NHTSA ID Number: 10130979
Manufacturer Communication Number: IK1201222
TSB/Document Date: 2018-04-02
Summary
Misfire Diagnostics
Yes. Fill out the Performance Diagnostic
Sheet. If no issues are noted and if
desired, open a case file with Navistar
's
Technical Support group with all relevant
information, pictures, parameter file and
recordings for further assistance.
Engine misfire is not present. Re-evaluate engine condition, operation, and "misfire"
operating conditions.
Other Possibilities:
9
1. Engine "misfire" at elevated RPMs
2. Engine surging due to other condition (EGR, ITV, FRP, Low Side Fuel Pressure,
Aftertreatment, Elevated Oil Level, etc.)
No. Complete any other work needed
and release unit to customer.
After reevaluation does the engine still qualify for misfire diagnostics?
Step
Action
Decision
DIAGNOSTIC:
Yes. Replace components and injector
reassemble engine. Reset the fuel
pressure adaptives; Step 11
Remove the valve cover and injector. Inspect the injector tip, rocker arms, and push
tubes.
10
Are any components damaged or worn?
NOTE: If the injector tip is heavily damaged the cylinder/piston may
exhibit unrepairable damage, if this is the case do not replace components at this time
and proceed to Step 12
Step
11
No. Replace injector reassemble engine.
Reset the fuel pressure adaptives; Step
11
Action
Decision
DIAGNOSTIC:
Yes. Return to Step 7, if the CPA tool
flags the same cylinder, Step 12
Does the engine still misfire?
No. Repair complete, release truck
Step
12
Action
Decision
DIAGNOSTIC:
Yes. Step 13
Remove the engine oil pan and inspect for debris and damage to the base engine
Lifters, Cam, Cylinder Walls, Crankshaft, or Pistons/Rods?
No. Step 14
Were any issue noted?
Step
Action
Decision
DIAGNOSTIC:
Yes. Open a case file with Navistar's
Technical Support group with all relevant
information, pictures, parameter file and
recordings for further assistance.
Does the engine fall under any of the following conditions?
13
1.
2.
3.
4.
Severe Camshaft Lobe Damage
Severe Cylinder Wall Damage
Severe Crankshaft Damage
Severe Crankcase Damage
No. If related and can be corrected
proceed with repairs, if not Step 14
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IK1201222 MaxxForce 7 Misfire Diagnostics
Step
14
Page 4 of 7
Action
Decision
DIAGNOSTIC:
Yes. Step 15
Remove the cylinder head per the Engine Service Manual and Perform Base Engine
Inspections.
No. Step 16
Were any Issues Noted?
Step
Action
Decision
DIAGNOSTIC:
Yes. Open a case file with Navistar's
Technical Support group with all relevant
information, pictures, parameter file and
recordings for further assistance.
Does the engine fall under any of the following conditions?
15
Step
1.
2.
3.
4.
Severe Camshaft Lobe Damage
Severe Cylinder Wall Damage
Severe Crankshaft Damage
Sever Crankcase Damage
No. If related and can be corrected
proceed with repairs, Step 16
Action
Decision
DIAGNOSTIC:
Yes. If non-condemning replace/repair
components per the Engine
Service Manual reassemble the engine. If
the issue has not been resolved by this
time open a case file with Navistar's
Technical Support group with all relevant
information, pictures, parameter file and
recordings for further assistance.
Remove the piston assembly and inspect.
Are any issues noted?
16
No. Open a case file with Navistar's
Technical Support group with all relevant
information, pictures, parameter file and
recordings for further assistance.
CYLINDER PERFORMANCE ANALYZER DIAGNOSTICS FOR ENGINE MISFIRES
NOTE: ON THE MAXXFORCE 7 THE CPA TOOL IS VERY ACCURATE IN FLAGGING ENGINE MISFIRES AT IDLE ONLY. ELEVATED ENGINE
SPEEDS BRINGS HIGHER TORSIONAL VIBRATIONS WHICH CAN AND WILL IMPROPERLY FLAG CYLINDERS FOR A MISFIRE. THE SAME
APPLIES FOR UNDER A LOAD AND DRIVING.
Connecting the CPA Tool
The Camshaft Position Sensor and Crankshaft Position Sensor connectors are reversed, in comparison to the DT, 9 and 10. On the CPA box, the
BNC cables need to be connected such that the correct sensor is feeding the correct port (Crank to Crank, Cam to Cam)--the crankshaft position
sensor is located on the right (passenger) side of the engine towards the front just above the oil pan and the camshaft position sensor is located on
the left (drivers) side of the engine.
If needed see the following iKNow article for further CPA instructions IK1200812 - Diagnosing Cylinder Performance Related Symptoms Using the
CPA Tool
CPA Software Preparation
After connecting the CPA tool to the truck and laptop, launch the Engine Cylinder Performance Analyzer software from the Desktop Icon. See
Figure 1.
NOTE: If launched from ServiceMaxx the software may not include the V8 Base Engine Class displayed in Figure 2. Fill out the information table
and then Proceed.
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IK1201222 MaxxForce 7 Misfire Diagnostics
Page 5 of 7
Figure 1: Desktop Cylinder Performance Analyzer
Icon
Figure 2: Cylinder Performance Analyzer
Information Table
Item 1: Base Engine Class V8
If done properly, selecting the Base Engine Class as "V8," the engine misfire display figure shows an 8 cylinder engine representation shown in
Figure 3.
Figure 3: Cylinder Performance Analyzer Information Table
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IK1201222 MaxxForce 7 Misfire Diagnostics
Page 6 of 7
Item 1: Base Engine Class V8
With the CPA tool, perform the standard "Signal Check." After passing the signal check, begin recording the engine data during the time of the
misfire complaint (Cold Idle or Hot Idle). The same standard misfire display follows the same rules as theDT, 9 and 10 Engines and can be seen in
Figure 4.
Figure 4: Cylinder Performance Analyzer MisFire
Indicator
Return to Step 7
REPAIR STEPS
See appropriate Service Manual for all repair procedures.
WARRANTY INFORMATION
Warranty Claim Coding:
Group: 12000 - Engines
Noun: 313 Carrier Assembly, Rocker Arm
404 - Lifter, Valve
416 - Rods, Push
563 - Injector Unit (Electrical)
137 - Piston, Pin, Lock, Bushing
192 Sleeve Cylinder
051 - Crankcase
Warranty Coding Manual
Standard Repair Times:
Due to extensive SRT options and requirements for the repair plans, see the Standard Repair Time Manual for specific engine/vehicle combinations.
Standard Repair Time Manual
STEP
Step 1
Step 2
Step 3 & 4
Step 6
Step 7
Step 8
DESCRITPTION
ECM Calibration
Visual Inspection
Check for DTCs & Reset Adaptives
Crankcase Pressure Test
Blow-by Test (EPA 2010)
Crankcase Breather Replacement
EPA (2010)
Cylinder Performance Analyzer
Relative Compression Test (EPA
2010)
MANUAL SECTION
ELECTRONIC CONTROL MODULE (ECM OR ECM/IDM) - ENGINE PROGRAM
ELECTRONIC ENGINE PERFORMANCE, DIAGNOSE
ELECTRONIC ENGINE PERFORMANCE, DIAGNOSE
ELECTRONIC ENGINE PERFORMANCE, DIAGNOSE
ELECTRONIC ENGINE PERFORMANCE, DIAGNOSE
CRANKCASE BREATHER HOUSING ASSEMBLY, REPLACE
TTime (0.7 Hours) CYLINDER PERFORMANCE ANALYZER (CPA) TOOL, DIAGNOSIS
ELECTRONIC ENGINE PERFORMANCE, DIAGNOSE
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IK1201222 MaxxForce 7 Misfire Diagnostics
Manual Compression Test (EPA
2007)
Rocker Arm Replacement
Injector Replacement
Oil Pan R&R
Cylinder Head Removal (EPA 2007)
Cylinder Head Removal (EPA 2010)
Piston and Rings Replace
Step 10
Step 12
Step 14
Step 16
Page 7 of 7
ELECTRONIC ENGINE PERFORMANCE, DIAGNOSE
ROCKER ARM, PUSH RODS AND/OR VALVE BRIDGES (V-ENGINES), REPLACE
FUEL INJECTOR(S) (ELECTRONIC ENGINES), REPLACE
OIL PAN AND/OR GASKET, REPLACE
CYLINDER HEAD GASKET (V-ENGINES), REPLACE
CYLINDER HEAD OR REPLACE GASKET (V ENGINES), R&R AND OR REPLACE
PISTON RINGS, REPLACE
OTHER RESOURCES
Master Service Information Site
Feedback Information
Hide Details
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Helpful:
3
Not Helpful: 1
Staff
ID
Client
ID
DY20525
Comments
You received the following feedback From: dy20525 - Peter Schnell Email Address: Job Classification: SE008, Service Technician Dealer: SANTEX TRUCK
CENTERS,LTD Feedback: happy this has been release, in the past year have replaced approxiamtely 12 2010 mf 7's displaying the popping through intake
problem.
Created
Date
10/16/2014
10:14:43 AM
Copyright © 2014 Navistar, Inc.
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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
MFR Component System:
MFR Component Subsystem:
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