NHTSA ID Number: 10115353
Manufacturer Communication Number: IK1201259
TSB/Document Date: 2017-08-16
Summary
MaxxForce 7 Fuel Dilution Diagnostics
IK1201259 MaxxForce 7 Fuel Dilution Diagnostics
Page 1 of 10
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IK1201259
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Revision: 8
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1/20/2015
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4/14/2016
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Title : MaxxForce 7 Fuel Dilution Diagnostics
Applies To : All MaxxForce 7
CHANGE LOG
04/14/2016 - Removed retired documents and instructed to see the diagnostic manual
07/24/2015 - Added clause to Step 5 to skip forward to Step 9 in severe dilution situations
07/22/2015 - Updated Step 9 to reflect new HPFP removal procedure is for the 20102014 MaxxForce 7 only. Removed Step numbers from SRTs to
alleviate confusion.
05/07/2015 - Clarified diagnostic steps and figure numbers, added exhaust system gasket part numbers
DESCRIPTION
This document will guide the user through step based diagnostics for fuel in the oil.
This document replaces/retires: IK1200990
SYMPTOMS
Diagnostic Trouble Codes:
2007 2009 MaxxForce 7
DTC/Light
Description
SPN 100 FMI 1
EOP below warning level
SPN 100 FMI 7
EOP below critical level
2010 2013 MaxxForce 7
DTC/Light
Description
SPN 100 FMI 1
Engine Oil System below Critical Pressure
SPN 100 FMI 18
Engine Oil System below Warning
Pressure
Customer Observations or Concerns:
1. Low Oil Pressure
2. Increasing Oil Level
3. Black Smoke
4. Excessive Oil Carry Over into Intake
5. High Crankcase Pressure
6. Engine Vibration
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IK1201259 MaxxForce 7 Fuel Dilution Diagnostics
Page 2 of 10
7. Loss of Power
8. MIL
9. Excessive Regenerations
SPECIAL TOOLS / SOFTWARE
Tool Description
Tool Number
SERVICEMAXX OR POCKETMAXX
PRESSURE TEST KIT
ZTSE4409
FITTING FUEL FILTER
1841403C1
CLEAN PAPER TOWELS
PACKAGING TAPE
CLEAN FUEL SOURCE TOOL
BLACK LIGHT
CUMMINS
FLUID DYE
LOCALLY
LOCALLY
1563701
LOCALLY
LOCALLY
Comments
Instructions
FITTING AND O-RING
Used to connect the pressure test kit to
QUICK CONNECT (10mm) the oil pressure port on the oil pan
SERVICE PARTS INFORMATION
2007-2009 MaxxForce 7
Kit Description
Part Number
Quantity
Notes
Required
KIT, INJECTOR REMAN, INTL
4307381R91
0-8
Injector Kit
TUBE ASSY FUEL RAIL TO INJCTR
RING, "O" SPECIAL .886" X .998"
GASKET, COMBUSTION
1886547C1
1834166C1
1855345C1
0-8
0-8
08
Tube Only
Injector O-Ring Only
Injector Combustion Gasket
KIT, HP FUEL PUMP REMAN INTL
4307291R91
1
SENSOR ASM, RAIL PRESSURE FUEL
1873400C92
1
TUBE ASSY PUMP RIGHT
1881361C1
1
HPFP to Right Rail
TUBE ASSY PUMP LEFT
1881375C1
1
HPFP to Left Rail
2010 - 2013 MaxxForce 7
Kit Description
Part Number
KIT INJECTOR
TUBE ASSY FUEL RAIL TO INJCTR
RING, "O" SPECIAL .886" X .998"
GASKET, COMBUSTION
1899239C92
1886547C1
1834166C1
1855345C1
Quantity
Required
08
0-8
0-8
08
Notes
Injector Kit
Tube Only
Injector O-Ring Only
Injector Combustion Gasket
KIT, FUEL PUMP HIGH PRESSURE W/HARNESS 7080839C93
1
Includes Pump Harness
SENSOR ASM, RAIL PRESSURE FUEL
1873400C92
1
TUBE ASSY RIGHT FUEL HIGH PRES
1883147C1
1
HPFP to Right Rail
TUBE ASSY LEFT FUEL HIGH PRESS
1883148C1
1
HPFP to Left Rail
1899241C93
1
CROSSOVER TUBE ORINGS
1841625C1
3
1878460C1
2
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IK1201259 MaxxForce 7 Fuel Dilution Diagnostics
Page 3 of 10
Exhaust/Aftertreatment Seals and Components
Kit Description
Part Number
Qty
Notes
GASKET TAPE EXHAUST 3/4"X36YDS
2604051C91
1
Heat resistant exhaust flange tape
GASKET,EXH PIPE FLANGE
1891515C1
12
Turbo outlet and down pipe extension gaskets
GASKET V-BAND TURBO
1883660C1
1-2
Exhaust UpPipe to XPipe OGaskets
GASKET, EXHAUST SINGLE LAYER
1875808C1
1-2
Exhaust Manifold to UpPipe Gaskets
GASKET TURBO INLET
1878460C1
2
Turbo/EGR Cooler Inlet Gaskets
GASKET DUAL PORT
1877824C1
1
Center Exhaust Manifold Gasket (1 of 3)
GASKET SINGLE PORT
1877823C1
2
Outside Exhaust Manifold Gasket (2&3 of 3)
DPF ASSEMBLY
2510963C1
1
Terrastar DPF Assembly (Verify Specific Application Before Ordering)
DPF KIT REPLACEMENT 11.25X12
1892211C91
1
DPF Replacement Kit (4300) (Verify Specific Application Before Ordering)
GASKET, FLANGE OFFSET 3 HOLE
2593986C1
1
DPF Outlet Gasket (4300)
GASKET, FLANGE 3 BOLT
2593998C1
1
DPF Inlet Gasket (4300)
DIAGNOSTIC STEPS
WARNING
To prevent personal injury or death, shift transmission to park or neutral, set parking brake, and block wheels before doing diagnostic or service
procedures.
WARNING
To prevent personal injury or death, make sure the engine has cooled before removing components.
WARNING
To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand cleaner and wash with soap and
water. Wash or discard clothing and rags contaminated with engine fluids.
WARNING
To prevent personal injury or death, read all safety instructions in the "Safety Information" section of the diagnostic manuals.
WARNING
These diagnostics require running the engine with cover(s) removed exposing moving components. Glasses are required due to oil splash and
do not touch moving components.
Step Action
Generate a Health Report
1
Was the health report successful?
Step Action
Decision
Yes. Step 2
No. Resolve, Step 2
Decision
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IK1201259 MaxxForce 7 Fuel Dilution Diagnostics
Verify calibration.
2
Page 4 of 10
Yes. Step 3
No. Update Calibration. Step 3
Is the calibration up-to-date?
Step Action
Perform visual checks per Diagnostic Manual and/or Performance Diagnostic
sheet.
3
1. Inspect Fuel System to Verify Fuel Level
2. Inspect Engine Oil Level
3. Inspect Coolant Recovery Bottle for Coolant Level
4. Inspect Electrical Group for Poor or Loose Connections
5. Inspect Air Filter Minder
6. Inspect Exhaust System
Any issues noted?
Step Action
Inspect engine operation.
4
Does the engine run rough with a corrected oil level?
Step Action
Yes. Correct the issue(s). If the oil level is
over full, drain it to a proper level and take
a sample for analysis.
Otherwise continue to Step 4.
No. If the oil level is normal, has no signs
of dilution, and the complaint is low
pressure, see Diagnostic Trouble
Shooting Procedures, Lubrication System,
Low Oil Pressure in the Diagnostic
Manual.
Decision
Yes. See Engine System Tests and
Inspections, Cylinder Performance
Analyzer Tests in the Diagnostic Manual.
No. Step 5
Decision
Disclose oil service habits from the customer and compare to the Operator
Manual service recommendation.
1. Current Oil life is within limits and
customer is following interval
requirements.
20072009 MaxxForce 7: 10,000 Miles or 350 hours, which ever comes first.
Step 6
2. Current Oil life is within limits but
the customer is not following interval
requirements.
2010-2013 MaxxForce 7:
Fuel Economy is less than 7 MPG: Every 7,000 miles
Fuel Economy is greater than 7 MPG but less than 11 MPG:
Miles = (2000 X MPG) - 7000
Ex. MPG = 8.2
2000(8.2) - 7000 = 9,400 miles
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TSB/Document ID: IK1201259
Replacement Service Bulletin Number:
MFR Communication Date: 2016-04-14
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
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