install the puller onto the injector. Position the puller fork in the groove on the injector
and lock the arm using the thumb screw on the side. Secure the puller by screwing down
the screw toward the inner cup of the injector. Install the slide hammer. Use reasonable
force with the slide hammer to pull the injector free from the cylinder head.

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NOTE: Use care when removing the injector because the injector hold down is not secure and
could fall off if not held in place.

11. Install the protective sleeve over the injector to prevent damage.

12. Clean the protective plug and install it into the injector bore of the cylinder head to
protect it from debris. Using compressed air, clean out the injector hold down bolt holes.

NOTE: Make sure the protective plug is clean so it does not introduce dirt or contaminants into
the engine.

13. To help determine if an injector can be reused, the following pictures show examples of
both reusable and not reusable injectors. Review the examples and compare the
removed injectors to the examples shown. Look for signs of carbon deposits and soot
above the sealing area caused by combustion gas leakage. Also look for signs of
uneven and broad wear around the sealing ring area that can be caused by the injectors
moving in the seats and letting combustion gas pass.

− Reusable Injector
(1) Non-contact area. Soot deposits are not visible and no combustion gas leakage shown.
(2) Sealing area uniform, normal sealing ring shown.
(3) Below the sealing area. Where combustion gases are present, it will normally be sooty.
(4) Just above the sealing area, no severe wear shown or soot deposits visible.

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 − Not Reusable Injector
(1) Non-contact area. Soot deposits are visible and combustion gas leakage shown.
(2) Sealing area, very broad sealing ring showing injector movement.
(3) Below the sealing area. Where combustion gases are present, it will normally be sooty.
(4) Just above the sealing area, severe ring wear shown, soot deposits visible.

14. If initial inspection indicates the injector may be reused, clean the cap nut seat surface of
hard carbon deposits with a soft cloth and diesel fuel. This is the only approved cleaning
procedure. There are new injector cap coatings that can be damaged by improper
cleaning methods.

15. After cleaning, inspect the injector nozzle cap nut seat surface for pitting or related
damage.

NOTE: Pitting on surfaces other than the cap nut seat surface does not affect the function of the
injector and is acceptable.

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 − If there is pitting or other damage, the injector and sleeve cannot be reused. When
installing a new injector, a new injector sleeve must also be installed. Proceed to Step 17
for injector sleeve removal.
− If there is no pitting on the seat surface, the injector can be reused. Proceed to the next
step for injector sleeve cleaning.

NOTE: When reinstalling the existing injector, it is acceptable to reuse the injector sleeve or
install a new sleeve.

16. Install the protective sleeve. Use brush to clean the injector sleeve. Wipe out injector
sleeve after brushing with a lint free cloth and brake clean or contact cleaner to remove
any loose deposits. After cleaning the sleeve, carefully inspect the inside surface of the
sleeve, especially the bottom surface. Any remaining contamination is unacceptable and
must be removed.
− If there is any indication of a discrepancy that raises concern about suitability of the
sleeve for reuse, replace it with a new sleeve. Proceed to the next step for sleeve
removal.
− If the sleeve can be reused, proceed to Step 39 for injector installation. The injector must
be reinstalled in the same cylinder from which it was removed.

17. Install two sealing rings to prevent dirt from entering the fuel gallery when the injector
sleeve is removed.

NOTE: Two sealing rings are required to cover the fuel gallery.

18. Apply multipurpose grease to all threads to prevent wear. Snug the collar nut against the
hex head of the center shaft. Turn the center shaft clockwise until it stops. Then back the
center shaft off one and a half turns.

19. Install the extractor into the sleeve. The puller is installed correctly when the outer barrel
tabs are resting on the cylinder head and the top outer diameter of the inner tool is
slightly above or flush with the bottom of the cutout on the outer barrel. Turn the center
shaft clockwise until contact with the sleeve is felt. Using a wrench, turn the center shaft
one additional flat. Turn the knurled collar clockwise until contact is made between the
thrust bearing and outer barrel.

NOTE: This tool can be used to remove both copper and conical sleeves.

20. Use a wrench to hold the center shaft to prevent it from turning. Turn the collar nut
clockwise until the injector sleeve is removed. Loosen the center shaft to release the
jaws from the injector sleeve.

21. Absorb any remaining coolant with a lint-free cloth.

NOTE: Check that the piston is free of any fluids.

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 22. Attach a small diameter air-line to a wet / dry shop vacuum nozzle that can reach into
the coolant passages in the injector sleeve bore. Remove all remaining fuel and coolant.
A lint free paper shop towel can also be used to absorb liquid. All fluids must be
completely removed before proceeding. Remove the two sealing rings from the fuel
passage when all fluid has been removed.

NOTE: Do not us a shop rag as it could possible contain contaminates, metal chips, etc.

23. Inspect condition of the J-42885-25 O-rings before installing the protective sleeve. If
necessary, replace O-rings. Install the injector bore sealing tool, J-42885-25, to protect
the fuel passage area and prevent debris from entering.

24. Using the cleaning kit clean the injector sleeve seat of the cylinder head.

NOTE: The injector bore sealing tool must be used to prevent dirt from entering the fuel
passage.

NOTE: A high speed drill or angle die grinder works best for cleaning with the brush tip.

25. Using the brush, clean the cylinder head injector bore walls for the injector sleeve.

NOTE: The injector bore sealing tool must be used to prevent debris from entering the fuel
passage.

NOTE: Inspect brush for missing wire bristles and for brush tightness in bore. If several wire
bristles are missing or brush fits loose in the bore replace brush.

26. Using the brush, clean the injector sleeve opening in the cylinder head.

NOTE: The injector bore sealing tool must be used to prevent debris from entering the fuel
passage.

NOTE: Inspect brush for missing wire bristles and for brush tightness in bore. If several wire
bristles are missing or brush fits loose in the bore replace brush.

NOTE: When replacing the injector sleeves, it is important to check that the sleeve bore in the
cylinder head is free from any carbon deposits or other residue (i.e., pieces of O-ring, etc.)
before installing a new injector sleeve. Repeat cleaning if necessary.

27. Using the chip vacuum, remove all debris from the injector sleeve bore.

NOTE: Injector sleeve seat in cylinder head and the bore for injector sleeve tip must be
COMPLETELY clean and dry.

28. Remove the injector bore sealing tool from the cylinder head. Using the chip vacuum,
remove any remaining debris.

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 29. Saturate a lint free paper shop towel with brake clean or contact cleaner. Wipe out
injector sleeve bore with special attention to the injector sleeve seating area and injector
sleeve O-ring sealing area in the cylinder head.

30. Ensure the piston is at the lowest position in the cylinder. If not, use the flywheel turning
tool to place the piston at its lowest position.

NOTE: This is to ensure that the sleeve installation tool does not damage the piston due to tool
length.

NOTE: Make sure the sleeve bore surface in the cylinder head is clean and dry prior to sealant
being applied.

31. Before installing a conical sleeve, apply Loctite spray activator 7649 to the bottom
surface of the sleeve where sealing compound is to be applied and allow to completely
dry. When activator is dry, apply a 2-3 mm bead of Mack approved sealing compound to
the bottom of the injector sleeve.

NOTE: Always use the new O-ring included in the sleeve kit.

32. Lubricate a new injector sleeve O-ring with clean coolant or soapy water. Install the O-
ring on the injector sleeve and lubricate again with clean coolant or soapy water.

33. Using calipers, measure the swaging bit to make sure that the proper swaging tool is
used. Measurement should read 7.9 ±0.05 mm. Also, verify that the swaging bit has one
stage and the length is 80 mm.

NOTE: Swaging bit, 88880054, can be ordered as a spare part if the bit is worn or broken.

34. Lubricate an injector sleeve O-ring with clean coolant or soapy water. Install the O-ring
on the injector sleeve installation tool and lubricate again with clean coolant or soapy
water.

NOTE: The O-ring is used on the tool to protect the cylinder head bore only. The O-ring only
needs to be replaced when damaged. A used injector sleeve O-ring can be used on the tool.

NOTE: Special tool can only be used on the conical injector sleeves. It CAN NOT be used on
the copper injector sleeve.

35. Place the new injector sleeve on the installation tool. Thread the swaging bit completely
into the flaring tool until it stops (finger tight). Loosen the swaging bit 180° before
installing the tool in the cylinder head. Lubricate the swaging bit and the threads on the
tool with fresh, extreme pressure NLGI #2 grease or equivalent.

NOTE: Remove any oil from the injector hold down bolt holes to avoid hydraulic lock for this
step and when the injector is installed.

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 36. Carefully place the sleeve installation tool and new injector sleeve into the injector bore
of the cylinder head. Carefully move the injector sleeve downward into the injector bore
so that the swaging bit is guided into the injector tip bore in the cylinder head. Using
hand force, press down on the installation tool until the injector sleeve bottoms against
the bore. The shoulder of the hold down should be flush with the top of the cylinder
head. Use the injector hold down yoke and bolt to hold the tool in position. To ensure
that the sleeve is bottomed in the cylinder head, tighten the bolt to 80 ±5 Nm (60 ±4 ft-
lb).

37. Flare the injector sleeve by turning the nut clockwise while holding the spindle until the
swaging bit has been pulled completely through the injector sleeve.

38. Remove sleeve installation tool from the injector bore. If the injector is not being installed
immediately, install the protective plug into the injector bore to protect it from debris.
Clean the protective plug before installation.

39. For MP7 and MP8 engines, before installing the new or reused injector, install a new
upper O-ring (large diameter, violet) on the top injector groove only. If new injectors have
O-rings installed on both top and bottom locations of the injector, remove the lower O-
ring (small diameter, violet). For MP10 engines, before installing the new or reused
injector, install a new upper O-ring (large diameter, violet) on the top injector groove and
a new V-ring on the lower O-ring groove. Install the V-ring so that the “V” is positioned
toward the top of the injector. Use special tool 22651843 to check for correct V-ring
installation. If new injectors have O-ring and V-ring installed, do NOT remove the lower
V-ring.

40. Lubricate the O-ring and V-ring with clean engine oil.

NOTE: Clean engine oil is the only approved lubricant for the injector O-ring and V-ring.

41. Clean the injector hold down yoke and apply light coat of oil to the threads and
underside of the head of a NEW bolt Slip the injector hold down and bolt onto the
injector.

NOTE: Always wear gloves when applying graphite sealant paste.

42. Wipe the injector conical area with a lint free paper shop towel to remove any residue
before applying the graphite paste. Use a fingertip to apply a thin layer of graphite
sealant paste all around the injector cap nut cone.

NOTE: Replace the injector hold down fastener each time an injector is installed. The bolt
cannot be reused and must be replaced.

NOTE: If available, use an electronic digital torque wrench for the tightening procedure.

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 43. Center the injector and hold down between the valve springs and then push down on the
injector using hand pressure to seat the O-ring. Clamp the injector in position with the
injector hold down by tightening the injector hold down bolt. Tighten the injector hold
down bolt using the following five step procedure:
− Tighten 20 ±5 Nm (15 ±4 ft-lb).
− Tighten 180 ±5 degrees angle of tightening.
− Loosen the hold down bolt until torque is 10 to 15 Nm (7 to 11 ft-lb).

NOTE: This should be achieved by loosening with an angle of 100-110 degrees. Do not
completely loosen the bolt to prevent components from moving after the previous seating
process.

44. When replacing injectors, the engine control module (ECM) must be programmed with
the new injector’s trim codes. The code is printed on top of the injector electrical
connector. The programming is performed using Tech Tool and is necessary to ensure
that engine timing and emission levels are correct.

NOTE: Due to the ECM self-learning capability, it is necessary to reset learned ECM
parameters after servicing some engine related components. This allows the ECM to learn the
new components behavior. After servicing is complete, perform the “Learned Data Reset” using
Tech Tool. This is located in the Function Group 1 menu.

NOTE: If reinstalling an injector into the same location, reprogramming is not required.

45. Install the valve bridges onto the same cylinders as marked at disassembly. Lubricate
the valve bridges and camshaft lobes with engine oil.

46. Install the rocker shaft.

47. Adjust all of the valves and injectors.

48. Install the valve cover on the cylinder head.

49. Secure the fuel supply line fitting at the fuel filter housing (loosened earlier to drain fuel
from the cylinder head). Clean any fuel that remains around the fitting. Always replace
the fuel line seal washers.

50. Install all previously removed cables to the ground (negative) battery terminals.

51. Use coolant extractor to fill the system with approved coolant.

52. Prime the fuel system by pumping the hand priming pump on the fuel filter housing until
resistance is felt indicating that the system is full of fuel.

53. Start the engine and run until the engine clears and runs without stumbling. This
procedure may need to be repeated once or twice to get the fuel system completely free
of air.

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NOTE: If the engine does not start on the first attempt, prime the fuel system again, and refer to
the previous step. Engine priming may need to occur several times in order to get the engine to
start.

54. Allow the engine to run at low idle for about 5 minutes. Check for any fuel leaks and
correct if necessary.

NOTE: The engine speed should not be increased as any air pockets can be forced into the
cylinder head which can result in the engine shutting off.

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