1986 Mack Engine Manual PDF

The 1986 Mack Engine Manual provides comprehensive technical documentation for Mack truck engines manufactured in 1986, covering the E6 and E7 series engines with detailed specifications, maintenance procedures, troubleshooting guides, and repair instructions. This manual includes engine specifications, fuel systems, cooling systems, lubrication systems, electrical systems, and emission controls specific to 1986 Mack engines. Below are key sections for technical specifications, maintenance schedules, troubleshooting, and operational guidelines.

1. Engine Specifications 2. Maintenance Procedures 3. Fuel System 4. Cooling System 5. Lubrication System 6. Electrical System 7. Troubleshooting Guide 8. Repair Instructions 9. Torque Specifications 10. Emission Controls 11. Parts Reference

Engine Specifications

Detailed technical specifications for 1986 Mack E6 and E7 series engines including displacement, horsepower, torque ratings, and dimensional data.

Specification	Description
Engine Series	E6 (6-cylinder), E7 (6-cylinder)
Displacement	E6: 672 cubic inches; E7: 728 cubic inches
Horsepower	E6: 250-300 HP; E7: 285-350 HP
Torque	E6: 860-1050 lb-ft; E7: 1050-1250 lb-ft
Bore & Stroke	E6: 4.875" x 6.00"; E7: 5.00" x 6.00"
Compression Ratio	16.0:1 (both series)
Fuel System	Robert Bosch P7100 injection pump
Governor Type	Mechanical limiting speed
Weight	E6: 2150 lbs; E7: 2350 lbs
Oil Capacity	E6: 40 quarts; E7: 44 quarts

Maintenance Procedures

Recommended maintenance schedules and procedures for 1986 Mack engines to ensure optimal performance and longevity.

Oil Change: Every 15,000 miles or 500 hours - Use SAE 15W-40 oil
Fuel Filter Replacement: Every 30,000 miles - Replace primary and secondary filters
Air Filter Service: Check every 15,000 miles, replace as needed
Coolant Change: Every 2 years or 100,000 miles
Valve Adjustment: Every 60,000 miles or 2,000 hours
Injector Timing: Check every 120,000 miles

WARNING! Always allow engine to cool before performing maintenance. Use proper safety equipment.

Fuel System

Robert Bosch P7100 injection system specifications and maintenance procedures.

Injection Pump: Robert Bosch P7100 with mechanical governor
Injection Pressure: 2,500-3,000 PSI
Injector Nozzles: Multi-hole, pressure tested at 3,500 PSI
Fuel Filter: Primary and secondary spin-on filters
Fuel Pump: Gear-type transfer pump
Timing: Static timing 18° BTDC (E6), 19° BTDC (E7)

CAUTION! Always bleed air from fuel system after filter changes.

Cooling System

Cooling system components and maintenance requirements for 1986 Mack engines.

Component	Specification
Radiator Capacity	E6: 12 gallons; E7: 14 gallons
Thermostat	Opens at 180°F (82°C)
Water Pump	Centrifugal, gear-driven
Coolant Type	Ethylene glycol with SCA additives
Fan Clutch	Viscous-type, thermostatic control
Pressure Cap	15 PSI rating

Lubrication System

Engine lubrication system components and oil specifications.

Oil Pump: Gear-type, crankshaft driven
Oil Pressure: 40-60 PSI at operating temperature
Oil Cooler: Shell and tube type
Oil Filter: Full-flow spin-on type
Recommended Oil: SAE 15W-40, API CD/SF or better
Oil Change Interval: 15,000 miles or 500 hours

Tip: Always check oil level when engine is cold and on level surface.

Electrical System

Electrical system specifications including starting, charging, and instrumentation.

Starter: 12V, 8-tooth pinion, 5.5 HP
Alternator: 12V, 75-100 amp output
Batteries: Two 12V in series (24V system)
Glow Plugs: 12V, ceramic type (cold weather starting)
Instrumentation: Oil pressure, coolant temp, tachometer
Wiring: Color-coded, weather-resistant harness

Troubleshooting Guide

Common engine problems and diagnostic procedures for 1986 Mack engines.

Symptom	Possible Cause	Corrective Action
Hard starting	Weak batteries, faulty glow plugs	Check battery voltage; test glow plug circuit
Low power	Clogged filters, turbo issues	Replace fuel/air filters; check turbo boost
Excessive smoke	Injection timing, injector problems	Check injection timing; test injectors
Overheating	Coolant low, thermostat stuck	Check coolant level; replace thermostat
Oil consumption	Worn rings, valve guides	Perform compression test; inspect valves
Knocking noise	Fuel timing, bearing wear	Check injection timing; inspect bearings

Repair Instructions

Step-by-step repair procedures for major engine components.

Cylinder Head Removal: Drain coolant, remove manifolds, mark and remove head bolts in sequence
Injector Replacement: Clean area, remove fuel lines, use proper puller tool
Turbocharger Service: Inspect for shaft play, check wastegate operation
Water Pump Replacement: Drain coolant, remove fan and belts, install new gasket
Oil Pump Service: Remove oil pan, check gear clearance, replace as needed

WARNING! Use proper torque specifications and sequences for all fasteners.

Torque Specifications

Critical torque values for engine assembly and component installation.

Component	Torque Value	Sequence
Cylinder Head Bolts	250 ft-lbs	Center-out pattern
Main Bearing Caps	180 ft-lbs	Center-out pattern
Rod Bearing Caps	120 ft-lbs	Even tightening
Flywheel Bolts	140 ft-lbs	Cross pattern
Injector Hold-down	35 ft-lbs	Even tightening
Oil Pan Bolts	25 ft-lbs	Cross pattern

Emission Controls

1986 emission control systems and maintenance requirements.

EGR System: Cooled EGR with vacuum control
Turbocharger: Garrett T04B with wastegate
Air-to-Air Aftercooler: Standard on E7, optional on E6
Smoke Opacity: Maximum 40% under acceleration
Certification: Meets 1986 EPA heavy-duty standards

Parts Reference

Common replacement part numbers and sources for 1986 Mack engines.

Part Description	Mack Part Number	Cross Reference
Fuel Filter	15MQ11	Baldwin BF1212
Oil Filter	15MQ13	Fleetguard LF670
Air Filter	35MQ45	Donaldson P182503
Water Pump	45MQ78	Gates 43128
Thermostat	55MQ23	Robert Shaw 330-180
Glow Plugs	65MQ34	Champion CH152

Service Support: Contact Mack Trucks at 1-800-866-1177 for technical assistance.