NHTSA ID Number: 10130979
Manufacturer Communication Number: IK1201222
TSB/Document Date: 2018-04-02
Summary
Misfire Diagnostics
IK1201222 MaxxForce 7 Misfire Diagnostics
Page 1 of 7
Countries:
CANADA, UNITED STATES, MEXICO, PUERTO
RICO
Document ID: IK1201222
Availability:
ISIS
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0
Major System:
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Created:
10/8/2014
Current
Language:
English
Last
Modified:
10/13/2014
Author:
Aaron
Mimbs
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Title : MaxxForce 7 Misfire Diagnostics
Applies To : All MaxxForce 7
CHANGE LOG
2014/10/10 Initial Article Release
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
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
ZTSE4146A
ZTSE4284
ZTSE4409 or ZTSE2217A
Obtained Locally
ZTSE4820
ZTSE4710
ZTSE4861
ZTSE4349
Tools Resource Center
SERVICE PARTS INFORMATION
Kit Description
KIT INJECTOR
HEAD ASSY CYL W/PLUGS & SLEEVE
PLATE ASSEMBLY DUAL FULCRUM
TUBE ASSY FUEL RAIL TO INJECTOR
Part Number
1899239C92
1882916C92
1880498C91
1886547C1
Quantity Required Notes
As Required
Includes Tube Assembly
As Required
Complete Cylinder Head
As Required
Rocker Arm Assembly (Exh & Int)
As Required
Injector to Rail Jumper Tube
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
11/3/2014
IK1201222 MaxxForce 7 Misfire Diagnostics
CAM ASM, FOLLOWER & GUIDE
ROD ASM, PUSH
PISTON ASSEMBLY
KIT, TURBO MOUNTING
1835139C93
1873916C2
1883516C91
18974455C93
As Required
As Required
As Required
As Required
Page 2 of 7
Lifter and Lifter Guide
Push Tube
Complete Piston Assembly
Turbo Seals & Oil Supply Tube
DIAGNOSTIC STEPS
Step
1
Step
2
Action
Decision
DIAGNOSTIC:
Yes. Step 2
Is the ECM Calibration UptoDate?
No. Update Calibration; Step 2
Action
Decision
DIAGNOSTIC:
Yes. Correct Issue; Step 3
Perform Visual Checks Per the Diagnostic Manual and/or Performance Diagnostic
Sheet.
No. Step 3
Any issues noted?
Step
Action
Decision
DIAGNOSTIC:
Yes. Perform an iKNow search for
documents relevant to the issue. If no
articles can be found see the proper
Diagnostic Manual for diagnostics. Step 4
Are there any PENDING/ACTIVE DTCs?
3
No. Step 5
Step
Action
Decision
DIAGNOSTIC:
Yes. Step 5
No. Contact a supervisor and ensure all
the proper decisions were
made. If necessary open a case file with
Navistar
's Technical Support group with
all relevant information and recordings for
further assistance.
Were the DTCs corrected using the Diagnostic Manual?
4
Step
5
Step
Action
Decision
DIAGNOSTIC:
Yes. Step 6
Reset the Fuel Pressure Adaptives. Does the engine still misfire?
No. Complete any other work needed
and release unit to customer. If this is a
problematic unit continue with Step 6
Action
Decision
DIAGNOSTIC:
Yes. Step 7
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
No. Potential Base Engine Issue.
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.
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.
Are the readings within specification?
Step
7
Action
Decision
DIAGNOSTIC:
Yes. Step 8
No. Step 8
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...
11/3/2014
IK1201222 MaxxForce 7 Misfire Diagnostics
Page 3 of 7
See Section Cylinder Performance Analyzer Diagnostics for Engine Misfires below.
Did the CPA tool flag a cylinder misfiring at idle?
Step
Action
Decision
DIAGNOSTIC:
1.CPA Flagged no Misfires and RCT (or
MCT) is within specification; Step 9
Relative Compression Test
8
Note: 2007 - 2009 MaxxForce 7 the RCT may not be accurate or has an inability to
2. CPA Flagged a Misfire and RCT (or
document cylinder compression. If this is the case then perform a manual compression MCT) is within specification; Step 10
test on the suspected bank ONLY (Both if Required). General Specification Rule - If
Cylinders are within 40 psi of each other after FOUR revolutions, compression is not an
issue.
3. CPA Flagged a Misfire and RCT (or
In ServiceMaxx under "Tests", "KOEO Tests", perform the "Relative Compression Test". MCT) is out of specification; Step 10
Specification: All cylinders are within 7 RPM of each other.
Step
Action
Decision
DIAGNOSTIC:
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TSB/Document ID: IK1201222
Replacement Service Bulletin Number:
MFR Communication Date: 2014-10-13
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING
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