IK1201259 Service Bulletin/Repair Instructions

IK1201259 ­ MaxxForce 7 Fuel Dilution Diagnostics
Page 1 of 9
Countries:
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REPUBLIC, ECUADOR, EL SALVADOR, TRINIDAD

Document

AND TOBAGO, UNITED STATES, URUGUAY,

IK1201259

VENEZUELA, MEXICO, ARUBA, NICARAGUA,

ID:

PERU, PUERTO RICO, Curaçao, GUAM,

GUATEMALA, GUYANA, HAITI, HONDURAS,

JAMAICA, KOREA, SOUTH KOREA, NEW

ZEALAND, PANAMA, SOUTH AFRICA
Availability: ISIS, Bus ISIS, FleetISIS

Major

System:

Current

Language:
Revision: 3
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English
Last

4/24/2015

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1/20/2015
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Title : MaxxForce 7 Fuel Dilution Diagnostics

Applies To : All MaxxForce 7
CHANGE LOG

04/23/2015 - Added Figure 3

04/20/2015 - Reorganized diagnostic steps

02/26/2015 - Corrected SRTs

01/22/2015 - Initial Article Release (Replaces IK1200990)



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
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IK1201259 ­ MaxxForce 7 Fuel Dilution Diagnostics
Page 2 of 9
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

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

15-637-01

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
FUEL PUMP SEAL KIT
1899241C93
1
CROSSOVER TUBE O­RINGS
1841625C1
3
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IK1201259 ­ MaxxForce 7 Fuel Dilution Diagnostics
TURBO/EGR COOLER INLET GASKET
1878460C1
Page 3 of 9
2
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

1
Verify calibration.
Yes. Step 2
Is the calibration up-to-date?
No. Update Calibration. Step 2
Step Action

Generate a Health Report
2
Are there any other ACTIVE/PENDING DTCs other than listed or relevant to fuel in

oil?
Step Action

Verify Repairs:

Were the DTCs resolved?

3
Step Action

4
Decision
Perform visual checks per Diagnostic Manual and/or Performance Diagnostic

sheet.

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?
Decision

Yes. Follow FCAP for DTCs. If none are

active, perform iKNow search regarding

the DTC. If nothing available, see the

appropriate Diagnostic Manual. Proceed

to Step 3.

No. Step 4
Decision

Yes. Step 4

No. If unrelated to the fuel or oil system,

continue to Step 4, and address at a later

time. Otherwise, contact a supervisor and

ensure all the proper decisions were

made. If necessary, open a case file with

Navistar's Technical Support group and all

relevant information or recordings.
Decision

Yes. Correct the issue(s). If the oil level is

over full, drain it to a proper level and take

a sample for analysis, if required.

If the oil level is normal, has no signs of

dilution, and the complaint is low pressure,

see IK1200744.

Continue to Step 5.

No. If the oil level is normal, has no signs

of dilution, and the complaint is low
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IK1201259 ­ MaxxForce 7 Fuel Dilution Diagnostics
Page 4 of 9
pressure, see IK1200744; otherwise

continue to Step 5.
Step Action

Inspect engine operation.

5
Does the engine appear to have a misfire?
Step Action
Decision

Yes. See IK1201222

No. Step 6
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 7

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

6

Fuel Economy > 11MPG: Every 15,000 Miles
Inform the customer of the proper service

interval for their application and continue

to

Step 7

3. Current Oil life is beyond the

service limits and the customer is

not following interval requirements.

Get customer approval to change the oil

out of warranty expense. Return the truck

to the customer and monitor the oil level.

If the oil level rises in an unreasonable

amount, the truck must be diagnosed

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
7
Decision
Inspect AMS and Exhaust System for Leaks
Yes. Correct the leaks, Step 8
If necessary, see IK1201142 Leak Locater Diagnostic Procedures. Tighten all AMS

pressure clamps to 115lb-in.
No. Step 8
Were any issues noted?
Step Action

8

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