further. Send the oil sample out for testing
and documentation.
Remember oil expands when heated, if
the oil level is checked cold, it will need to
be rechecked cold.

Step Action
Inspect AMS and Exhaust System for Leaks

6

See IK1201142 Leak Locater Diagnostic Procedures. Tighten all AMS
pressure clamps to 115lb-in.

Yes. Correct the leaks, use the above
listed gaskets and exhaust tape to prevent
leaks in the Service Parts Information
Section (Click Here). Step 7

Were any issues noted?

No. Step 7

Step Action
7

Decision

Perform aftertreatment cleaning.
Warning: Move the vehicle outside before performing this step.
2010 - 2013 MaxxForce 7: Perform an On Board Filter Cleanliness Test in
ServiceMaxx
and record it.
See the V-8 DPF and DOC Catastrophic Failure Performance Assessment Sheet
and evaluate the regeneration.

Decision
Yes. Step 8
No. Attempt procedure again. If the results
are the same, diagnose the aftertreatment
temperature sensors and remove the
aftertreatment. Bake and blow out the
DPF, clean the face of the DOC, and blow
out the DPFDP sensor tubes. Reinstall
everything and inspect for leaks. Attempt
procedure again. If the results are the
same, open a case file with Navistar's
Technical Support group with all relevant

OR

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IK1201259 ­ MaxxForce 7 Fuel Dilution Diagnostics

Page 5 of 9

2007-2009 MaxxForce 7: Perform a DOC Cleaning See IK1200478

information and recordings for further
evaluation.

EGT1 (DOC Inlet) must reach above 950F

Continue to Step 8

Were the procedures successful?

Step Action
Road test vehicle.
While hot and the engine OFF, mark the oil level on the dipstick. Road test for 30
miles (preferable highway loading). Also record a 0­60 full throttle snapshot in
ServiceMaxx. Allow the engine to cool down and recheck the oil level.

2010 - 2013 MaxxForce 7: For Performance Analysis see IK1201172

8

2007-2009 MaxxForce 7: Note engine performance and sound, analyze snapshot,
and verify boost is within specification (typically 20-25psi). If lower than expected,
remove and clean the IMP and EBP sensor and tubes­­reassemble and recheck
performance. EBP and MAP sensor voltage readings at KOEO should be equal and
roughly 0.76V in the continuous monitor session.

Decision
1. Oil did not rise; engine performance is
good.
Release to the customer for
monitoring. Send the oil sample out for
testing and documentation.
2. Oil did not rise; engine performance is
not good.
Diagnose low power complaint; keep in
mind truck weight, loading, and grading.
Once complete, release the unit to the
customer for monitoring. Send the oil
sample out for testing and documentation.
3. Oil level has risen, engine performance
is not good.
Diagnose and repair low power complaint;
keep in mind truck weight, loading, and
grading. Return to Step 7
4. Oil level has risen; engine performance
is good.
Step 9

Step Action
9

Inspect for fuel leaks.

Decision
Yes. Double check with a coworker or
manager. If the pump is still determined
leaking, replace the HPFP and harness.

1. Hook up the clean fuel source with heavily saturated and mixed dyed diesel fuel
(use Cummins' Dye). Create a test spot of fuel/dye to make sure it illuminates under
a black light. If desired add more dye.
On the failed pump, please circle the
leak location with a paint pen for
2. Run the engine for 5 minutes and monitor fuel consumption. Open the manual
warranty review.
drain valve on the fuel filter module and inspect fuel with a black light. Make sure it
illuminates sufficiently.
Reassemble the engine; return to Step 7.
3. Remove the High Pressure Fuel Pump cover. (Follow elemental SRT steps for
NEW procedure. The turbochargers can remain on the engine.)
No. Reassemble the engine and pump
cover. Step 10
4. Reassemble the fuel lines temporarily for diagnostic purposes. The steel
HPFP supply lines are crush fit, meaning one time use only. They must be replaced
after diagnostics are complete.
5. Clean off the pump using brake cleaner to remove any remaining dye/fuel. Inspect
the pump with a black light for remaining traces of dye and remove if necessary.
6. The pump cover can be left off or rested over the pump to help contain the oil.
7. Run the Standard test in ServiceMaxx and perform a few brake stalls to raise
FRP.
8. After sufficient FRP has been built and sufficient time has gone by to cycle the
dyed fuel through the system, shut the engine down and use a black light to inspect
the pump for fuel/dye. See Figure 1 below for most likely leak locations. Use a small
mirror to inspect hard to see locations.
NOTE: Engine oil has a natural luminous glow to it under a black light. If unsure the
glow is dye, drain a small amount of fuel from the manual drain valve on the fuel
filter module and inspect with a black light. Make sure the fuel glows. A test spot of

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IK1201259 ­ MaxxForce 7 Fuel Dilution Diagnostics

Page 6 of 9

dyed fuel on the pump can help determine if it is properly illuminating under black
light.
Were any fuel leaks found?

Figure 1: Ranked High Pressure Fuel Pump Leak Locations
1. HPFP Shaft Seal
2. Pump Cylinder Expander Screws
3. Pressure Relief Valve

ATTENTION
Do NOT replace an injector unless it is confirmed to have a body leak. If a leak is found at the jumper tube, replace ONLY that tube.

Step Action
10 Inspect for fuel leaks.
With the dyed clean fuel source still connected.
1. Remove the PASSENGER side valve cover. Reassemble other components as
needed to operate the engine with the cover removed.

Decision
Yes. Repair leaks and torque everything
to specification, per the Engine Service
Manual. Rerun the dye test. If all is well,
reassemble the engine and return to Step
7.

If the FRP sensor is leaking replace it.
2. Spray, clean, and dry the high pressure fuel connections (brake cleaner works
Once removed, make sure the
well). Wrap the high pressure fuel connections and the FRP sensor with clean paper compression gasket is in place see Figure
towels and secure with tape (this will also help prevent oil contamination).
3 below.
3. The valve cover can be left off or rested in place to prevent oil splash.
4. Run the Standard Test in ServiceMaxx and perform a few brake stalls to raise
FRP

NOTE: The fuel rail must be replaced if
the FRP sensor continues to leak after
replacement.
No. Step 11

5. After sufficient FRP has been built, and time has gone by to cycle the dyed fuel
through the system, shut the engine down and one at a time, remove the paper
towels inspect them with a black light for dyed fuel or wetness. See Figures 2, and 3
below for most likely leak locations.
6. Inspect around the base of the injectors for any signs of fuel leaking past the orings. See Figure 4 for most likely leak locations.
NOTE: It is possible but very unlikely that the injector body o-rings will leak. These oring are under very little pressure (MAX 5 psi). The most likely leak locations are at
the high pressure fittings and connections.
Were any fuel leaks found?

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IK1201259 ­ MaxxForce 7 Fuel Dilution Diagnostics

Page 7 of 9

Figure 2: Injector Jumper Tube Leak Locations

Figure 3: FRP Sensor and Compression Gasket

Figure 4: Injector Leak Locations

Step Action
11 Inspect for fuel leaks.

Decision
Yes. Repair Leaks and torque everything
to specification per the Engine Service

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IK1201259 ­ MaxxForce 7 Fuel Dilution Diagnostics

Page 8 of 9

1. Remove the DRIVER's side valve cover. Reassemble other components as
needed to operate the engine.

Manual. Reassemble the engine and
return to Step 7.
No. Step 12

3. Spray and clean the high pressure fuel connections. Wrap the high pressure fuel
connections with clean paper towels and secure with tape (this will also prevent oil
contamination).
4. The valve cover can be left off or rested in place, to prevent oil splash.
5. Run the Standard test in ServiceMaxx and perform a few brake stalls to raise FRP
6. After sufficient FRP has been built and time has gone by to cycle the dyed fuel
through the system, shut the engine down and one at a time remove the paper
towels inspect them with a black light for dyed fuel or wetness. See Figure 2
above for most likely leak locations.
7. Inspect around the base of the injectors for any signs of fuel leaking past the orings. See Figure 4 for most likely leak locations.
NOTE: It is possible but very unlikely that the injector body o-rings will leak. These oring are under very little pressure (MAX 5 psi). The most likely leak locations are at
the high pressure fittings and connections.

Decision

Step Action
Were any fuel leaks found?
12

Reassemble the engine and release to the customer to monitor dilution.

Diagnostics complete.

REPAIR STEPS
See appropriate engine service manuals for removal and installation procedure.
2007 - 2009 MaxxForce 7: Engine Service Manual
2010 - 2013 MaxxForce 7: Engine Service Manual

WARRANTY INFORMATION
Warranty Claim Coding:
Group: 12000 - ENIGNES
Noun: 716 - Reprogram Engine - Calibration
792 - Injector Fuel Lines (High PSI)
563 - Injector Unit (Electrical)
562 ­ O­Ring, Injector Unit
454 - Pump, Oil/Fuel (High Pressure System)
858 - Converter, Catalytic (Diesel Oxidation) (DOC)
235 ­ Diesel Particulate Filter (DPF)
Standard Repair Times:
2007 ­ 2009 MaxxForce 7
Step

Description

Chassis Engine

SRT

Hours

Step 1
Step 2
Step 4

Update Engine Calibration
Health Report and DTC
Visual Inspections

ALL
ALL
ALL

MaxxForce 7
MaxxForce 7
MaxxForce 7

A12-3510J
SEE MANUAL
SEE MANUAL

0.4

Step 5

Misfire Diagnostics

MaxxForce 7

SEE IK1201222

Step 7
Step 8

AMS Leak Testing
DOC Cleaning
Diesel Particulate Filter R&R

MaxxForce 7
MaxxForce 7
MaxxForce 7

SEE IK1201142
SEE MANUAL
SEE MANUAL

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IK1201259 ­ MaxxForce 7 Fuel Dilution Diagnostics

Step 9

Diesel Oxidation Catalyst R&R
Road Test

MaxxForce 7
MaxxForce 7

SEE MANUAL
SEE MANUAL

MaxxForce 7

SEE MANUAL

ALL

MaxxForce 7

T­Time

0.4

ALL

MaxxForce 7

SEE MANUAL

0.2

MaxxForce 7

SEE MANUAL

MaxxForce 7

SEE MANUAL

MaxxForce 7
MaxxForce 7

T­Time
SEE MANUAL

Step 10 & 11 Valve Cover R&R
Dye Testing Prep and Check
Injector Replacement (Each Additional
Cylinder)
FRP Sensor Replace
Step 12

HPFP Cover R&R
HPFP Cleaning and Dye Testing
HPFP Replace (Includes Cover R&R)

Page 9 of 9

ALL

0.2

2010 - 2013 MaxxForce 7
Step

Description

Chassis Engine

SRT

Hours

Step 1
Step 2

Update Engine Calibration
Health Report and DTC

ALL
ALL

2010 Emissions MF7
2010 Emissions MF7

A12-3510X
SEE MANUAL

0.4

Step 4

Visual Inspections

ALL

2010 Emissions MF7

SEE MANUAL

Step 5

Misfire Diagnostics

2010 Emissions MF7

SEE IK1201222

Step 7

AMS Leak Testing

2010 Emissions MF7

SEE IK1201142

Step 8

OBFCT
Diesel Particulate Filter R&R
Diesel Oxidation Catalyst R&R

2010 Emissions MF7
2010 Emissions MF7
2010 Emissions MF7

A12-7235A-20
SEE MANUAL
SEE MANUAL

Step 9

Road Test

2010 Emissions MF7

SEE MANUAL

ALL

2010 Emissions MF7
2010 Emissions MF7

SEE MANUAL
T-Time

0.4

ALL

2010 Emissions MF7

SEE MANUAL

0.2

2010 Emissions MF7
2010 Emissions MF7
2010 Emissions MF7
2010 Emissions MF7

SEE MANUAL
SEE MANUAL
T-Time
SEE MANUAL

Step 10 & 11 Valve Cover R&R
Dye Testing Prep and Check
Injector or Tube Replacement (Each
Additional Cylinder)
FRP Sensor Replace
Step 12
HPFP Cover R&R
HPFP Cleaning and Dye Testing
HPFP Replace (Includes Cover R&R)

ALL

ALL

0.3

0.2

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