This document pertains to E-TECH CCRS Engine Tune-Up Manuals, covering a range of E-TECH engines, including the V-MAC III, EM7, and E7 series. These engines, prevalent in heavy-duty trucks from the mid-1990s through the early 2000s, are known for their robust engineering and performance in the commercial trucking industry. The manual addresses various engine configurations, from 275 HP to 460 HP, and highlights key technologies such as the E-TECH electronic fuel injection system and wastegate turbochargers. It also details differences between CCRS and Pre-CCRS engines concerning emissions, providing specific tune-up specifications and procedures essential for maintaining these powerful diesel units.
This comprehensive service and technical manual is designed to assist professional technicians, mechanics, and advanced enthusiasts in the maintenance and repair of E-TECH engines. It thoroughly covers essential tune-up specifications and procedures, fuel injection system diagnostics and repair, including nozzle inspection and cleaning, and wastegate turbocharger troubleshooting. The manual delves into engine management systems, emission control technologies, and provides guidance on safe workshop practices. Its detailed troubleshooting sections, implicit diagnostic code references, and advanced diagnostic capabilities ensure that users can effectively maintain engine performance and address potential issues within the E-TECH engine line.
MACK
TRUCK ENGINE
TUNE-UP
SPECIFICATIONS
INCLUDES
E-TECH
CCRS ENGINES
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Advisory Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Procedures and Tool Usage . . . . . . . . . . . . . . . . . . . . . . .
EXPLANATION OF THREE-DIGIT NUMERICAL CODE . . . . . . . . . .
CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VISUAL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE INFORMATION PLATE LOCATION . . . . . . . . . . . . . . . . . . .
E-Tech Pre-CCRS and CCRS Engine Identification . . . . . . . . .
ENGINE INFORMATION PLATE EXPLANATION . . . . . . . . . . . . . . .
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASTEGATE TURBOCHARGER DESCRIPTION AND OPERATION
Diaphragm-Controlled Wastegate . . . . . . . . . . . . . . . . . . . . . . . . .
Barometric and Boost Pressure Sensors . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL INJECTION NOZZLE TESTING . . . . . . . . . . . . . . . . . . . . . . . .
Testing the One-Way Check Valve (Pre-CCRS Nozzle Assemblies
WASTEGATE TURBOCHARGER TROUBLESHOOTING . . . . . . . . .
Wastegate Diagnostics and Fault Activation . . . . . . . . . . . . . . . . .
Wastegate Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL INJECTION NOZZLE INSPECTION AND CLEANING . . . . . . .
Disassembly and Inspection of Nozzle Holder and Nozzle . . . . . .
Injection Nozzle Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nozzle Cleaning (Ultrasonic Method Preferred) . . . . . . . . . . . . . .
Mechanical Method (Alternate) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nozzle Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-TECH (V-MAC III) SIX CYLINDER ENGINE SPECIFICATIONS .
E-Tech EM7-275 Engine Specifications . . . . . . . . . . . . . . . . . . .
E-Tech Pre-CCRS EM7-275 Engine Performance . . . . . . . . . .
E-Tech CCRS EM7-275 Engine Performance . . . . . . . . . . . . . .
E-Tech EM7-300 Engine Specifications . . . . . . . . . . . . . . . . . . .
E-Tech Pre-CCRS EM7-300 Engine Performance . . . . . . . . . .
E-Tech CCRS EM7-300 Engine Performance . . . . . . . . . . . . . .
E-Tech E7-300 Engine Specifications . . . . . . . . . . . . . . . . . . . .
E-Tech Pre-CCRS E7-300 Engine Performance . . . . . . . . . . . .
E-Tech CCRS E7-300 Engine Performance . . . . . . . . . . . . . . .
E-Tech Pre-CCRS E7-300A Engine Specifications . . . . . . . . . .
E-Tech Pre-CCRS E7-300A Engine Performance . . . . . . . . . . .
E-Tech E7-310/330 Engine Specifications . . . . . . . . . . . . . . . . .
E-Tech Pre-CCRS E7-310/330 Engine Performance . . . . . . . .
E-Tech CCRS E7-310/330 Engine Performance . . . . . . . . . . . .
E-Tech E7-330/350 Engine Specifications . . . . . . . . . . . . . . . . .
E-Tech Pre-CCRS E7-330/350 Engine Performance . . . . . . . .
E-Tech CCRS E7-330/350 Engine Performance . . . . . . . . . . . .
E-Tech E7-355/380 Engine Specifications . . . . . . . . . . . . . . . . .
E-Tech Pre-CCRS E7-355/380 Engine Performance . . . . . . . .
E-Tech CCRS E7-355/380 Engine Performance
E-Tech CCRS E7-380/410 Engine Specification
E-Tech CCRS E7-380/410 Engine Performance
E-Tech E7-350 Engine Specifications . . . . . . .
E-Tech Pre-CCRS E7-350 Engine Performance
E-Tech CCRS E7-350 Engine Performance . .
E-Tech E7-400 Engine Specifications . . . . . . .
E-Tech Pre-CCRS E7-400 Engine Performance
E-Tech CCRS E7-400 Engine Performance . .
E-Tech E7-427 Engine Specifications . . . . . . .
E-Tech Pre-CCRS E7-427 Engine Performance
E-Tech CCRS E7-427 Engine Performance . .
E-Tech Pre-CCRS E7-460 Engine Specification
E-Tech Pre-CCRS E7-460 Engine Performance
E-Tech CCRS E7-460P Engine Specifications
E-Tech CCRS E7-460P Engine Performance .
E-Tech CCRS E7-460E Engine Specifications
E-Tech CCRS E7-460E Engine Performance .
MACK
TRUCK ENGINE
TUNE-UP
SPECIFICATIONS
INCLUDES
E-TECH
CCRS ENGINES
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Advisory Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Procedures and Tool Usage . . . . . . . . . . . . . . . . . . . . . . .
EXPLANATION OF THREE-DIGIT NUMERICAL CODE . . . . . . . . . .
CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VISUAL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE INFORMATION PLATE LOCATION . . . . . . . . . . . . . . . . . . .
E-Tech Pre-CCRS and CCRS Engine Identification . . . . . . . . .
ENGINE INFORMATION PLATE EXPLANATION . . . . . . . . . . . . . . .
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASTEGATE TURBOCHARGER DESCRIPTION AND OPERATION
Diaphragm-Controlled Wastegate . . . . . . . . . . . . . . . . . . . . . . . . .
Barometric and Boost Pressure Sensors . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL INJECTION NOZZLE TESTING . . . . . . . . . . . . . . . . . . . . . . . .
Testing the One-Way Check Valve (Pre-CCRS Nozzle Assemblies
WASTEGATE TURBOCHARGER TROUBLESHOOTING . . . . . . . . .
Wastegate Diagnostics and Fault Activation . . . . . . . . . . . . . . . . .
Wastegate Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL INJECTION NOZZLE INSPECTION AND CLEANING . . . . . . .
Disassembly and Inspection of Nozzle Holder and Nozzle . . . . . .
Injection Nozzle Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nozzle Cleaning (Ultrasonic Method Preferred) . . . . . . . . . . . . . .
Mechanical Method (Alternate) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nozzle Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-TECH (V-MAC III) SIX CYLINDER ENGINE SPECIFICATIONS .
E-Tech EM7-275 Engine Specifications . . . . . . . . . . . . . . . . . . .
E-Tech Pre-CCRS EM7-275 Engine Performance . . . . . . . . . .
E-Tech CCRS EM7-275 Engine Performance . . . . . . . . . . . . . .
E-Tech EM7-300 Engine Specifications . . . . . . . . . . . . . . . . . . .
E-Tech Pre-CCRS EM7-300 Engine Performance . . . . . . . . . .
E-Tech CCRS EM7-300 Engine Performance . . . . . . . . . . . . . .
E-Tech E7-300 Engine Specifications . . . . . . . . . . . . . . . . . . . .
E-Tech Pre-CCRS E7-300 Engine Performance . . . . . . . . . . . .
E-Tech CCRS E7-300 Engine Performance . . . . . . . . . . . . . . .
E-Tech Pre-CCRS E7-300A Engine Specifications . . . . . . . . . .
E-Tech Pre-CCRS E7-300A Engine Performance . . . . . . . . . . .
E-Tech E7-310/330 Engine Specifications . . . . . . . . . . . . . . . . .
E-Tech Pre-CCRS E7-310/330 Engine Performance . . . . . . . .
E-Tech CCRS E7-310/330 Engine Performance . . . . . . . . . . . .
E-Tech E7-330/350 Engine Specifications . . . . . . . . . . . . . . . . .
E-Tech Pre-CCRS E7-330/350 Engine Performance . . . . . . . .
E-Tech CCRS E7-330/350 Engine Performance . . . . . . . . . . . .
E-Tech E7-355/380 Engine Specifications . . . . . . . . . . . . . . . . .
E-Tech Pre-CCRS E7-355/380 Engine Performance . . . . . . . .
E-Tech CCRS E7-355/380 Engine Performance
E-Tech CCRS E7-380/410 Engine Specification
E-Tech CCRS E7-380/410 Engine Performance
E-Tech E7-350 Engine Specifications . . . . . . .
E-Tech Pre-CCRS E7-350 Engine Performance
E-Tech CCRS E7-350 Engine Performance . .
E-Tech E7-400 Engine Specifications . . . . . . .
E-Tech Pre-CCRS E7-400 Engine Performance
E-Tech CCRS E7-400 Engine Performance . .
E-Tech E7-427 Engine Specifications . . . . . . .
E-Tech Pre-CCRS E7-427 Engine Performance
E-Tech CCRS E7-427 Engine Performance . .
E-Tech Pre-CCRS E7-460 Engine Specification
E-Tech Pre-CCRS E7-460 Engine Performance
E-Tech CCRS E7-460P Engine Specifications
E-Tech CCRS E7-460P Engine Performance .
E-Tech CCRS E7-460E Engine Specifications
E-Tech CCRS E7-460E Engine Performance .
