NHTSA ID Number: 10115377
Manufacturer Communication Number: IK1201222
TSB/Document Date: 2017-08-16
Summary
Misfire Diagnostics
IK1201222 MaxxForce 7 Misfire Diagnostics
Page 1 of 7
Countries:
CANADA, TAIWAN, UNITED STATES, MEXICO,
PUERTO RICO, GUAM, KOREA, SOUTH KOREA
Document
ID:
IK1201222
Availability:
ISIS
Revision:
4
Created:
Last
Modified:
10/8/2014
Major System: ENGINES
Current
English
Language:
Other
NONE
Languages:
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Author:
5/1/2015
Aaron
Mimbs
5422
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Title : MaxxForce 7 Misfire Diagnostics
Applies To : All MaxxForce 7
CHANGE LOG
2015/05/01 - Added keywords to article
2015/04/22 - Added keywords to article
2015/04/06 - Updated CPA launching instructions, added EPA13 IPA monitor warning
2015/01/28 - Added 20072009 MaxxForce 7 Part Numbers
2015/01/20 - Clarified step 10 decision
DESCRIPTION
Due to the lack of misfire diagnostics in the Manual, this document will guide the user through misfire diagnostics on the MaxxForce 7.
SYMPTOMS
Diagnostic Trouble Codes:
DTC/Light
NONE
Description
Customer Observations or Concerns:
•
•
•
•
Engine Idles Rough
Popping through Intake
Oil Above FULL
Distinct Engine "Thuds" Corresponding with Engine Speed
SPECIAL TOOL(s) / SOFTWARE
Tool Description
Cylinder Performance Analyzer
ServiceMaxx
Clean Fuel Source
Engine Blow-by Orifice Tool
Oil Fill Tube Orifice Adapter
Pressure Test Kit or Slack Tube Manometer
Standard Plug
Fuel Injector Electrical Connector Release Tool
Kit, Fuel System Cap
Plugs, High Pressure Pump-Rail
Flex Hone
Tool Number
1299901
Comments
Instructions
1563701
ZTSE4146A
ZTSE4284
ZTSE4409 or ZTSE2217A
Obtained Locally
ZTSE4820
ZTSE4710
ZTSE4861
ZTSE4349
Tools Resource Center
SERVICE PARTS INFORMATION
Kit Description
Part Number
FUEL, DIESEL FUEL INJECTOR CLEANER 7080427C1
Quantity RequiredNotes
1 Bottle
Tank additive for fuel injector cleaning
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IK1201222 MaxxForce 7 Misfire Diagnostics
Page 2 of 7
2007 - 2009 MaxxForce 7
Kit Description
INJECTOR ASM, FUEL
LEVER, BRIDGE VALVE ARM
TUBE ASSY FUEL RAIL TO INJECTOR
CAM ASM, FOLLOWER & GUIDE
ROD ASM, PUSH
PISTON ASSEMBLY
MOUNTING KIT TURBOCHARGER
Part Number
1875072C91
1854009C1
1886547C1
1835139C92
1837730C2
1874918C91
1876540C92
Quantity Required
As Required
As Required
As Required
As Required
As Required
As Required
As Required
Notes
Includes Tube Assembly
Rocker Arm
Injector to Rail Jumper Tube
Lifter and Lifter Guide
Push Tube
Complete Piston Assembly
Turbo Seals & Oil Supply Tube
Part Number
1899239C92
1880498C91
1886547C1
1835139C93
1873916C2
1883516C91
1897455C93
Quantity Required
As Required
As Required
As Required
As Required
As Required
As Required
As Required
Notes
Includes Tube Assembly
Rocker Arm Assembly (Exh & Int)
Injector to Rail Jumper Tube
Lifter and Lifter Guide
Push Tube
Complete Piston Assembly
Turbo Seals & Oil Supply Tube
2010 2013 MaxxForce 7
Kit Description
KIT INJECTOR
PLATE ASSEMBLY DUAL FULCRUM
TUBE ASSY FUEL RAIL TO INJECTOR
CAM ASM, FOLLOWER & GUIDE
ROD ASM, PUSH
PISTON ASSEMBLY
KIT, TURBO MOUNTING
Action
Decision
DIAGNOSTIC:
Yes. Follow the FCAP as outlined. If no
FCAP is available perform an iKNow
search for documents relevant to the
issue. If no articles can be found see the
proper Diagnostic Manual. Step 2
Generate Health Report
1
Are there any PENDING/ACTIVE DTCs not related to an engine misfire?
Note: On EPA13 MaxxForce 7's SPN 651-658 are Injector Timing Faults which can be No. Step 2
false, generated due to excessive parasytic loading on the engine. The false codes have
been corrected in Calibration PRS24LR2 and later.
Step
2
Action
Decision
DIAGNOSTIC:
Yes. Step 4
Is the ECM Calibration Up-to-Date?
No. Update calibration.
EPA13 MF7 Step 3
EPA10 MF7 Step 4
Step
Action
Decision
CALIBRATION EFFECTIVENESS:
Yes. Step 4
On EPA13 OBD engines, perform the following with calibration PRS24LR2.
3
1.
2.
3.
4.
5.
6.
7.
8.
9.
Clear any faults
Start the engine
Allow the engine to idle for 2 minutes in NEUTRAL
Shut down the engine
Make note of any faults that became PENDING or ACTIVE
Clear any faults that may have come PENDING or ACTIVE
Turn on the excessories (Air conditioning, lights, booster pumps, ect.)
Start the engine and put it in DRIVE
Allow the engine to idle for two minutes in DRIVE
No. Release to the customer
Did the injector timing faults return?
Step
4
Action
Decision
DIAGNOSTIC:
Yes. Correct Issue; Step 5
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IK1201222 MaxxForce 7 Misfire Diagnostics
Page 3 of 7
No. Step 5
Perform Visual Checks Per the Diagnostic Manual and/or Performance Diagnostic
Sheet.
Any issues noted?
Step
5
Action
Decision
DIAGNOSTIC:
Yes. Step 6
In ServiceMaxx go to Procedures >> KOEO Procedures >> Fuel Pressure Adaptation
Reset and follow the on screen commands.
No. Complete any other work needed
and release unit to customer. If this is a
problematic unit continue with Step 6
Does the engine still misfire?
Step
Action
Decision
DIAGNOSTIC:
Yes. Step 7
ONLY using ZTSE4146A (Orifice size 0.406")
Perform Crankcase Pressure and Blow-By Tests. If it is determined unsafe to do so,
please skip and continue to Step 7.
2007 - 2009 MaxxForce 7
Measure Crankcase Pressure (9" H2O) per the Diagnostic Manual or IK1200881
6
2010 - 2013 MaxxForce 7
Measure Crankcase Pressure (Spec 24" H2O) and Blow-by (9" H2O) per the
Diagnostic Manual.
NOTE: If Blow-by is in specification and Crankcase Pressure is beyond specification,
verify the crankcase breather is a nonserviceable certified breather. Please See
121203 New Non-Serviceable Crankcase Breather - EPA 10 MaxxForce® 7. If
required, replace the Crankcase Breather and reevaluate readings.
No. Potential Base Engine Issue.
Perform Step 7 & Step 8 and then open a
case file with Navistar
's Technical
Support group with all relevant
information, pictures, parameter file and
recordings for further assistance.
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TSB/Document ID: IK1201222
Replacement Service Bulletin Number:
MFR Communication Date: 2015-05-01
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL
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