IK1200753 - Hydrocarbon Injector Housing Cleaning Procedure (AFI Plugging)

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IK1200753

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4

Major System:

ENGINES

Created:

4/19/2012

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Modified:

3/19/2013

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Author:

Jaime
Ochoa

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Title: Hydrocarbon Injector Housing Cleaning Procedure (AFI Plugging)
Applies To: 2010 EPA MF DT, 9, 10, 11, 13, 15
DESCRIPTION
Proper cleaning procedure of exhaust brake housing for proper Hydrocarbon (HC) Injector operation.
SYMPTOMS





Frequent regens
Inability to regen
Plugged aftertreatment fuel injector port
White smoke

POSSIBLE DIAGNOSTIC TROUBLE CODES
I6 Diagnostic Codes
SPN

FMI

MODULE

3556

0

ECM

3556

1

ECM

3471

1

ECM

3471
3471

7
10

ECM
ECM

DESCRIPTION
AFT Fuel Pressure 2 excessively high (Restricted
injection)
AFT Fuel Pressure 2 below desired (Possible
system leak)
Fuel Pressure 1 below desired (Low system
pressure)
AFT Fuel Doser Valve not responding as expected
AFT Fuel Doser Valve abnormal rate of change

BB Diagnostic Codes
SPN

FMI

MODULE

DESCRIPTION

3556

0

ECM

3556

1

ECM

3556

7

ECM

AFT Fuel Pressure 2 excessively high
(Restricted injection)
AFT Fuel Pressure 2 below desired (Possible
system leak)
AFT Fuel Injector not responding as expected

3480

0

ECM

AFTFP1 too high while dosing

3480
3471

1
7

ECM
ECM

AFTFP1 too low while dosing
Incorrect dosing pressure, multiple events

3481

7

ECM

AFT Fuel Injector not responding as expected

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IK1200753 - Hydrocarbon Injector Housing Cleaning Procedure (AFI Plugging)

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PARTS INFORMATION
Replace the below gasket and bolts when servicing the HC Injector [aftertreatment fuel injector (AFI) and doser injector].
Part #

Description

Qty.

3018016C1

GASKET HYDROCARBON INJECTOR

1

3006707C1

BOLT,HEX FLANGE M8 X 45 B16

2

The old gasket (p/n 3005521C1) has been reworked and replaced with p/n 3018016C1. The new style gasket will have
the raised center portion of the gasket removed (Figure 1).
Figure 1 - Gasket Changes

BACKGROUND
A plugged HC injector port will result in improper or frequent aftertreatment regenerations (regens). If the AFI port is
plugged use this procedure and the Navistar Engine Diagnostic Manual (I6 MF DT, 9 & 10 EGES 455; BB MF 11 & 13
EGES 470; MF 15 EGES 515) for additional reference.

SUPERCEDES PREVIOUS GUIDENCE ON AFI CLEANING
PROCEDURE
Remove the HC Injector per the procedure in the Navistar Engine Service Manual (I6 MF DT, 9 & 10 EGES 450; BB MF
11 & 13 EGES 465; MF 15 EGES 510).
1. Remove fuel and coolant lines to the HC Injector.
2. Remove the HC Injector from the exhaust brake housing (for I6; MF 11 & 13 - exhaust back pressure assembly;
MF 15 - turbocharger exhaust duct).
Note: The HC Injector needle at the tip of the valve is extremely sensitive to damage, set it aside in a safe location. IT

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IK1200753 - Hydrocarbon Injector Housing Cleaning Procedure (AFI Plugging)

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WILL NOT BE CLEANED OR SERVICED
3. Discard the gasket and two M8 x 45 bolts.
4. Disconnect and remove clamp from the exhaust system from the exhaust brake housing assembly.
Note: Take measures to have sufficient space between the housing and exhaust system so debris can be removed.
5. Remove the carbon plugging with a chisel or other appropriate tool.
6. Remove the carbon debris from the exhaust brake housing (A shop vac can be used).
Note: Any remaining chunks of carbon debris may damage the aftertreatment system or cause plugging of the
PDOC / DOC / DPF.
7. Install the original HC Injector with new gasket and new bolts per the Navistar Engine Service Manual.
8. Re-install the rest of the exhaust system.
9. Use ServiceMaxx to perform On Board Filter Cleanliness Test (OBFCT).
a. If test is successful/complete and original complaint is resolved, release the unit into service.
b. MF DT, 9 or 10: If test is unsuccessful/incomplete or original complaint is not resolved, folloe EGED 555
PERFORMANCE DIAGNOSTICS.
c. MF 11, 13 or 15: If test is unsuccessful/incomplete or original complaint is not resolved, refer to IK1200425.
Below are photos of a partially plugged port (fig 1), a completely plugged doser (fig 2) and a clear port (fig 3).
Figure 2 – Partially plugged AFI port

Figure 3 – Fully plugged AFI port

Figure 4 – Clear AFI port

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IK1200753 - Hydrocarbon Injector Housing Cleaning Procedure (AFI Plugging)

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You received the following feedback From: dy11605 - Dyllon Oatman Email Address: [email protected] Job Classification:
SE008, Service Technician Dealer: TRANSAUTHORITY, INC. Feedback: "Note: The HC Injector needle at the tip of the valve is
DY11605 extremely sensitive to damage, set it aside in a safe location. It will not be cleaned or serviced" At the end of this article it links to
IK1200425 for the MF 11, 13, & 15 which in strucks you to clean the AFI. That article is for the 2007-2009 MF 11, 13, & 15. Is the
newer style AFI on the 2010 IBB engines not cleanable?

Created
Date
3/20/2013
7:22:42 AM

Copyright © 2013 Navistar, Inc.

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