NHTSA ID Number: 10115375
Manufacturer Communication Number: IK1201172
TSB/Document Date: 2017-08-16
Summary
Turbocharger Step-Based Diagnostics
IK1201172 EPA 2010 2013 MaxxForce 7 Turbocharger StepBased Diagnostics
Page 1 of 16
Countries:
CANADA, UNITED STATES, MEXICO Document ID: IK1201172
Availability:
ISIS
Revision:
4
Major System:
ENGINES
Created:
8/1/2014
Current Language: English
Last Modified: 5/11/2015
Other Languages: NONE
Author:
Viewed:
Caleb Iverson
3481
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Title : EPA 2010 - 2013 MaxxForce 7 Turbocharger Step-Based Diagnostics
Applies To : EPA 2010 - 2013 MaxxForce 7 Engines
CHANGE LOG
2015/05/07 - Added DTCs
2014/12/08 - Fixed specs for CCP & Blowby
2014/12/02 Minor gramatical/formatting changes
2014/11/01 - Launch to field
QUICK LINKS
Description
Symptoms
Tools
Parts
Diagnostics
Repair-Removal
Repair-Installation
Warranty
DESCRIPTION
This document is intended to help with turbocharger diagnostics because there is no diagnostics in the Diagnostic Manual.
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SYMPTOMS
DTC/Light
Description
Malfunction Indicator Light (MIL)
OBD Faults
SPN 102 FMI 10
Boost slow response
SPN 102 FMI 18
Underboost
Non-OBD Faults
SPN 1692 FMI 17
Boost unable to achieve setpoint
SPN 1692 FMI 18
Boost unable to achieve setpoint
- Low Power
- Vehicle Speed Loss with Maximum Driver Demand
- Slow Performance Response
Excessive Regenerations
- Low Fuel Economy
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IK1201172 EPA 2010 2013 MaxxForce 7 Turbocharger StepBased Diagnostics
Page 2 of 16
SPECIAL TOOLS
Tool Description
Tool Number
Electronic Service Tool (EST)
E-Z Tech
ZTSE4409
Crankcase Pressure Test adapter
ZTSE4284
Crankcase Pressure Orifice Tool
ZTSE4146A
Comments
Instructions
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SERVICE PARTS INFORMATION
Kit Description
Part Number
Breather Assembly w/Jet Pump
1886483C93
Quantity Notes
1
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PROCEDURE OVERVIEW
WARNING
To prevent personal injury or death, read all safety instructions in the "Safety Information" section of the diagnostic manual, linked
here.
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
Install crankcase breather tube into shop exhaust vent. Failure to comply may result in personal injury / or death.
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IK1201172 EPA 2010 2013 MaxxForce 7 Turbocharger StepBased Diagnostics
Page 3 of 16
DIAGNOSTIC STEPS
Step Action
Decision
Visually inspect the air intake system. Check for oil or coking in the intake system.
Yes. Go To Step 2
Is there oil or coking present?
No. Go to performance
diagnostic sheet.
1
Step Action
Verify engine oil level.
Park vehicle on level ground and check oil level.
2
Decision
Low: Top off oil, proceed to
Step 3
Full: Go to Step 3
Is the oil level low, full, or overfull?
Overfull: Take an oil sample for
analysis and drain to normal
level. Proceed to Step 3
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IK1201172 EPA 2010 2013 MaxxForce 7 Turbocharger StepBased Diagnostics
Step Action
3
Page 4 of 16
Decision
Perform the following: Crankcase Pressure Test at engine operating temperature
of 158°F (70°C) or higher.
S ave results for later review.
1. Ensure the oil level is not above the full mark.
2. Remove the oil level gauge from the dipstick tube. Attach 11/16" hose with clamps
and 1/4" pipe adapter to magnahelic gauge on gauge kit ZTSE4409.
3. Start engine and run at high idle (no load) RPM. Allow reading to stabilize, before
recording reading.
Go to Step 4.
See Figure 1 or refer to Diagnostic Manual.
Specification: at High Idle, Below 24" of H2O
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IK1201172 EPA 2010 2013 MaxxForce 7 Turbocharger StepBased Diagnostics
Page 5 of 16
Figure 1: CrankCase Pressure Test
Item 1: Adapter (Obtain Locally)
Item 2: Line to Magnahelic Gauge (ZTSE4409)
Item 3: Oil Dipstick Tube
Step Action
Perform the following: Blow-By Test at engine operating temperature of 158°F (70°
C) or higher.
Decision
Save steps for later steps
Go to Step 5.
4
1. Ensure the engine oil level is not above the full mark and the oil level gauge is
secured.
2. With engine OFF, remove oil fill cap.
3. Install crankcase pressure test adapter ZTS4284 to oil fill tube.
4. Connect orifice ZTSE4146A to crankcase pressure test adapter ZTSE4284.
5. Connect a line from the orifice ZTSE4146A to the magnahelic gauge on the gauge kit
ZTSE4409.
6. Using a standard plug, block off the road draft tube, located on the bottom right side of
the engine.
7. Run engine at high idle (no load) RPM. Monitor magnahelic gauge and record high
idle blowby pressure.
See Figure 2 or refer to Diagnostic Manual.
Specification: at High Idle, Below 9" of H20
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IK1201172 EPA 2010 2013 MaxxForce 7 Turbocharger StepBased Diagnostics
Page 6 of 16
Figure #2: Blow-By Test
Item 1: ZTSE4284
Item 2: ZTSE4146A
Item 3: Line to Magnahelic Gauge (ZTSE4409)
Item 4: Oil Fill Tube
Step Action
5
Decision
Perform the following Relative Compression Test at engine operating temperature
of 158°F (70°C) or higher.
Save results for later steps
1. Hook-up a battery charger before running the relative compression test.
2. Using Electronic Service Tool (EST) with ServiceMaxx software, go to Tests > KOEO
Tests > Relative Compression Test.
3. Save the Relative Compression Test (RCT) results file.
Go to Step 6.
Refer to Diagnostic Manual.
Compare Cylinders: are cylinders within 20% variation?
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IK1201172 EPA 2010 2013 MaxxForce 7 Turbocharger StepBased Diagnostics
Step Action
Review results from Steps 3, 4 and 5.
Page 7 of 16
Decision
CCP - Yes
Blow-By - Yes
Relative Compression Test Yes
Crankcase Pressure High Idle Below 24" of H2O
Go To Step 7.
Blow-By - High Idle - Below 9" of H2O
Relative Compression Test - Compare cylinders, are cylinders within 20% variation?
Were Step 3 Crankcase Pressure (CCP), Step 4 (Blow-by), and/or Step 5 (Relative
Compression) in specification?
CCP No
Blow-By - No
Relative Compression Test - No
Go To Step 8.
6
CCP - No
Blow-By - Yes
Relative Compression Test Yes
Go To Step 9.
CCP Yes
Blow-By - No
Relative Compression Test Yes
Go To Step 10.
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IK1201172 EPA 2010 2013 MaxxForce 7 Turbocharger StepBased Diagnostics
Step Action
Perform the following:
7
1. Induction Cleaning Process (IK1201173).
2. If needed, flush CAC. (refer to IK1201175).
3. Check for engine performance issues. Perform 0 to 60 MPH Test procedure below.
a. Using Electronic Service Tool (EST) with ServiceMaxx™ software, go to Sessions
> Performance
b. Find an open stretch of road where minimum speed limit is 50 MPH or higher.
c. Pull over to the side of the road.
d. When driving conditions are safe and vehicle has reached normal operating
temperature, select the record snapshot icon from the toolbar.
e. Press accelerator pedal fully to the floor and accelerate from 0 MPH to max
allowed highway speed. After 0 to 60 MPH Test is complete, stop recording and
save snapshot.
4. Using an Electronic Service Tool (EST) with ServiceMaxx™ software, use the
playback feature and graph the following signal values from the 0 to 60 MPH Test:
Page 8 of 16
Decision
Yes. Diagnostics Complete.
No. Go to performance
diagnostic sheet.
• Time
• Vehicle Speed (MPH)
• Torque: Engine Actual Percent (%)
• Torque: Driver's Engine Demand (%)
• Intake Manifold Temperature (IMP)
Compare the snapshot to Figure 3 and associated Graph Analysis below. Is "Torque:
Engine Actual Percent (%)" meeting "Torque: Driver's Engine Demand (%)" and IMP
meeting specification as per Figure 3 Graph Analysis?
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IK1201172 EPA 2010 2013 MaxxForce 7 Turbocharger StepBased Diagnostics
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TSB/Document ID: IK1201172
Replacement Service Bulletin Number:
MFR Communication Date: 2015-05-11
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING:ENGINE:OTHER FUEL TYPES:TURBO/SUPERCHARGER
MFR Component System:
MFR Component Subsystem:
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