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No. Step 10

Decision
Yes. Step 10

Can the code(s) be recreated?
No. Release unit to the customer

Step Action

Decision

See EGED 0000001681

10

1. Hard Start No Start Diagnostics
Special Test Procedures
Low-pressure Fuel System (LP.1 - LP.8)
NOTE: Do not continue to the High Pressure Fuel System Diagnostic section once complete

Yes. Repair and rediagnose for the
issue. If resolved Step 11.

No. Perform Fuel Rail Pressure
Monitoring with ServiceMaxx as
outlined below; then see Step 12

Were any low pressure fuel system issues noted?

Step Action

Decision

Reset the Fuel Pressure Adaptives.

Yes. Perform Fuel Rail Pressure
Monitoring with ServiceMaxx as
outlined below then see Step 12

Can the code(s) be recreated?

No. Release unit to the customer

11

Step Action
Review manitored data.

12

Decision
Yes. Step 14

After monitoring, does the Fuel Rail Pressure Trace resemble Figure 3 (FRP drops below desired
at times but can meet desired intermittently)?
No. Step 13
DTCs associated with this are 3055 FMI 15/16

Step Action
Review monitored data.

13

Does the Fuel Rail Pressure Trace resemble Figure 4 (FRP rises above desired at times but can
meet desired intermittently)?
DTCs associated with this are 3055 FMI 17/18

Step Action

14

Yes. Step 14

No. See Cylinder Performance
Analyzer Data Collection section
below. Record the data as outlined
in this section then see Step 16

Decision

Replace the High Pressure Fuel Pump Harness 7080246C91 Per the Engine Service Manual.
Zip-tie the FPCV and FVCV connectors as outlined in the Installation Procedure at the end
of this document and use dielectric grease on the connector. Reset the fuel pressure
adaptives assemble enough to run the engine with the turbochargers and HPFP cover
removed. Reperform ServiceMaxx Recording.

Yes. Step 15

WARNING: Please keep clear of moving gears and use extreme caution. Failure to do so
may result in serious injury, or death. If desired, cover and secure cardboard over the
opening to contain oil splash to engine compartment.

No. Reassemble and reevaluate
performance. If the codes still do
not return road test. Upon passing
the road test release unit to the
customer

Can the codes be recreated?

Step Action
15

Decision

Decision
Yes. See Cylinder Performance
Analyzer Data Collection section

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IK1201213 ­ MaxxForce 7 DTC 3055 Fuel System Diagnostics

If not already done so, replace the FRP sensor and UVC harness Reset the Fuel Pressure
Adaptives.

Can the code(s) be recreated?

Step

Action
Review the data recording.

Was the recording successful?
16

Page 5 of 9

below. Record the data as outlined
in this section then see Step 16
No. Release unit to the customer

Decision
Yes. Open a case file with
Navistar's Technical Support
group with all relevant information
and recordings for further
assistance.
No. Attempt to resolve the issue.
If required contact Navistar's
EZtech support group for
assistance or open a case file with
Navistar's Technical Support
group with all relevant information
and recordings for further
assistance.

FUEL RAIL PRESSURE MONITORING WITH SERVICEMAXX
Recording Steps
1.
2.
3.
4.
5.
6.
7.

Connect ServiceMaxx
Warm up the engine
Under "Tests" deselect "Load Test Specific Session" (See Figure 1)
Begin recording in the "Default Session"
Run the "Standard Test" twice
Perform 2 Snap Throttles
End Recording

Figure 1: ServiceMaxx Test Preparation
Item 1: Load Test Specific Session
Reviewing the Recording in ServiceMaxx
1. In ServiceMaxx Select "File" then "Open Snapshot Recording File..." as shown in Figure 2

Figure 2: Opening a Recording in ServiceMaxx
Item 1: Open Snapshot Recording File...

2.

Select the Parameters "FRP Desired" and "Fuel Rail Pressure" and study the FRP trace as-well-as Figure 3.

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IK1201213 ­ MaxxForce 7 DTC 3055 Fuel System Diagnostics

Page 6 of 9

Figure 3: Fuel Rail Pressure Data Recording
Item 1: FRP Drops Below Desired
Item 2: FRP Meets Desired

Figure 4: Fuel Rail Pressure Data Recording
Item 1: FRP Above Desired
RETURN TO STEP 12

CYLINDER PERFORMANCE ANALYZER DATA COLLECTION
NOTE: The data recording channels will not be used as labeled on the CPA box. FPCV and FVCV will be recorded using channels 1 and 2 while the Cam will
be recorded using channel 3 and FRP sensor recorded using channel 4. Figure 2 below shows the CPA box and labeled channels.

Figure 2: Cylinder Performance Analyzer Data Acquisition Box
Item 1: Fuel Pressure Control Valve (Black Pin E-18 and Red 12V
Power Pinned from Pin-16 on ZTSE4762 with Banana Clip Extension)
Item 2: Fuel Volume Control Valve (Black Pin E-16 Red 12V Power
Pinned from Pin­16 on ZTSE4762 with Banana Clip Extension)
Item 3: Cam Sensor (Connected using the Standard YELLOW CPA
Cable)
Item 4: Fuel Rail Pressure Sensor (Pinned from E-10 Red & E-6 Black
on the Breakout Box)

Figure 3 below shows the pin locations of the desired signals. As stated above the FPCV and FVCV 12V supply needs to be wired using ZTSE4762 with a
banana clip extension (NOTE: Use electrical tape to wrap the exposed metal clip, failure to do so may result in personal injury or component damage). The
Cam signal will require the use of the standard CPA cable connected directly to the sensor (This is reverse from Navistar's DT 9 & 10 Diesel Engine
Connections)

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IK1201213 ­ MaxxForce 7 DTC 3055 Fuel System Diagnostics

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Figure 3: Breakout Box Pin Diagram
Item 1: FPCV & FVCV 12V Supply
Item 2: Fuel Rail Pressure Sensor E-06 & E-10
Item 3: FVCV E­16
Item 4: FPCV E­18

To access the proper recording program see Activate CPA Recorder document and follow the instructions.

Once in the recorder the user will be able to label the channels as desired. To begin the recording the user selects "Record Data" then to stop the recording
select "Stop Recording" shown in Figure 6. The CPA tool records a file know as a ".mondat", this is what this technical support team will need for analysis.

Figure 6: CPA Recorder Window
Item 1: Fuel Pressure Control Valve (FPCV)
Item 2: Fuel Volume Control Valve (FVCV)
Item 3: Cam Signal
Item 4: Fuel Rail Pressure (FRP)

Data Recording
NOTE: Clear active/pending codes after each test if required
Cold Recordings
1.
2.
3.
4.

In the Recorder Label the "Test Description" as "KOEO Output State"
While cold and at KOEO, begin recording CPA data (No need to record ServiceMaxx data at this time)
With ServiceMaxx, perform Output State Tests High and Low alternating between the two 5 times to cycle the valves
End recording

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IK1201213 ­ MaxxForce 7 DTC 3055 Fuel System Diagnostics

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Warm-Up Recordings
1.
2.
3.
4.

In the Recorder Label the "Test Description" as "Engine Warm Up"
At KOEO begin to record CPA data as well as ServiceMaxx Data (Default Session)
Start the engine and set the cruise to 1500rpm allow the engine to warm up until ECT reaches 180F
End both recordings

Hot Recordings
1.
2.
3.
4.
5.
6.

In the Recorder Label the "Test Description" as "Standard Tests"
In ServiceMaxx deselect "Load Test Specific Session" if not already done so
Begin recording CPA and ServiceMaxx data
Run the "Standard Test" 3 times
Perform 3 WOT throttle snaps allowing to sit at WOT for at least 10 seconds each time
End both recordings

Brake Stall Recording
1. Begin recording CPA and ServiceMaxx (Default Session)
2. Perform 3 brake stalls with the Parking Brake OFF while recording allow to idle for 1 minute after completing the 3rd stall
3. End both recordings

RETURN TO STEP 16

REPAIR STEPS
INSTALLATION PROCEDURE:
See links below for HPFP harness zip tie images.
HARNESS 1889577C92 ZIPTIE IMAGES
HARNESS 7080246C91 ZIPTIE IMAGES

RETURN TO STEP 14

WARRANTY INFORMATION
Warranty Claim Coding:
Group: 12000 - Engines
Noun:

563 - Injector Unit (Electrical)
792 - Injector Fuel Lines (High PSI)
454 - Pump, Oil / Fuel (High Pressure Injection System)
168 - Sensor, ICP / FRP
791 - Engine Mechanical or Electrical Fuel Lift Pump

Use appropriate noun, relative to the actual repair made.
Standard Repair Times:
Due to the number of engine/vehicle combinations and possibilites for repairs, see appropriate SRT manual section, linked below.
Step
Step 1
Step 2
Step 3
Step 6
Step 6
Step 6
Step 6
Step 10
Step 12 &13
Step 13 & 15
Step 14
Step 6 & 14
CASE DIRECTION ONLY

Description
ECM Calibration
Visual Inspections
Check for DTCs & Reset Adaptives
FRP Sensor Diagnose
Valve Cover Removal
UVC Harness Replacement
FRP Sensor Replacement
Low Pressure Fuel System (LP.1 - LP.8) Diagnostics
Stationary Recording
Breakout Box/CPA Installation and Recording
High Pressure Pump Harness Replacement
Harness Wiggle Test
High Pressure Pump Replacement

Manual Section
ELECTRONIC CONTROL MODULE (ECM OR ECM/IDM) - ENGINE PROGRAM
ELECTRONIC ENGINE PERFORMANCE, DIAGNOSE
ELECTRONIC ENGINE PERFORMANCE, DIAGNOSE
"FRP" SENSOR, DIAGNOSTICS
VALVE COVER(S) AND/OR GASKET (V ENGINES), R&R AND/OR REPLACE
ENGINE COMPARTMENT ELECTRONIC HARNESSES, REPLACE
ELECTRONIC ENGINE CONTROL SENSORS/REGULATORS (MAXXFORCE 7), REPLACE
ELECTRONIC ENGINE HARD START/NO START, DIAGNOSE
STATIONARY SNAPSHOT, PERFORM
ELECTRONIC ENGINE CONTROL SYSTEMS DIAGNOSTICS
ENGINE COMPARTMENT ELECTRONIC HARNESSES, REPLACE
HARNESS WIGGLE TEST (INTERMITTENT DIAGNOSIS), PERFORM
HIGH PRESSURE FUEL PUMP & DRIVE GEAR, REPLACE

Special Requirements:
Do not replace the HPFP without Navistar's Technical Support Groups approval.

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IK1201213 ­ MaxxForce 7 DTC 3055 Fuel System Diagnostics

Page 9 of 9

OTHER RESOURCES
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