NHTSA ID Number: 10131064
Manufacturer Communication Number: IK1201004
TSB/Document Date: 2018-04-02
Summary
Electric fuel pump step-based diagnostics
IK1201004 MaxxForce DT, 9 & 10 electric fuel pump stepbased diagnostics
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Countries:
CANADA, UNITED
STATES, PUERTO
RICO
Availability:
ISIS, Bus ISIS, FleetISIS Revision:
Major System: ENGINES
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Title : MaxxForce DT, 9 & 10 electric fuel pump step-based diagnostics
Applies To : EPA 2010 and later MaxxForce DT, 9 & 10
Step-based diagnostics for electric fuel pump: here
Tools needed for electric fuel pump step-based diagnostics:
-ServiceMaxx or Pocketmaxx
-Multimeter / DVOM
-ZTSE6023 fuel pump break-out tee
-3 test leads with male banana ends (part of ZTSE4435c)
-Battery charger or 12 volt auto/truck battery (charger must not be a smart-charger)
SYSTEM DESCRIPTION & SUPPLEMENTAL INFORMATION
EPA 2010 and later DT, 9 & 10 engines use a fuel module that incorporates many features,
including an electric fuel pump, fuel heater and fuel pump strainer.
-The fuel strainer can be seen when the pump is removed from the filter module. The strainer should
be serviced at the filter replacement interval (30K miles / 43K Km / or 12 months). The strainer P/N
is 1899335C91 (see images below)
-Navistar
has recently discovered that low fuel pressure DTC's 94-1 and 94-17 are being
erroneously set. Do not perform diagnostics for these faults unless there is a starting or
performance complaint. See IK1201055
Some low fuel pressure complaints are caused by a worn fuel pressure regulator valve & spring.
Kit 1893801C94 is available to remedy this.
-Fuel pressures above 60 psi will not cause low power or performance complaints on this engine
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IK1201004 MaxxForce DT, 9 & 10 electric fuel pump stepbased diagnostics
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Fuel inlet restriction should not exceed 8.14" Hg. / 4 psi. High inlet restriction can cause the pump
to draw too much current and shut off or behave erratically (this could be caused by an intermittent
fuel restriction in the fuel tank or anywhere in the line). Use ZTSE6009 adapter to attach a vacuum
gauge to the fuel inlet.
ELECTRIC FUEL PUMP OVERVIEW
At key ON, the ECM closes the fuel pump relay (provides ground via pin C-76) and battery voltage is
supplied to the pump. The pump will run for ten seconds (time varies with coolant temperature) and
then shuts off. During the run time if the ECM does not detect crankshaft rotation it switches the fuel
pump relay off. The key must be OFF for at least 10 seconds and then cycled ON before the
ECM will restart the fuel pump.
The ECM receives a 12 volt signal on pin E-69 that informs it that power is being provided to the fuel
pump.
DIAGNOSTIC TIPS
The pump has internal overload protection that turns the pump off under overload (high current draw
situations). High current draw can be caused by high inlet restriction or restriction in return line to
tank. When current limiting protection is triggered, the pump will cycle on and off causing the system
pressure to fluctuate until the overload condition is resolved. The pump may eventually turn itself off.
This situation can occur without a fault code being set. When the ignition key is cycled OFF for
10+ seconds and ON the pump will restart.
EPA 2010 (I334) and HD-OBD 2013 (I367) use different fuel pressure sensors. They cannot be
interchanged.
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 3/5/2014
IK1201004 MaxxForce DT, 9 & 10 electric fuel pump stepbased diagnostics
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There are two fuel pressure test ports on the engine. The first port is a Compuchek and is located on
the front of the filter module (unfiltered fuel pressure) The second port is a Schrader™ valve located
on the front of the intake manifold (filtered fuel pressure). The Schrader port can also be used to
bleed air out of the system. Note- Double check any below spec. pressure reading from this port as
a poor connection can cause a low pressure reading (but fuel rail pressure could be ok). Use
ZTSE4681 and adapter ZTSE4657.
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IK1201004 MaxxForce DT, 9 & 10 electric fuel pump stepbased diagnostics
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IK1201004 MaxxForce DT, 9 & 10 electric fuel pump stepbased diagnostics
Page 5 of 6
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IK1201004 MaxxForce DT, 9 & 10 electric fuel pump stepbased diagnostics
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SRT for electric fuel pump step-based diagnostics:
-KL12-2048T .7 hours (includes all steps of step-based diagnostic and pump replacement) - most
models
- I12-2048T 1.6 hours (RE bus)
Warranty code for electric fuel pump:
-12000 / 791 Engine Mechanical or Electric Fuel Lift Pump / T- Inoperative
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Copyright © 2014 Navistar, Inc.
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- Restores fuel economy
- Stabilizes ethanol
- Maximizes horsepower
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- For use in both gasoline and diesel engines
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TSB/Document ID: IK1201004
Replacement Service Bulletin Number:
MFR Communication Date: 2014-02-27
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, GASOLINE
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
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