NHTSA ID Number: 10136271
Manufacturer Communication Number: IK1201004
TSB/Document Date: 2018-05-07
Summary
electric fuel pump diagnostic tips
IK1201004 - MaxxForce DT, 9 & 10 electric fuel pump diagnostic tips
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Countries:
CANADA, UNITED
STATES
Document
ID:
IK1201004
Availability:
ISIS, Bus ISIS,
FleetISIS
Revision:
4
Major System:
ENGINES
Created:
10/28/2013
Current
Language:
English
Last
Modified:
11/21/2013
Other
Languages:
NONE
Author:
Mark
Ehlers
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894
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Title: MaxxForce DT, 9 & 10 electric fuel pump diagnostic tips
Applies To: EPA 2010 MaxxForce DT, 9 & 10
DESCRIPTION
The EPA 2010 DT, 9 & 10 engines use a fuel module that incorporates many features, including
an electric fuel pump 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
-About 50% of the fuel pumps returned to Navistar
are not defective (click to see examples)
*Any part that is found to perform to the original manufacturer’s specification is subject to
chargeback of the entire claim amount
-Most low fuel pressure complaints are caused by a worn fuel pressure regulator valve &
spring. A kit for this is available.
*Follow fuel system diagnostic procedure here (Hard Start and No Start Diagnostics >
Special Test Procedures > Fuel System)
*The 2013 OBD version of the diagnostic manual is linked above and later in this article
-When this fuel pump fails it usually builds no pressure
The following are commom causes of low fuel pressure. Each should be inspected / tested
before replacing the electric fuel pump (in this order):
Is the fuel filter plugged
Is the pressure regulator valve is performing correctly- perform flow test in diagnostic manual
(a kit is available from Parts to service this- the regulator for the 2010 is unique))
Step 14 of "fuel delivery pressure system check"
Does the pump meet the pressure and flow specification listed in the diagnostic manual
Is the fuel pump strainer restricted or plugged (replacement P/N 1899335C91)
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IK1201004 - MaxxForce DT, 9 & 10 electric fuel pump diagnostic tips
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Do low fuel pressure diagnostic trouble codes exist indicating a performance issue related to
fuel pressure (SPN 94)
Is the pump is receiving 9 volts or more at pin 4 and pin 6 (see below)
Does fuel inlet restriction exceed 8.14" Hg. / -4 psi, causing the pump to draw too much
current and shut off or behave erratically (this could be cause by an intermittent fuel
restriction in the fuel tank or anywhere in the line). Use ZTSE6009 adaptor 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.
The pump is capable of operating from 9V to 14V and relies on a clean strainer (see image below)
and a properly functioning regulator valve (serviceable) in order to maintain system pressure. 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 excessive fuel back
pressure. 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 and ON the pump will restart.
The ECM monitors the fuel delivery pressure sensor located on the bottom of the fuel filter
housing. If the ECM determines that the pressure is low a diagnostic trouble code is set. EPA 2010
(I334) and HD-OBD 2013 (I367) use different fuel pressure sensors. They cannot be
interchanged.
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IK1201004 - MaxxForce DT, 9 & 10 electric fuel pump diagnostic tips
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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- see image below). 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).
SYMPTOMS
Erratic engine performance, engine stall, hard start/ no start, low power complaints, low fuel
pressure faults, aftertreatment fault codes relating to low fuel pressure
Likely causes:
Clogged fuel pump strainer (see image below)
Worn fuel pressure regulator valve (serviceable)
Plugged fuel filter element
High fuel inlet restriction caused by plugged strainer, kinked fuel line, fuel pickup tube
interference with fuel tank bottom, or tank debris
Low voltage to fuel pump
Common DTCs associated with an issue with the fuel pump are SPN 94-1 and 94-17. These
codes can be caused by a variety of issues should be investigated before servicing the pump.
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IK1201004 - MaxxForce DT, 9 & 10 electric fuel pump diagnostic tips
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IK1201004 - MaxxForce DT, 9 & 10 electric fuel pump diagnostic tips
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Copyright © 2013 Navistar, Inc.
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TSB/Document ID: IK1201004
Replacement Service Bulletin Number:
MFR Communication Date: 2013-11-21
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
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