IK1201344 ­ Power Cylinder Replacement Process

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Document ID: IK1201344

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Revision:

7

Major System:

ENGINES

Created:

9/28/2016

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Author:

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Iverson

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Title : Power Cylinder Replacement Process
Applies To : EPA 2010 MaxxForce DT/9/10 & N9/N10 Engines

CHANGE LOG
Please refer to the change log text box below for recent changes to this article:
02/14/2017 - Added a table of what is included in the Power Cylinder Seals Kit. (see parts section)
01/26/2017 - Added note to replace all components that come in the power cylinder seals kit.
01/10/2017 - Updated parts section
11/15/2016 - removed SRT links
11/11/2016 - Added links to section of diagnostic manual where hydro lock is a possible cause ­ listed as internal engine damage.

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DESCRIPTION
NOTE: REPLACE ALL COMPONENTS THAT YOU RECEIVE IN THE POWER
CYLINDER SEALS KIT.
The purpose of this document is to assist:
1. Determining correct repair path
2. Identify correct parts for warranty repair
3. Ensure correct warranty documentation
The above applies for the following base engine conditions:
1. CPA BEAM Warranty Authorization Code (WAC)
2. Hydro lock condition

SYMPTOM(s)
Diagnostic Trouble Code(s) & Dashboard Indicator Light(s):
DTC/Light

Description

N/A
Customer Observations or Concerns:

NOTE: REPLACE ALL COMPONENTS THAT YOU RECEIVE IN THE POWER
CYLINDER SEALS KIT.
Hard Start / Extended crank
Low Power

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IK1201344 ­ Power Cylinder Replacement Process

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Rough idle
No crank (hydro lock) - For Hydro lock symptom refer to the "Engine Does Not Start Symptom" Section of the Diagnostic
Manual.
Crank No start
Popping through the intake

DIAGNOSTIC STEP(s)

NOTE: REPLACE ALL COMPONENTS THAT YOU RECEIVE IN THE POWER
CYLINDER SEALS KIT.
Follow symptom based diagnostics through the diagnostic manual found here.
For Hydro lock symptom refer to the "Engine Does Not Start Symptom" Section of the Diagnostic Manual.
Note: RCT+ WAC is only valid if the engine was tested at operating temperature.
Note: Any CPA RCT+ Test that issues a WAC will require a BBT to be performed
If required, contact Technical Services and attach all appropriate .zip file

SPECIAL TOOL(s) / SOFTWARE
Tool Description

Tool Number

Comments

Instructions

N/A

REPAIR STEP(s)
NOTE: REPLACE ALL COMPONENTS THAT YOU RECIEVE IN THE POWER
CYLINDER SEALS KIT.
The CPA BEAM WAC will determine how many cylinders need replacement (See below for details). Depending on the
engine configuration the parts that should be ordered is outlined in the parts section below.

Warranty Authorization Code Logic Table

WAC Logic Table
Group 1: VIN and Date Identifier
Group 2: Cylinder Identifier (Examples below)
Group 3: Symptom Identifier

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IK1201344 ­ Power Cylinder Replacement Process

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Cylinder Identifier (group 2):
Currently the CPA will deliver a WAC for 1, 2 or all 6 Cylinder(s)
Examples of WAC cylinder identifier:
WAC for 1 cylinder example:
XXXX_03_X ‐ replace power cylinder 3 only
XXXX_30_X ‐ replace power cylinder 3 only
WAC for 2 cylinders example:
XXXX_56_X ‐ replace power cylinders 5 & 6
XXXX_65_X ‐ replace power cylinders 5 & 6
WAC for all 6 cylinders example:
XXXX_99_X ‐ replace all 6 power cylinders

SERVICE PARTS INFORMATION
NOTE: REPLACE ALL COMPONENTS THAT YOU RECIEVE IN THE POWER
CYLINDER SEALS KIT.

The following component inspections and/or replacements are NOT COVERED under warranty for this repair:
Any additional parts that are replaced will be considered customer responsibility.
•
•
•
•
•
•
•
•
•

Works Kits (1893941C9*, 1889893C9*, 1889894C9*)
Oil Pump
Main Bearings
Turbocharger(s)
Fuel Injector(s)
Oil Cooler
Engine Coolant
Cylinder Head
HPOP (High-Pressure Oil Pump)

NOTE: REPLACE ALL COMPONENTS THAT YOU RECIEVE IN THE POWER
CYLINDER SEALS KIT.

Kit Description

Quantity Required

466ST
W/o Inner-Stage
Cooler
Under 245 H.P.

466HT
W/ Inner-Stage
Cooler
245 H.P and
Above

570

KIT, POWER CYLINDER SEALS

NOTE: REPLACE ALL
COMPONENTS THAT YOU
RECEIVE IN THE POWER
CYLINDER SEALS KIT.

1 Per Repair

2516372C9*

Contains intake components, all gaskets and
hardware necessary for repair (does not contain
power cylinder kits)

TUBE ASSEMBLY TURBOCHARGER OIL
SUPPLY
Must be replaced whenever disconnected

1885590C9*
1 Per Repair

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IK1201344 ­ Power Cylinder Replacement Process

Kit Piston Sleeve and Ring

1 Per Cylinder

Connecting Rod

1 Per Cylinder -Hydro
lock condition only

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1893925C9*

1889320C9*

1877895C9*

1889068C9*

1873875C9*

2516372C91 - Power Cylinder Seals Kit Contents

NOTE: REPLACE ALL COMPONENTS THAT YOU RECIEVE IN THE POWER
CYLINDER SEALS KIT.
Example for cylinder wear WAC:
CPA delivered a WAC - XXXX_99_X - all 6 cylinders
The parts necessary would be:
1 Power Cylinder Seals Kit
1 Turbocharger Oil Supply Tube
12 Rod bolts
6 connecting rod bearing kits
6 Piston sleeve and rings kits
CPA delivered a WAC - XXXX_23_X - 2 cylinders
The parts necessary would be:
1 Power Cylinder Seals Kit
1 Turbocharger Oil Supply Tube
4 Rod bolts
2 connecting rod bearing kits
2 Piston sleeve and rings kits

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IK1201344 ­ Power Cylinder Replacement Process

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CPA delivered a WAC - XXXX_03_X - 1 cylinder
The parts necessary would be:
1 Power Cylinder Seals Kit
1 Turbocharger Oil Supply Tube
2 Rod bolts
1 connecting rod bearing kits
1 Piston sleeve and rings kits

NOTE: REPLACE ALL COMPONENTS THAT YOU RECIEVE IN THE POWER
CYLINDER SEALS KIT.

WARRANTY INFORMATION
All CPA BEAM tests .zip files must be saved and sent to Navistar Warranty Group upon request.
Hydro lock Condition:
Group: 12000 - Engines
Noun: 892 - Cooler, EGR

Warranty Claim Coding:
Refer to the Warranty Coding Manual for Group and Noun Codes.

Standard Repair Time(s):
Refer to the SRT Manual for Repair Times

NOTE: REPLACE ALL COMPONENTS THAT YOU RECIEVE IN THE POWER
CYLINDER SEALS KIT.
SRT Description

Qualifier/Notes
One

Power Cylinder Replacement

Each additional (if
Necessary)

Connecting Rod Replace

if necessary

Sleeve Protrusion

All Models

Counter bore

All Models

CPA Hook­up

All Models

Relative Compression Test Plus (RCT+)

All Models

Blow-by Test (BBT)

All Models

NOTE: REPLACE ALL COMPONENTS THAT YOU RECIEVE IN THE POWER
CYLINDER SEALS KIT.

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IK1201344 ­ Power Cylinder Replacement Process

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OTHER RESOURCES
Master Service Information Site

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