NHTSA ID Number: 10130969
Manufacturer Communication Number: IK1201150
TSB/Document Date: 2018-04-02
Summary
Injector Sleeve Replacement
IK1201150 Maxxforce 15L Injector Sleeve Replacement
Page 1 of 14
Countries:
CANADA, UNITED STATES Document ID: IK1201150
Availability:
ISIS, FleetISIS
Revision:
1
Major System:
ENGINES
Created:
6/24/2014
Current Language: English
Last Modified: 10/29/2014
Other Languages: NONE
Author:
Viewed:
Josh Bowman
205
Less Info
Coding Information
Hide Details
Copy Link
Copy Relative Link
Bookmark
Add to Favorites
Provide Feedback
Helpful
Not Helpful
0
0
View My Bookmarks
Title : Maxxforce 15L Injector Sleeve Replacement
Applies To : 2011 Maxxforce 15L
CHANGE LOG:
2014/10/28 Updated format
2014/08/11 - Updated SRT information
2014/08/04 - Launch to field
DESCRIPTION:
This article provides the procedure for injector sleeve replacement on the Maxxforce 15L engine. If diagnosing one or more of
the symptoms listed below and you have determined that the injector sleeve is the root cause, follow the repair procedure below.
SYMPTOMS:
- Coolant leak to fuel
Fuel in coolant
Fuel in lube oil
- Compression to fuel
SPECIAL TOOLS:
Tool Description
Tool Number
Maxxforce 15L Tool Kit - TL2900007
ZTSE5028
Injector Sleeve Kit
ZTSE6095
Fuel Injector Kit
ZTSE6102
SERVICE PARTS INFORMATION:
Kit Description
Part Number
Quantity Required
Kit, Injector Sleeve
7092980C91
6
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
11/3/2014
IK1201150 Maxxforce 15L Injector Sleeve Replacement
Page 2 of 14
Kit, Injector Seal Kit
3014430C91
6
Tube Assy Rail to Injector
3007916C2
1
Tube Assy Rail to Injector
3007915C2
1
Tube Assy Rail to Injector
3007914C2
1
Tube Assy Rail to Injector
3007913C2
1
Tube Assy Rail to Injector
3007912C2
1
Tube Assy Rail to Injector
3007911C2
1
REPAIR PROCEDURE
To prevent personal injury or death, read all safety instructions in the Safety Information section of the
Service and Diagnostic Manuals for the application that is being serviced
To prevent damage to the vehicle or engine, read all safety instructions in the Safety information section
of the Service and Diagnostic Manual for the application that is being serviced
REMOVAL:
1. Remove the rail to injector tube assembly, valve brake actuator assembly, rocker arm assembly and lost motion
pedestals, following the removal procedures in the EGES-510 Engine Service Manual. Discard the rail to injector tube assembly.
2. Remove the highpressure connector retaining nut
3. Remove high pressure connector from cylinder head
4. Remove the 3/8 -16 x 4 hex bolt, 9.8 x 15.85 x 37.6 spacer, and injector clamp for affected cylinders
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
11/3/2014
IK1201150 Maxxforce 15L Injector Sleeve Replacement
Page 3 of 14
Figure 1: Installation of threaded legs into lost motion pedestal bolt holes
Item 1 - ZTSE6095-4 Threaded Legs
5. Install the two threaded legs (Figure 1, Item 1)--with wrench flats up--into lost motion pedestal bolt holes. Hand tighten
threaded legs.
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
11/3/2014
IK1201150 Maxxforce 15L Injector Sleeve Replacement
Page 4 of 14
Figure 2: Installation of ZTSE6102-1 jaw puller assembly on fuel injector
Item 1 - ZTSE6102-1 Jaw Puller Assembly
Item 2 - Fuel Injector
6. Install the jaw puller assembly onto the fuel injector (Figure 2, Item 1).
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
11/3/2014
IK1201150 Maxxforce 15L Injector Sleeve Replacement
Page 5 of 14
Figure 3: Installing ZTSE6095-3 threaded leg into injector hold-down bolt hole
Item 1 - ZTSE6095-3 Threaded leg
Item 2 - ZTSE6102-1 Jaw Puller Assembly Installed on fuel injector
7. Install ZTSE6095-3 threaded leg into the injector hold-down bolt hole. Hand tighten threaded leg.
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
11/3/2014
IK1201150 Maxxforce 15L Injector Sleeve Replacement
Page 6 of 14
Figure 4: Installing Tee Plate
Item 1 - ZTSE6095-1 Tee plate
Item 2 - Threaded legs (ZTSE6095-3, ZTSE6095-4)
Item 3 - ZTSE6102-1 Jaw puller assembly
8. Install Tee plate ZTSE6095-1 over threaded legs and jaw puller assembly
9. Install three nuts on threaded legs and hand tighten
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
11/3/2014
IK1201150 Maxxforce 15L Injector Sleeve Replacement
Page 7 of 14
Figure 5: Installed tee plate
Item 1 - Hand tightened nuts on threaded legs
Item 2 - 5/8 washer and 5/8-18 nut on ZTSE6102-1 jaw puller assembly
10. Install 5/8 washer and 5/8-18 nut onto jaw puller assembly ZTSE6102-1 and turn clockwise until injector is out.
11. Remove three nuts from threaded legs
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
11/3/2014
IK1201150 Maxxforce 15L Injector Sleeve Replacement
Page 8 of 14
Figure 6: Removed Injector
Item 1 - ZTSE6102-1 Jaw puller assembly
Item 2 - Fuel injector
12. Lift Tee plate vertically and then remove injector assembly from jaw puller assembly
13. Place injector into fuel injector rack holder ZTSE4299B
Continue with procedure to remove fuel injector sleeve
14. Thread the sleeve puller (ZTSE6095-2) into the fuel injector sleeve.
15. Place the Tee plate (ZTSE6095-1) over the sleeve puller and threaded legs. Install the three nuts on threaded legs and
hand tighten.
16. Install the washer and large hex flange nut onto the sleeve puller. Turn the large hex flange nut clockwise until the fuel
injector sleeve is removed from cylinder head.
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
11/3/2014
IK1201150 Maxxforce 15L Injector Sleeve Replacement
Page 9 of 14
Figure 7: Removal of injector sleeve
Item 1 - ZTSE6095-2 sleeve puller
Item 2 - Injector sleeve
Item 3 - ZTSE6095-1 Tee plate
Item 4 - Hand tightened nuts on threaded legs
17. Remove three nuts from the threaded legs. Lift the Tee plate (ZTSE6095-1) from sleeve puller and discard.
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
11/3/2014
IK1201150 Maxxforce 15L Injector Sleeve Replacement
Page 10 of 14
Figure 8: Removed injector sleeve
Item 1 - ZTSE6095-1 Tee plate
Item 2 - ZTSE6095-2 sleeve puller
Item 3 - Injector sleeve
Item 4 - Injector sleeve O-Rings
INSTALLATION
1. Lubricate the top two O-rings on the new fuel injector sleeve with P-80.
2. Lubricate the bottom O-ring with Loctite retaining compound 620
3. Align the hole on side of fuel injector sleeve with hole in cylinder head for high-pressure connector and then place new fuel
injector sleeve into injector port in cylinder head.
4. Place injector sleeve installer assembly (ZTSE6095-5) into fuel injector sleeve. Ensure the spring pin on bottom of the
sleeve installer assembly aligns with groove on fuel injector sleeve. Place sleeve and installer in injector sleeve bore
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
11/3/2014
IK1201150 Maxxforce 15L Injector Sleeve Replacement
Page 11 of 14
Figure 9: Spring pin alignment
Item 1 - Spring pin
Item 2 - Injector sleeve groove
5. If not already done, install two threaded legs ZTSE6095-4 into bolt holes for lost motion pedestal assembly, and one
threaded leg ZTSE6095 3 into bolt hole for fuel injector clamp bolt.
6. Install Tee plate ZTSE6101-1 onto threaded legs and secure with three nuts hand tight.
There is a "U" shaped cutout on threaded leg ZTSE6095-3 that must be aligned with cup driver
7. Thread forcing screw assembly ZTSE6101-3 into Tee plate ZTSE6101-1 and turn clockwise until injector cup is completely
installed. Injector cup is completely installed when you cannot turn driving bolt anymore. (approx 24.9 lbfft)
8. Unscrew forcing screw assyembly ZTSE6101-3 until it is not in contact with driver and remove the three nuts from the
threaded legs. Lift the Tee plate vertically and remove.
9. Remove threaded legs from cylinder head
10. Remove injector sleeve installer assembly (ZTSE6095-5).
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
11/3/2014
IK1201150 Maxxforce 15L Injector Sleeve Replacement
Page 12 of 14
Figure 10: Fuel Injector
Item 1 Injector
Item 2 - O-ring
Item 3 - Combustion gasket
11. Remove and discard O-ring from each fuel injector
12. Install a new O-ring on each fuel injector. Lubricate O-ring with clean engine oil
13. Install a new combustion gasket on each fuel injector
14. Remove disposable air and fuel caps from cylinder head injector bore
To prevent engine damage, align injector correctly with cylinder head so injector tube inlet port
aligns with pressure pipe holes in cylinder head; do not twist injector when inserting injector into
cylinder head
15. Install injector using injector installer ZTSE4777. Push firmly until injector is seated all the way into injector sleeve.
16. Install injector clamp(s), 9.8 x 15.85 x 37.6 spacer(s) and 3/8 – 16 x 4 hex bolt(s). Tighten 3/8 – 16 x 4 hex bolt(s) hand
tight.
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
11/3/2014
IK1201150 Maxxforce 15L Injector Sleeve Replacement
Page 13 of 14
Figure 11: High-pressure connector
Item 1 - High-pressure connector retaining nut (6)
Item 2 - High-pressure connector body (6)
Item 3 - 13 x 3 O-ring (6)
17. Lubricate the 13.5 x 3 O-rings on the high pressure connector bodies with clean engine oil.
18. Install six new high-press connector body and 13.5 x 3 O-ring assemblies.
19. Lubricate the high-pressure connector retaining nut threads with clean engine oil
20. Install high-pressure connector retaining nut(s). Tighten high-pressure connector retaining nut(s) to 55 N·m (40 lbf ·ft)and
then loosen completely. Tighten retaining nut(s) again 10 N·m (88 lbf·in).
21. Tighten 3/8-16 x 4 injector clamp hex bolts to 25 N·m (18 lbf·ft) + 90°.
22. Tighten high-pressure connector retaining nuts to 20 N·m (15 lbf·ft) + 25°.
23. Re-install lost motion pedestal(s), rocker arm assembly(s) and valve brake actuator(s) following the service procedures in
the EGES510 service manual
WARRANTY INFORMATION:
Warranty Claim Coding:
Group:
12000 - Engine
Noun:
563 - Injector Unit (Electrical)
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
11/3/2014
IK1201150 Maxxforce 15L Injector Sleeve Replacement
Page 14 of 14
STANDARD REPAIR TIMES:
Hours
Code
Model
1.7
FA12-7563O-2
Injector Sleeves, Replace
9900i
1.7
R12-7563O-2
Injector Sleeves, Replace
ProStar
1.7
T12-7563O-2
Injector Sleeves, Replace
5000
1.7
TC12-7563O-2
Injector Sleeves, Replace
CAT CT660
Engine
Qualifier 1
|MAXXFORCE 15|
Fuel Injector, Replace
Add On
|MAXXFORCE 15|
Fuel Injector, Replace
Add On
|MAXXFORCE 15|
Fuel Injector, Replace
Add On
|MAXXFORCE 15|
Fuel Injector, Replace
Add On
OTHER RESOURCES:
EPA 2010 MaxxForce 11, 13, N13, and 15 Service Resource Center
MaxxForce® 15L Engine Service Manual (Supersedes EGES-510)
2011 MaxxForce® 15 Engine Diagnostic/Troubleshooting Manual (Revision 1)
Hide Details
Feedback Information
Viewed:
204
Helpful:
0
Not Helpful: 0
No Feedback Found
Copyright © 2014 Navistar
, Inc.
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
11/3/2014
- 💯【Conta.ct us for Support Directly】If you met any...
- 🔥🔥🔥【2026 AUTEL FLAGSHIP MK900BT MK900-BT, NEW...
- 🚗【3000+ ACTIVE TESTS (50➡3000+), SAME AS MS...
- 🚗【40+ HOT SERVICES FOR 150 MAKES (28+➡40+)】Full...
- 🚗【OE ALL SYSTEM DIAGNOSE, AUTO SCAN 2.0: SCAN LICENSE...
- 【TURN OFF CEL】 This AL319 car scanner diagnostic tool...
- 【EXTENSIVE APPLICATION】 Autel AL319 Compatible with...
- 【FOR END USER & DIYERS】 This error code reader AL319 is...
- 【USER-FRIENDLY DESIGN】 This OBD2 scanner and check...
- 【HIGH-QUALITY SERVICES】 12 months war.ranty from the...
Last update on 2026-06-23 / Affiliate links / Images from Amazon Product Advertising API
If the PDF is very large, it may not load in the preview below.
Some older TSBs had multiple PDFs — visit the NHTSA Website to view all PDFs.
If the TSB PDF does not show, download or view it on the NHTSA Website.
Click on the (+) Plus Sign
Then Click on Associated Document(s)
Search NHTSA Database for Recalls
Search NHTSA Database for Vehicle Investigations
View Latest Vehicle Investigations
Search NHTSA Database for Vehicle Complaints
View Latest Vehicle Complaints
TSB/Document ID: IK1201150
Replacement Service Bulletin Number:
MFR Communication Date: 2014-10-29
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
- Stay Updated with Lifetime Access: This obd2 scanner includes lifetime free software updates for all app service functions. With a single payment, enjoy full access to diagnostics, reset tools, and maintenance features — zero subscription fees. A budget-friendly choice for weekend mechanics, home car owners, and DIYers, supporting vehicles from 1996 onward. Come to us with your VIN to check compatibility.
- Full Bidirectional Control/Active Tests & Stable Wireless Connectivity: This car code reader features full bidirectional control, allowing you to send commands to the vehicle's ECU for active tests on components such as fuel pumps, injectors, A/C clutches, windows, sunroofs, and more. This car scanner diagnostic tool helps DIYers quickly diagnose and test vehicle parts, cutting down troubleshooting and repair time. With BT 4.0 wireless connectivity, you can enjoy cable-free diagnostics up to 33 feet. Stand in your garage and test windows, wipers, or even engine components—all without needing to move around your car.
- Portable Car Scanner with 26 Special Functions: Scheduled vehicle maintenance with the A30M car diagnostic scanner can keep your vehicle in peak condition and save you big on dealership trips. The XTOOL A30M obd2 scanner diagnostic tool features essential reset and relearn functions, such as Oil Reset, EPB Reset (Electronic Parking Brake Release), SAS, ABS Brake Bleeding, Throttle Body Relearn, Injector Coding, Crank Sensor Relearn, Headlight Adjustment, and Tire Size Reset. Note: Service functions may vary by vehicle model – check compatibility beforehand!
- Wide Compatibility CAN FD & FCA
Autoauth: This obd2 scanner diagnostic tool is compatible with over 85+ car brands from the U.S., Europe, and Asia, providing extensive coverage through a BT connection with your smartphone or iPad. Now upgraded to support the latest protocols, it includes FCA AutoAuth access for Chrysler, Jeep, Dodge, and Fiat (2018+), and supports CAN FD for GM (2020+) models, giving you greater access to newer vehicles and systems. Note: The FCA AutoAuth account is not included with the device. Users must register and pay separately through the official FCA AutoAuth website to access diagnostic functions for vehicles that require it. - Up to 8 Live Data Streams Graphing – Real-Time Graphing for Deeper Insight: This car scanner supports up to 8 live data streams simultaneously with intuitive, real-time graphing. Gain comprehensive insights into your vehicle’s performance, making it easier to spot issues, detect trends, and make informed diagnostic decisions with confidence.
- Comprehensive OBD2 Scanner with 16 Resets: The XTOOL D5S car code reader and vehicle reset tool provides an advanced diagnostic solution with 16 commonly needed reset functions, including Electronic Parking Brake Reset (EPB Reset), SAS, BMS Reset (Battery Test), Throttle Body Relearn, TPMS Reset, ABS Bleeding, Injector Coding, Gearbox Match, Suspension Adjustment, Headlight, Window Initialization, Crank Sensor Relearn and more. Equipped with CAN FD Protocol and FAC AutoAuth, the D5S obd2 scanner diagnostic tool ensures compatibility with a broad range of modern vehicles, allowing users to address common maintenance needs quickly. NOTE: Please Check the Compatibility before ordering.
- 4 Main System Car Scanner & Full OBD2 Diagnostics: The XTOOL D5S car code reader is ideal for home mechanics, DIYers, and professionals, providing access to Transmission/Engine/ABS/SRS systems to read DTCs, Live data can be displayed in text or up to 4 PID data graphs, along with full OBD2 diagnostics to check the engine light on, other obd2 issues and routine maintenance. This car diagnostic scanner ensures you can keep your vehicles in top condition, avoiding costly repairs or unexpected breakdowns. NOTE: Some vehicles display three systems after connection because the transmission and engine of some vehicles are integrated into one.
- Check Engine Code Reader & Real-Time Engine Monitoring: Whether you're a car owner, a DIYer, or run a repair shop, the XTOOL D5S obd2 scanner diagnostic tool makes engine diagnostics fast and frustration-free, reading and explaining trouble codes in seconds—no confusion. Check live data like fuel trim, 02 sensor voltage, RPM, and coolant temp to pinpoint mis~fires, rough idle, or sensor issues. After repairs, simply use the D5S check engine code reader and reset tool to turn off the check engine light and confirm the problem’s fixed—saving time, money, and unnecessary shop visits. - Note: If the check engine light comes back on, it indicates the original problem still exists.
- Portable Car Scanner for ABS and SRS: XTOOL D5S gives you peace of mind when ABS or airbag warning lights come on. It reads and clears ABS codes to help you fix brake sensor, traction control, or wheel speed issues, and supports ABS bleeding after repairs like caliper or master cylinder replacement. For airbag systems, it scans and clears SRS codes related to airbags, seatbelt tensioners, and crash sensors. Whether you're doing repairs at home or running a small shop, the D5S is a cost-effective solution for safety diagnostics. Note: If a fault code returns after clearing, it usually means the issue hasn’t been fully resolved. Please check the compatibility before ordering.
- Transmission Warning Light ON? Here’s the Transmission Diagnostic and Reset Tool You Need: The XTOOL D5S is more than just a basic car scanner—it’s an easy-to-use transmission diagnostic tool. From rough shifts to slipping gears, the D5S lets you read and clear transmission trouble codes, monitor real-time TCM data, and perform transmission resets after fluid changes or repairs. Whether you’re a hands-on car owner or a pro running a busy shop, this OBD2 scanner with transmission functions helps you catch problems early—saving you time, money, and future headaches.. Note: Clearing fault codes is equivalent to a reset on some vehicles, but not all. For help, contact XTOOL Tech Support.
- Save $500+/Year with Pro-Level Diagnostics -No Subscriptions: The Portable XTOOL Anyscan A30D OBD2 scanner diagnostic tool includes free lifetime software updates for all app service functions, without extra cost. With a single payment, enjoy full access to diagnostics, relearn scan tools, and maintenance features. A cost-effective, smart choice for car owners and DIY enthusiasts, compatible with vehicles from 1996 onward. Please provide the car VIN and the special functions you need in advance so that we can confirm compatibility
- Bi-Directional Control for Faster Troubleshooting: Unlike a basic code reader, the A30D bi directional scan tool sends commands directly to your vehicle’s ECU to actively test components like fuel pump, valves, wipers, windows, doors, sunroof, and headlamps right from your smartphone. See component responses in real time without disassembly—perfect for brake jobs, electrical issues, and hard-to-find problems. This bidirectional obd2 scanner helps pinpoint faults faster, reduce guesswork, and avoid replacing good parts. An efficient, easy-to-use car scanner diagnostic tool built for DIYers, home garage users, and small-shop technicians who want real two-way scanner, not just codes
- 19 Reset Functions for Routine Maintenance: The A30D car diagnostic scanner provides 19 relearn functions without extra charges, including EPB Reset for parking brake replacement, TPMS Reset after tire changes, ABS Auto Bleeding, Oil Reset, SAS Reset, BMS Reset, Throttle Relearn, Injector C0ding, Gear Learning, Crank/Crankshaft/Cam/Ckp Sensor Relearn Tool, Transmission Match, Seat Calibration, Airbag Repair and more. This XTOOL A30D automotive scanner diagnostic tool supports preventive care, helping extend vehicle life and reduce costly shop visits. Functions vary by vehicle make and year—plz confirm compatibility before purchase
- Stable BT Connection & All-System & 8 Pids Live Data: The A30D wireless OBD2 scanner delivers a fast and stable wireless connection up to 33 feet, letting you move freely around the vehicle without tangled cables. Pair with with Android 9.0+ and iOS 10.0+ devices to turn your phone into a mobile auto scanner—perfect for home garages, driveways, or on-the-spot repairs. This full system scanner for cars provides real-time access to all major modules, including Engine, Gearbox, ABS, SRS, AC and more. with clear graphs, meters, and up to 8 PIDs displayed at once. This car code reader makes system monitoring visual, simple, easy to understand, and offering data logging for playback and deeper
- Wide Compatibility with CAN-FD & FCA Support: The A30D car computer diagnostic reader works with most 1996 and newer vehicles with a standard OBD2 port, including for Ford, for GM, for Toyota, for Honda, for Nissan,for Hyundai etc, with ongoing updates covering more car models and functions later. It also supports newer communication protocols like CAN-FD and FCA AutoAuth (Personal AutoAuth account and active subscription required, not included with the device!for Chrysler, for Dodge, for Jeep, for Fiat models). It is a future-ready automotive scanner diagnostic tool for households with multiple vehicles or part-time techs. Coverage vary by cars, plz check the compatibility first
Last update on 2026-06-23 / Affiliate links / Images from Amazon Product Advertising API
This product presentation was made with AAWP plugin.