2007 TM MaxxForce 11 And MaxxForce 13 Engine Diagnostics
Study Guide A N AV I S TA R C O M PA N YStudy GuideTMT-120802MaxxForceTM 11 and MaxxForce 13 Engine Systems2007MaxxForceTM 11andMaxxForce 13Engine DiagnosticsTMT-120802
2008 International Truck and Engine Corporation4201 Winfield Road, Warrenville, IL 60555All rights reserved.No part of this publication may be duplicatedor stored in an information retrieval systemwithout the express written permission ofInternational Truck and Engine Corporation.
Table of ContentsIntroduction. 1Module 1: Hard Start No Start Diagnostics. 3Components. 3Right Side Components. 3Left Side Components. 3Fuel System Components. 4Special Tools. 4Additional Special Tools. 5Introduction to HSNS Diagnostics. 5Hard Start No Start. 5#1 Visual Inspection. 6#2 Ignition Switch On.11#3 Engine Cranking.13#4 Diagnostic Trouble Codes.14#5 Actuators.15#6 EST Data.17#7 Relative compression.20Special Tests.21#8.1 Low Pressure Fuel System .22#8.2 High Pressure Common Rail Fuel System.27#9 Aftertreatment.34#10 Cold Start Assist.35Evaluating the Data. 40
Introduction IntroductionObjectivesWelcome to the 2008 International MaxxForceTM 11 and MaxxForce 13 Engine Diagnostics Web BasedTraining Course. This is the secondof two web-based training programscovering theMaxxForce 11 andMaxxForce 13. This program will coverHard Start No Start Diagnostics andPerformance Diagnostics.Upon Completion of thisprogram, you will be able to:To receive credit for completing thistraining course, you must take a posttest on ISIS /Education/Service/OnlineTesting. Identify the tests of theHard Start No Start process Identify possible causesof Hard Start No Startconditions Identify the steps of the lowFuel Pressure Diagnostics Identify the special toolsrequired for each stepof low Fuel PressureDiagnostics Identify the steps of thelow Fuel Rail PressureDiagnostics Identify the special toolsrequired for each step oflow Fuel Rail PressureDiagnostics Identify the steps of theCold Start Assist systemdiagnostics
NOTES2007 MaxxForce 11 and MaxxForce 13 Engine Diagnostics
Module 1: Hard Start No Start Diagnostics Hard Start No StartDiagnosticsModule 1ObjectivesComponentsThe components discussed in thissection of the course are listed below.Upon Completion of this topic,you will be able to: Identify the tests of the HardStart No Start process Identify possible causes ofHard Start No Start conditions Identify the steps of the lowFuel Pressure Diagnostics Identify the special toolsrequired for each step of lowFuel Pressure DiagnosticsLeft Side Components Identify the steps of the lowFuel Rail Pressure Diagnostics AFT Cut-Off Valve CKP Sensor CMP Sensor CSA Glow Plug CSA Relay ECM EIM Fuel Filter Module High Pressure Pump ITV MAP/IAT2 Identify the special toolsrequired for each step of lowFuel Rail Pressure Diagnostics Identify the steps of theCold Start Assist systemdiagnosticsRight Side Components EGR Valve Actuator HP-CAC LP-CAC Retarder Actuator
2007 MaxxForce 11 and MaxxForce 13 Engine DiagnosticsFuel System Components #6 Injector High Pressure Fuel Line AFT Cut-Off Valve Pressure Line Clean Low Fuel Pressure Supply Line Cylinder Head Fuel Return Line Fuel Strainer Supply Line Fuel Supply Pump Suction Line High Pressure Pump Fuel Inlet High Pressure Pump Fuel Return Line PLV Return Line Banjo BoltSpecial ToolsThe following special tools are usedin the Hard Start No Start proceduresdescribed in this section of theprogram: ZTSE 4905 Fuel Block Off Tool ZTSE 4891 Disposable Air and FuelCaps ZTSE 4906 Fuel Fitting Adapter ZTSE 4886 Fuel Inlet Restriction andAeration Tool ZTSE 4887-1 High Pressure ReturnLine Tester - 17 mm ZTSE 4887-2 High Pressure ReturnLine Tester - 19 mm
Module 1: Hard Start No Start Diagnostics Additional Special Tools ZTSE 4900 High Pressure Rail Plugs ZTSE 4681 Fuel Pressure Gauge ZTSE 4909 Gauge Bar Tool ZTSE 4575 AMP Clamp ZTSE 4828 Cam and Crank BreakoutHarness ZTSE 4773 Fuel Line DisconnectingToolIntroduction to HSNSDiagnosticsThis section shows you the individualsteps of the Hard Start No Startdiagnostic process. When working ona vehicle that will not start or is hard tostart, use this process to direct yourwork.Hard Start No StartHard Start No Start diagnosticsconsists of seven required tests andfour special tests. You should performthese tests in sequence, unlessotherwise stated.Start with the first seven tests. If youfind a problem and correct it, verify thatthe engine starts properly.Do not complete the remaining testsif you have found the cause of the NoStart.
2007 MaxxForce 11 and MaxxForce 13 Engine Diagnostics“If the oil level islow, there couldbe a problemwith oil leaks, oilconsumption, orimproper servicing.If the oil level isabove the ADDmark, there may bea problem with fueldilution, coolantcontamination, orimproper servicing.”Perform one or more of the four specialtests only if you are directed there bythe results of a required test.#1 Visual InspectionThe first area of the diagnostic form isVisual Inspection. A visual inspection ofthe engine will allow you to answer thefollowing questions: Is the engine oil level correct? Is there sufficient clean fuel? Is there a restriction in the intake airsystem? Is the exhaust system restricted? Are the camshaft and crankshaftposition sensors connected? And is there any visible damage to theengine harness?Is the engine oil level correct?Check the oil with the vehicle on levelground. The level on the gauge shouldbe between the FULL and ADD lines.If the oil level is low, there could be aproblem with oil leaks, oil consumption,or improper servicing. If the oil levelis above the ADD mark, there may bea problem with fuel dilution, coolantcontamination, or improper servicing.Although low or high oil level will notdirectly stop the engine from starting, itmay indicate a mechanical problem thatrequires further investigation.
Module 1: Hard Start No Start Diagnostics Possible problems include improperservicing, oil leaks, oil consumption, fueldilution, and coolant contamination.Is there enough fuel to start theengine?Use the dash gauge and/or fuel tankfill port to verify the level in the fueltank. Then do a visual inspection of theleft side of the engine for fuel leaks ordamaged fuel lines.Are there any fuel leaks?Inspect the following components forfuel leaks: high pressure lines, highpressure pump, low pressure lines, lowpressure pump, suction lines, returnlines, and the fuel filter module.Is the fuel contaminated?Retrieve a fuel sample from the tankand check it for signs of water, waxing,and sediment.Does the fuel smell like gasolineor kerosene? If the fuel quality isquestionable, a clean secondary fuelsource may need to be connected tothe engine to aid in diagnosing theissue.Possible problems include water in thefuel, gasoline or kerosene in the fuel,and debris in the fuel.“If the fuel qualityis questionable, aclean secondaryfuel sourcemay need to beconnected to theengine to aid indiagnosing theissue.”
2007 MaxxForce 11 and MaxxForce 13 Engine Diagnostics“Perform a visualinspection of theentire engine areafor coolant leaks,including bothcharge air coolersand the externalcoolant pipingat the rear of theengine.”Is the fuel strainer clean?Visually check the fuel strainer bowl forsediment and service if necessary.Open the fuel filter housing drainand take a fuel sample into a cleancontainer. Inspect the sample fordebris, icing and contamination. If anyfuel issues exist, the fuel filter elementmay need to be replaced.Possible problems include improperservicing and fuel contamination.Is the coolant level correct?Check the coolant level in the surgetank. Perform a visual inspection of theentire engine area for coolant leaks,including both charge air coolers andthe external coolant piping at the rear ofthe engine.Possible problems include, improperservicing, external coolant leaks,coolant leak in the EGR cooler, coolantleaking into the cylinders, coolant leakin a charge air cooler, and coolant leakin the aftertreatment injector.
Module 1: Hard Start No Start Diagnostics Is there a restriction in the intake airsystem?Perform a visual inspection of theintake air system for signs of damage,restrictions, and air leaks. Air isrequired in the cylinders to createthe compression needed to ignitethe diesel fuel. If air cannot enter thecylinders during cranking, the enginewill not start.Check the restriction gauge on the airfilter housing, both charge air coolers,the air inlet duct, the intake throttlevalve, and the intake piping to the turbofor signs of damage. Inspect all intakesystem connections and clamps. If anair induction issue is found, repair asrequired.Possible problems include looseor damaged clamps, damagedconnectors, restricted air filter, intakethrottle valve stuck closed, and an airintake restricted by debris, rags, orplastic bags.Is there a restriction in the exhaustsystem?Perform a visual inspection of theexhaust system for damage that couldrestrict the flow. If exhaust cannot exitthe cylinder, fresh air cannot enter thecylinders, and the engine will not start.“Check therestriction gaugeon the air filterhousing, bothcharge air coolers,the air inlet duct,the intake throttlevalve, and theintake piping to theturbo for signs ofdamage.”
102007 MaxxForce 11 and MaxxForce 13 Engine Diagnostics“The engine canstart with only onesensor workingbut the crank timewill be longer. Theengine cannot startwith both sensorsdisconnected orfailed.”Possible problems include, damagedexhaust pipes, aftertreatment systemregeneration required, restrictedaftertreatment system, and the retarderbutterfly stuck closed.Are the camshaft and crankshaftposition sensors connected?Check the engine and chassisharnesses for signs of damage. Verifythe camshaft and crankshaft positionsensors are connected. The enginecan start with only one sensor workingbut the crank time will be longer. Theengine cannot start with both sensorsdisconnected or failed.Possible problems include damagedharnesses and disconnected cam andcrank position sensors.
Module 1: Hard Start No Start Diagnostics11#2 Ignition Switch OnThe ECM and EIM must have power andground for the engine to start. The thirdmodule, the aftertreatment control module(ACM), should be powered up with theignition switch-On, but is not required tostart the engine. The ignition switch-On testhas you answer the following questions: Is the ECM powered up? Is the EIM powered up? Does the ECM and EIM stay powered upduring cranking?Are the engine control modules poweredup?Step 1 of 3A quick test of the module’s power is tocheck if the EST will display either the EIMand ECM calibrations or sensor values fromboth modules. To perform this test follow thesteps below.First, start the engine by turning the ignitionkey.Second, click the Connect button in theupper left of the SA MD screen.Step 2 of 3Next, click the Launch EST button in thelower right corner after the EST connects tothe ECM and engine data is displayed.“A quick test of themodule’s power isto check if the ESTwill display eitherthe EIM and ECMcalibrations orsensor values fromboth modules.”
122007 MaxxForce 11 and MaxxForce 13 Engine Diagnostics“If the modulecalibrations orthe sensor datafrom both theEIM and the ECMare displayed,the EIM and ECMhave power. If thecalibrations and thesensor data are notdisplayed, one orboth modules maynot be powered up.”Step 3 of 3Finally, click the VIN button to startthe VIN session.Look for the ECM calibration, EIMcalibration, Inlet Air Temp, and theCoolant Temp values.Are both the ECM and EIM displayingdata?If the module calibrations or the sensordata from both the EIM and the ECMare displayed, the EIM and ECM havepower. If the calibrations and thesensor data are not displayed, one orboth modules may not be powered up.Are the ECM and EIM powered upwhile cranking?Verify both ECM and EIM stay incommunication with the EST whilecranking. If the ECM and EIMcalibrations were not displayed duringcranking, the starter load on thebatteries may have caused the batteryvoltage to fall below the required level.
Module 1: Hard Start No Start Diagnostics13Are the fuses, breakers, and relaysokay?If you suspect that the modules are notpowered up, check the fuses, breakers,and relays for the ECM and EIM.The cover to the power distributionpanel has a diagram of the fuse,circuit breaker, and relay locations. Ifnecessary, consult the ECM and EIMPWR section of Electronic ControlSystem Diagnostics in the diagnosticmanual on ISIS to diagnose theproblem.Possible Problems include no Keypower (V-ign) to the modules, failedEIM relay, poor EIM and/or ECMgrounds, EIM or ECM failure, damagedharness, corroded or blown fuses orbreakers, both cam and crank positionsensors failed, and engine CAN linefailure.#3 Engine CrankingCranking RPM must be high enoughfor the high pressure fuel pump tobuild the correct pressure and for thecompression in the cylinders to createthe heat required to ignite the fuel.“Cranking RPMmust be highenough for the highpressure fuel pumpto build the correctpressure and for thecompression in thecylinders to createthe heat required toignite the fuel.”
142007 MaxxForce 11 and MaxxForce 13 Engine Diagnostics“Check the crankingspeed on theinstrument panelTach or the EST.If engine speed isbelow the minimumcranking speed,the engine will notstart.”The Engine Cranking Test has youanswer the following questions: Does the engine cranking speed meetthe specification? Does the engine have sufficient oilpressure?Is the cranking speed sufficient to startthe engine?Check the cranking speed on theinstrument panel Tach or the EST. Ifengine speed is below the minimumcranking speed, the engine will notstart. Check the instrument panel oilpressure gauge. Does the engine haveoil pressure while cranking?Possible problems include loose orcorroded battery connections, low orno battery power, cylinder hydraulic ormechanical lock, starter motor problem,and incorrect oil viscosity for climate.#4 Diagnostic Trouble CodesChecking for diagnostics troublecodes will let you answer the followingquestion: Are there any DTCs that indicate afailure in any of the following systems:electrical, high pressure fuel system,air management system, fuel supplysystem, aftertreatment system, or thecold start assist system?
Module 1: Hard Start No Start Diagnostics15Are there active diagnostic troublecodes?Use the EST to check for diagnostictrouble codes that would effect theengine starting.When working on a vehicle, record allthe DTCs onto the diagnostic form. Ifthere are unknown codes, record theSPN and the FMI. Correct the cause ofthe active codes before continuing tothe next test. Then clear the codes.Possible problems include EIM or ECMfailure, high pressure fuel system failure,air management system failure, fuelsupply system failure, aftertreatmentsystem failure, cold start assist systemfailure, and Intake throttle valve failure.#5 ActuatorsThree of the actuators that must workproperly for the engine to start are theEGR actuator, the retarder actuator,and the inlet throttle valve.“Three of theactuators thatmust work properlyfor the engineto start are theEGR actuator, theretarder actuator,and the inlet throttlevalve.”
162007 MaxxForce 11 and MaxxForce 13 Engine Diagnostics“The three engineactuators must be inthe proper positionduring cranking.”Performing the Actuator test allowsyou to answer the following questions: Is the EGR valve closed? Is the retarder flap open? Is the inlet throttle open?Are the engine actuators workingcorrectly?The three engine actuators must be inthe proper position during cranking.Both the EGR and Retarder actuatorsmust be in the correct position forstarting.The inlet throttle valve can bechecked by placing your hand on thevalve during the test and feeling themovement of the flap. It will open andclose several times during the Actuatortest. If the valve is suspect, remove thevalve and check for free movement ofthe shaft.Performing the Actuator TestStart the Actuator test by completingthe following steps on the EST screen.First, click the Session icon to openthe Sessions menu. Second, clickD Actuator.ssn to open the actuatorsession. Third, click Diagnostics on themenu bar. Fourth, use your mouse to
Module 1: Hard Start No Start Diagnosticshover the cursor over Diagnostics onthe drop down menu. Finally, click onActuator Test.During the test, the ECM will commandeach of the engine actuators one at atime. Each of these actuators will beactuated once for 3-4 seconds.Verify the operation of the EGR valveactuator, the inlet throttle valve, and theretarder actuator during the test.If the ambient conditions are correctfor the operation of the CSA system, orthe system is suspected of causing thestarting condition, go to test #10 onthe diagnostic form.Possible problems include a failedactuator, stuck retarder flap, stuck ITV,insufficient vehicle air pressure andelectrical component or circuit failure.#6 EST DataReviewing the EST data duringcranking will allow you to answer thefollowing questions: Is the exhaust back pressure high?Is the ECM voltage low?Is the cranking speed correct?Is the EGR valve open?Is the inlet throttle valve closed?“During the test,the ECM willcommand eachof the engineactuators one at atime. Each of theseactuators will beactuated once for3-4 seconds.”17
182007 MaxxForce 11 and MaxxForce 13 Engine Diagnostics“If the enginecranking speed isbelow the minimum,the engine will notstart.” Is the FRP low? Is fuel supply pressure low?Are the engine systems operatingcorrectly?Use the EST to check the enginesystems parameters during cranking.First, click on the session icon. Second,Click on the D HardStart NoStart.ssn.Third, turn the ignition key to crank theengine for twenty seconds.Why do we look at the followingvalues?Engine SpeedIf the engine cranking speed is belowthe minimum, the engine will not start.Fuel Rail PressureThere is a minimum rail pressure thatmust be met for the ECM to activatethe injectors.If a fuel system PID value is out ofspecification when cranking, you wouldrefer to the appropriate Special Test onthe HSNS form.
Module 1: Hard Start No Start DiagnosticsFuel Pressure Control PercentageThe ECM has a cranking value thatshould be sent to the FPCV on the highpressure pump.EGRV PositionThe EGR valve should be closedduring cranking or the engine will inhaleexhaust instead of fresh air.EGRV DesiredThe ECM should command the EGRvalve closed during cranking.Engine Fuel PressureIf the EFP is low, the engine may not bereceiving the right amount of fuel.ITV PositionThe intake throttle valve must be open.If the ITV is closed the engine will notbe able to draw in fr
6 2007 MaxxForce 11 and MaxxForce 13 Engine Diagnostics Perform one or more of the four special tests only if you are directed there by the results of a required test. #1 Visual Inspection The first area of the diagnostic form is Visual Inspection. A visual inspection of the engine will allow you to answer the following questions:
International MaxxForce DT, 9, and 10 Diesel Engines Engine configuration 4 stroke, inline six cylinder diesel MaxxForce DT displacement 7.6 L (466 in3) MaxxForce 9 and 10 displacement 9.3 L (570 in3) Bore (sleeve diameter) 116.6 mm (4.59 in) Stroke MaxxForce DT MaxxForce 9 and 10 119 mm (4.68 in) 146 mm (5.75 in .
1171971R1 MaxxForce 7EngineOperation andMaintenanceManual 0000002383 MaxxForce 7(EPA10)with HD-OBDEngineServiceManual 0000001681 MaxxForce 7(EPA10)with HD-OBDEngineDiagnostic Manual 0000003382 MaxxForce 7(EPA10)with HD-OBDHardStartandNoStart DiagnosticForm 0000003381 MaxxForce 7(EPA10)with HD-OBDPerformanceDiagnostic Form 0000003201 .
2. J1939‐All MaxxForce engine (2007‐present). f. DPA 4 i. DG Dearborn GroupÆDG DPA 4/4 Plus USB 1. J1708‐All pre‐MaxxForce (pre‐2007) electronic engines. 2. J1939‐All MaxxForce engine (2007‐present). 5. S
EGES-455 MaxxForce DT, 9, and 10 Engine Diagnostic Manual EGED-460 MaxxForce DT, 9, and 10 Diagnostic Form EGED-495 MaxxForce DT, 9, and 10 Electronic Control System Diagnostics Form Technical Service Literature is revised periodically. Use only up to date service information.
international vehicle backed by the industry’s largest network, international trucks equipped with maxxforce 11l and 13l engines are built for the long haul. maintenance information guide 2 - maxxforce 11l & 13l
MaxxForce DT, 9, & 10 0000001837 EP A 10, 2013 HD-OBD-US, Canada, Mexico 4328100R3 March 2015 MaxxForce DT,9,&10 EngineOperationandMaintenanceManual Navistar,Inc .
MaxxForce 7 turbodiesel engine MAXXFORCE 7 For more about MaxxForce Configuration Warranty V-8 5 yrs/100,000 mi, whichever comes first VERTICALLY-INTEGRATED FROM ThE GROUND UP Peak Torque 660 lb.-ft. Power Output 260 hp Displacement 6.4L (3
well as themes from PALS enquiries and formal complaints received within Western Sussex Hospitals NHS Trust during 2018. Patient experience monthly reports are provided to operational teams and patient comments are automatically shared with our staff. Leaders of our clinical services use the feedback we receive from patients to shape quality improvement activities at ward level and see whether .
