International Engines models MaxxForce 11, MaxxForce 13, MaxxForce 15 Diagnostics/Troubleshooting/Repair/Operation & Maintenance Technical Manuals
Complete service repair manual with Electrical Wiring Diagrams for International Engines model MaxxForce 11, MaxxForce 13, MaxxForce 15, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
International / Navistar MF11/MF13/MF15 Diesel Engines workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 16,291 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
0000001682 - MaxxForce 11 and 13 Engine Service Manual (2013-02).pdf
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EGED-430-2 - Engine Wiring Diagram Maxxforce 11 and 13 2008 Model Year.pdf
EGED-435 - Maxxforc ETM 11 and 13 2008 Model Year Signal Values (All values with the breakout box installed on the ECM, EIM, ACM, and harness).pdf
EGED-475-3 - Hard Start and No Start Diagnostics MaxxForce 11 & 13 Beginning with 2010 Model Year.pdf
EGED-520-2 - Hard Start and No Start Diagnostics MaxxForce 15 Beginning with 2011 Model Year.pdf
EGED-525-1 - Engine Wiring Diagram Form Maxxforce 15 Beginning with 2011 Model Year.pdf
EGED-530-3 - Performance Diagnostics MaxxForce 11 & 13 EPA 2010.pdf
EGED-535-2 - Performance Diagnostics MaxxForce 15 Beginning with 2011 Model Year.pdf
EGES-415-2 - MaxxForce 11 and 13 Engine Service Manual (2009-05).pdf
EGES-415-2 - MaxxForce 11 and 13 Engine Service Manual (2011).pdf
EGES-415 - MaxxForce 11 and 13 Service Manual.pdf
EGES-420-2 - MaxxForce 11 and 13 Engine Diagnostic_Troubleshooting manual.pdf
EGES-420 - MaxxForce 11 and 13 Engine Diagnostic_Troubleshooting manual.pdf
EGES-465-2 - MaxxForce 11 and 13 Engine Service Manual (2011).pdf
EGES-470-1 - MaxxForce 11 and 13 Engine Diagnostic_Troubleshooting Manual (2011).pdf
EGES-470-1 - MaxxForce 11 and 13 Engine Electronic Control Systems Diagnostics.pdf
EGES-510-2 - MaxxForce 15 Diesel Engine Service Manual Model Year 2011 and Up.pdf
EGES-511 - Manuel d'entretien Et De Réparation MaxxForce 15 Moteur diesel Année modèle 2011 et plus.pdf
EGES-512 - Manual de Servicio MaxxForce 15 Motor Diesel Modelo del año 2011 y más recientes.pdf
EGES-515-1 - MaxxForce 15 Engine Diagnostic_Troubleshooting Manual.pdf
EGES-515 - MaxxForce 15 Engine Electronic Control Systems Diagnostics.pdf
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MAIN SECTIONS
0000001682 - MaxxForce 11 and 13 Engine Service Manual (2013-02)....4
Highlights....6
Safety Terminology....12
Safety Instructions....12
Work Area....12
Safety Equipment....12
Protective Measures....12
Vehicle....12
Engine....12
Fire Prevention....12
Batteries....12
Compressed Air....13
Tools....13
Fluids Under Pressure....13
Fuel....13
Removal of Tools, Parts, and Equipment....13
Table of Contents....14
Engine Identification....16
Engine Serial Number....16
Engine Serial Number Examples....16
Engine Serial Number Codes....16
Engine Emission Label ....16
Engine Accessory Labels and Identification Plates....17
Engine Specifications....17
Heavy Duty On Board Diagnostics (HD-OBD)....19
Engine Description....19
Optional Equipment....20
Chassis Mounted Equipment....20
Engine Component Locations....21
Air Management System....25
Airflow....26
Turbochargers....27
Air Control Valve (ACV)....28
Boost Control....28
Low-Pressure Charge Air Cooler (LPCAC)....28
High-Pressure Charge Air Cooler (HPCAC)....28
High-Pressure Boost Pressure (HPBP) Sensor ....29
High-Pressure Boost Temperature (HPBT) Sensor ....29
Low-Pressure Boost Pressure (LPBP) Sensor and Low-Pressure Boost Temperature (LPBT) Sensor ....29
Exhaust Gas Recirculation (EGR) System....30
EGR System Overview....31
EGR Flow....31
EGR System Control....31
EGRV Control....31
EGR ? Open Loop....32
EGR ? Closed Loop ....32
EGR Flow Cooling....32
Aftertreatment (AFT) System....33
Diesel Particulate Filter (DPF)....34
Diesel Oxidation Catalyst (DOC)....34
Aftertreatment (AFT) System Conditions and Responses....34
Downstream Fuel Injection....35
Downstream Injection (DSI) Unit....36
Hydrocarbon Injector (HCI) Assembly....36
Crankcase Oil Separator....37
Fuel Management System....39
Fuel System....39
Fuel Flow....40
Low-Pressure Fuel System....41
Chassis Mounted Filter/Water Separator....41
Fuel Primer Pump Assembly....41
Low-Pressure (LP) Fuel Pump....42
Fuel Filter Assembly....42
High-Pressure Fuel System....43
High-Pressure (HP) Pump....44
Fuel Pressure Control Valve (FPCV)....44
Fuel Rail....44
Fuel Rail Pressure (FRP) Sensor....44
Pressure Limiting Valve....44
Injectors....44
Cold Start Assist System....44
Cold Start Assist System Components....44
Cold Start Fuel Ignitor (CSFI)....44
Cold Start Relay (CSR)....45
Cold Start Solenoid (CSS) Valve....45
Cold Start Assist System Operation....45
Oil Flow and Components....46
Crankcase Oil Separator....48
Remote Mounted Centrifugal Oil Filter (Optional)....49
Engine Cooling System....50
Cooling System Flow....50
Thermostat Operation....51
Coolant Control Valve (CCV) operation....52
Coolant Flow Valve (CFV)....52
Coolant Mixer Valve (CMV)....52
Engine Brake System....53
Engine Brake Control System Components....53
Engine Brake System Operation....55
Electronic Control System....56
Electronic Control System Components....56
Operation and Function....56
Reference Voltage (VREF)....56
Signal Conditioner....56
Microprocessor....56
Diagnostic Trouble Codes....56
Microprocessor Memory....56
ROM....56
RAM....56
Actuator Control....57
Actuators....57
Coolant Control Valve (CCV)....57
Exhaust Back Pressure Valve (EBPV) Control....57
Exhaust Gas Recirculation (EGR) Valve ....57
Air Control Valve (ACV)....57
Cold Start Relay (CSR)....57
Cold Start Solenoid (CSS) Valve....58
Engine Throttle Valve (ETV)....58
Fuel Pressure Control Valve (FPCV)....58
Aftertreatment Fuel Doser (AFTFD)....58
Aftertreatment Shutoff Valve (AFTSV)....58
Engine and Vehicle Sensors....58
Thermistor Sensors....58
Aftertreatment Temperature Sensors....59
Engine Coolant Temperature (ECT) Sensors....59
Engine Oil Temperature (EOT) Sensor....59
Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....59
Charge Air Cooler Outlet Temp (CACOT) Sensor....59
Intake Manifold Temperature (IMT) Sensor....59
Exhaust Gas Recirculation Temperature (EGRT) Sensor....60
Ambient Air Temperature (AAT) Sensor....60
Variable Capacitance Sensors....60
DPF Differential Pressure (DPFDP) Sensor....60
Engine Fuel Pressure (EFP) Sensor....60
Engine Oil Pressure (EOP) Sensor....60
Fuel Rail Pressure (FRP) Sensor....60
Intake Manifold Pressure (IMP) Sensor....61
Aftertreatment Fuel Inlet (AFTFI) Sensor....61
Aftertreatment Fuel Pressure 2 (AFP2) sensor....61
Turbocharger 1 Turbine Outlet Pressure (TC1TOP)....61
Magnetic Pickup Sensors....61
Crankshaft Position (CKP) Sensor....61
Camshaft Position (CMP) Sensor....62
Vehicle Speed Sensor (VSS)....62
Crankcase Oil Separator Speed (CCOSS) sensor....62
Potentiometer Sensors....62
Accelerator Pedal Position (APP)....62
Switches....63
Driveline Disengagement Switch (DDS)....63
Engine Coolant Level (ECL) Switch....63
Oil Level Sensor (OLS)....63
Additional Sensors....63
Oxygen Sensor (O2S)....63
Humidity Sensor (HS)....63
Table of Contents....64
Mounting Engine....66
Engine Cleaning....66
Mounting Engine on Stand....66
Table of Contents....70
Electronic Component Location....72
Electronic Components ? Right Front....72
Electronic Components ? Left Rear....73
Description of Engine Sensors, Valves and Actuators....74
Crankshaft Position (CKP) Sensor....74
Camshaft Position (CMP) Sensor....74
Engine Coolant Temperature (ECT) Sensors....74
Engine Oil Temperature (EOT) Sensor....75
Engine Oil Pressure (EOP) Sensor....75
Crankcase Oil Separator Speed (CCOSS) Sensor....75
Fuel Delivery Pressure (FDP) Sensor....76
Fuel Pressure Control Valve (FPCV)....76
Mass Air Flow (MAF) Sensor....76
Humidity / Air Inlet Temperature (IAT) Sensor....77
Charge Air Cooler Outlet Temperature (CACOT) Sensor....77
Intake Manifold Pressure (IMP) Sensor....77
Fuel Rail Pressure (FRP) Sensor....78
Intake Manifold Temperature (IMT) Sensor....78
Oxygen Sensor (O2S)....78
Engine Throttle Valve (ETV)....79
Coolant Control Valve (CCV)....79
Air Control Valve (ACV) Assembly....79
Exhaust Gas Recirculation (EGR) Valve....80
Exhaust Gas Recirculation Temperature (EGRT) Sensor....80
Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....81
Removal....82
Warnings and Cautions....82
Crankshaft Position (CKP) Sensor....82
Camshaft Position (CMP) Sensor....83
Engine Coolant Temperature 1 (ECT1) Sensor....83
Engine Coolant Temperature 2 (ECT2) Sensor....83
Engine Oil Temperature (EOT) Sensor....84
Engine Oil Pressure (EOP) Sensor....84
Crankcase Oil Separator Speed (CCOSS) Sensor....85
Fuel Delivery Pressure (FDP) Sensor....85
Fuel Pressure Control Valve (FPCV)....85
Mass Air Flow (MAF) Sensor (If equipped)....86
Humidity / Intake Air Temperature (IAT) Sensor....86
Charger Air Cooler Outlet Temperature (CACOT) Sensor....87
Intake Manifold Pressure (IMP) Sensor....87
Fuel Rail Pressure (FRP) Sensor....88
Intake Manifold Temperature (IMT) Sensor....88
Oxygen Sensor (O2S)....88
Engine Throttle Valve (ETV)....89
Coolant Control Valve (CCV)....89
Air Control Valve (ACV)....90
Exhaust Gas Recirculation (EGR) Valve....90
Exhaust Gas Recirculation Temperature (EGRT) Sensor....91
Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....91
Wiring Harness ECM Connections....91
Engine Injector (Wiring) Harness....92
Engine Sensor (Wiring) Harness....94
Engine Control Module (ECM) and Support....97
Cleaning and Inspection....98
Engine Injection and Engine Sensor Wiring Harnesses....98
Sensors and Valves....98
Engine Control Module (ECM)....98
Installation....99
Engine Control Module (ECM) and Support....99
Engine Sensor (Wiring) Harness....100
Engine Injector (Wiring) Harness....103
Wiring Harness ECM Connections....105
Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....105
Exhaust Gas Recirculation Temperature (EGRT) Sensor....106
Exhaust Gas Recirculation (EGR) Valve....106
Air Control Valve (ACV)....107
Coolant Control Valve (CCV)....107
Engine Throttle Valve (ETV)....108
Oxygen Sensor (O2S)....108
Intake Manifold Temperature (IMT) Sensor....109
Fuel Rail Pressure (FRP) Sensor....109
Intake Manifold Pressure (IMP) Sensor....109
Charger Air Cooler Outlet Temperature (CACOT) Sensor....110
Humidity / Air Inlet Temperature (IAT) Sensor....110
Mass Air Flow (MAF) Sensor (If equipped)....111
Fuel Pressure Control Valve (FPCV)....111
Fuel Delivery Pressure (FDP) Sensor....111
Crankcase Oil Separator Speed (CCOSS) Sensor....112
Engine Oil Pressure (EOP) Sensor....112
Engine Oil Temperature (EOT) Sensor....113
Engine Coolant Temperature 2 (ECT2) Sensor....113
Engine Coolant Temperature 1 (ECT1) Sensor....114
Camshaft Position (CMP) Sensor....114
Crankshaft Position (CKP) Sensor....114
Table of Contents....116
Exploded View....118
Cold Start Assist Components....118
Removal....119
Relay Assembly....119
Glow Plug and Fuel Supply Cold Start Hose....120
Fuel Supply Solenoid Hose....120
Glow Plug....121
Installation....122
Glow Plug....122
Fuel Supply Solenoid Hose....123
Glow Plug and Fuel Supply Cold Start Hose....124
Relay Assembly....125
Table of Contents....128
Illustrations....130
Catalyst and Aftertreatment System Fuel Supply Components....130
Removal....133
Supply Fuel After Filter Hose and Tubes....133
Metering Unit Valve Assembly....135
Pre-Diesel Oxidation (PDOC) Catalyst....137
HCI Coolant Supply Tube Assembly....138
HCI Coolant Return Tube Assembly ....139
Hydrocarbon Injector (HCI) Assembly ....140
Cleaning and Inspection....140
Hydrocarbon Injector Cleaning....140
Installation....141
Metering Unit Valve Assembly....141
Hydrocarbon Injector (HCI) Assembly....142
HCI Coolant Return Tube Assembly....143
HCI Coolant Supply Tube Assembly....144
Pre-Diesel Oxidation (PDOC) Catalyst....144
HCI Fuel Tube Assembly ....145
Table of Contents....148
Exploded Views....150
Control System....150
Removal....151
Warnings....151
Air Control Valve (ACV)....152
Exhaust Back Pressure Valve Actuator and TC1 Turbine Outlet Pressure Sensor Tubes....153
Exhaust Back Pressure Valve Assembly....154
Installation....154
Exhaust Back Pressure Valve Assembly....154
Air Control Valve (ACV)....155
Exhaust Back Pressure Valve Actuator and TC1 Turbine Outlet Pressure Sensor Tubes....156
Table of Contents....160
Exploded Views....162
Turbochargers and Charge Air Cooler Assembly....162
Coolant Tube, Coolant Hoses and Low-pressure Charge Air Cooler (LPCAC)....163
Turbocharger Oil Supply Tube and Support Bracket....164
Turbocharger Oil Return Tubes....165
Air Inlets, Wastegate High-Pressure Actuator, and Air Control Valve....166
Turbochargers....167
Removal....168
High-pressure (HP) Wastegate Hose....168
Low-pressure Charge Air Cooler (LPCAC)....169
Low-pressure Charge Air Cooler (LPCAC) Coolant Tube and Hoses....170
High-pressure (HP) Compressor Out Duct and Air Inlet Duct....172
High-pressure Turbocharger Air Supply Duct....172
Turbocharger Oil Return and Oil Supply Tubes....173
Turbocharger Heat Shields....174
Turbocharger Support Bracket....175
High-pressure (HP) Turbocharger Wastegate Actuator....175
Turbocharger Mounting....176
Disassembly....177
Turbochargers....177
Cleaning and Inspection....178
Turbochargers and Related Parts Cleaning....178
Turbocharger Inspection....178
Low-pressure Charge Air Cooler (LPCAC) Pressure Test....178
Installation....180
Turbocharger Mounting....180
Turbocharger Support Bracket....182
High-pressure (HP) Turbocharger Wastegate Actuator....182
Turbocharger Heat Shields....183
Turbocharger Oil Return and Oil Supply Tubes....183
High-pressure Turbocharger Air Supply Duct....185
High-pressure (HP) Compressor Out Duct and Air Inlet Duct....185
Low-pressure Charge Air Cooler (LPCAC) Coolant Tube and Hoses....186
Low-pressure Charge Air Cooler (LPCAC)....188
High-pressure (HP) Wastegate Hose....189
Table of Contents....192
Exploded Views....194
Power Steering and One-Cylinder Air Compressor....194
Power Steering and Two-Cylinder Air Compressor....195
Removal....196
Power Steering Pressure Tubes....196
Power Steering Elbows....197
Power Steering Pump....198
Air Compressor Coolant Hoses....198
Air Compressor....199
Cleaning....199
All components....199
Installation....200
Air Compressor ....200
Air Compressor Coolant Hoses....200
Power Steering Pump....201
Power Steering Elbows....202
Power Steering Pressure Tubes....202
Table of Contents....206
Exploded Views....208
High-pressure Fuel Lines....208
Fuel Supply and Drain (Return) Lines....209
Fuel Filter Housing Assembly....210
High-pressure Fuel Pump and Drive Housing....211
Removal....212
High-pressure Fuel Lines....213
Injector and Fuel Drain (Return) Lines....215
Fuel Rail Assembly....216
Fuel Primer Pump Assembly....216
Fuel Supply and Drain (Return) Lines....217
Fuel Primer Pump Assembly....219
Fuel Filter Housing Assembly....220
Fuel Filter Stand Pipe Replacement....220
High-pressure Pump (Drive Belt) Pulley....221
High-pressure Pump (Drive Belt) Pulley Housing and Radial Shaft Seal....222
High-pressure Fuel Pump (HPFP) and Drive Housing....222
Fuel Injectors....225
Cleaning and Inspection....228
Low-pressure and High-pressure Fuel System Components....228
Fuel Injector Bore....228
Fuel Injector Harness....228
Installation....229
Fuel Injectors....229
High-pressure Fuel Pump (HPFP) and Drive Housing....233
High-Pressure Pump (Drive Belt) Pulley Housing and Radial Shaft Seal....235
High-Pressure Pump (Drive Belt) Pulley....236
Fuel Filter Housing Assembly....236
Fuel Primer Pump Assembly....237
Fuel Supply and Drain (Return) Lines....238
Fuel Rail Assembly....240
Injector and Fuel Drain (Return) Lines....241
High-pressure Fuel Lines....241
Filter and Fuel Strainer Element....244
Fuel System Priming....244
Fuel System Priming Tool Method....244
Hand Primer Pump Method....249
Table of Contents....254
Exploded Views....256
Oil Module Assembly....256
Oil Module....257
Removal....258
Oil Filter Cover and Filter....258
Oil Centrifuge....259
Oil Module Assembly....260
Oil Cooler....262
Oil Pressure Relief Valve....262
Cleaning, Inspection and Testing....263
Oil Cooler....263
Oil Cooler Leak Test....263
Extension Tubes....263
Oil Centrifuge....263
Installation....264
Oil Pressure Relief Valve....264
Oil Cooler....264
Oil Module Assembly....265
Oil Centrifuge....267
Oil Filter Cover and Filter....267
Table of Contents....270
Exploded Views....272
EGR Coolant Manifold and Elbow....272
Removal....277
Coolant Manifold....277
Coolant Elbow ....278
EGR Cooler Bracket....278
EGR Outlet Tubes....279
EGR Module Cover....279
Heat Protection (Cylinders 4-6) Shield....280
EGR Inlet Tubes....280
Heat Protection EGR Shield....281
EGR Dual Flap Valve....281
EGR Cooler Assembly....283
Disassembly and Assembly of EGR Cooler....284
EGR Cooler High-Temperature or Low-Temperature Side Replacement....284
Cleaning, Inspection and Testing....290
EGR System Components Cleaning....290
EGR Cooler Assembly Cleaning....290
EGR Cooler Assembly Leak Test....297
Installation....298
EGR Cooler Assembly....298
EGR Dual Flap Valve....298
Heat Protection EGR Shield....300
EGR Inlet Tubes....300
Heat Protection (Cylinders 4-6) Shield....301
EGR Module Cover....302
EGR Outlet Tubes....302
EGR Cooler Bracket....303
Coolant Elbow....303
Coolant Manifold....304
Table of Contents....306
Exploded Views....308
Exhaust Manifold....308
Air Intake Throttle Horizontal Duct....309
Air Intake Throttle Vertical Duct....310
Removal....311
Exhaust Manifold....311
Air Intake Throttle Duct....312
Cleaning, Inspection and Testing....313
Air Intake Throttle Duct and Exhaust Manifolds....313
Manifold Warp Test for Exhaust Manifolds....313
Installation....315
Air Intake Throttle Duct....315
Exhaust Manifold....315
Table of Contents....320
Exploded Views....322
High Mount Fan Drive System and Vibration Damper....322
Accessory Drive System (Typical)....323
Thermostat Assembly and Coolant Outlet Manifold (Low Mount Fan)....324
Thermostat Assembly and Coolant Outlet Manifold (High Mount Fan)....325
Water Pump Assembly, Coolant Control Valve (CCV), Water Distribution Housing, Thermostat Housing and EGR Cooler Return Manifold....326
Front Belt-Driven Fan Cover (High Mount Fan)....327
Front Gear-driven Fan Cover (Low Mount Fan)....328
Fan Low Mount Drive (Typical)....329
Removal....330
Pulley (High Mount Fan)....330
Tensioner Bracket (High Mount Fan)....331
High Mount Fan Drive....331
Coolant Outlet Manifold and Thermostat Assembly....332
Automatic Belt Tensioner and Idler Pulleys....333
Water Pump Assembly and Pulley....333
Vibration Damper....334
Coolant Control Valve (CCV) Assembly....335
Thermostat Housing....335
Water Distribution Housing....336
Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal....337
Front Belt- or Gear-Driven Fan Cover....337
Radial Shaft Seal (Fan Low Mount Drive)....338
Fan Low Mount Drive Assembly....338
Cleaning, Inspection and Testing....339
Installation....340
Fan Low Mount Drive Assembly....340
Radial Shaft Seal (Fan Low Mount Drive)....340
Front Belt- or Gear-Driven Fan Cover....341
Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal....341
Water Distribution Housing....342
Thermostat Housing....342
Coolant Control Valve (CCV) Assembly....343
Vibration Damper....344
Water Pump Assembly and Pulley....345
Automatic Belt Tensioner and Idler Pulley....345
Coolant Outlet Manifold and Thermostat Assembly....346
High Mount Fan Drive....347
Tensioner Bracket (High Mount Fan)....348
Pulley (High Mount Fan)....348
Table of Contents....350
Exploded Views....352
MaxxForce? Engine Brake Housing Assembly....353
Engine Injector Wiring Harness With Engine Brake Solenoid Leads....354
Removal....355
Engine Brake Housing Assembly....355
Disassembly....355
Solenoid....356
Control Valve....356
Master Piston....357
Slave Piston....357
Cleaning and Inspection....359
Solenoid Assembly Check....359
Assembly....360
Slave Piston....360
Master Piston....361
Control Valve....362
Solenoid....362
Installation....363
Engine Brake Housing Assembly....363
Engine Brake Lash Adjustment....364
Table of Contents....366
Exploded Views....368
Valve Cover and Base....368
Non-Brake Rocker Arm Assembly And Valve Bridges....369
Camshaft and Cylinder Head Idler Gear....370
Cylinder Head....371
Periodic Service....372
Crankshaft Rotation Procedure....372
Cylinder No. 1 TDC Procedure....372
Valve Overlap Procedure....373
Valve Lash Adjustment Procedure....373
Removal....376
Upper Valve Cover and Base....376
Rocker Arm Assembly (Non-Brake Engine)....377
Camshaft....378
Cylinder Head....381
Cylinder Head Idler Gear....383
Cleaning, Inspection, and Testing....385
Cylinder Head and Crankcase Components....385
Camshaft Bearings....385
Fuel Injector Bore....386
Valves Leak Test....386
Installation....388
Cylinder Head Idler Gear....388
Cylinder Head....388
Camshaft....392
Rocker Arm Assembly (Non-Brake Engine)....394
Upper Valve Cover and Base....395
Table of Contents....400
Exploded Views....402
Flywheel Housing and Flywheel (Manual Transmission)....402
Flywheel and flexplate assembly (automatic transmission)....403
Rear Engine Mounts....404
Removal....405
Preliminary Checks and Measurements....405
Flywheel Assembly (Manual Transmission)....405
Flywheel Surface Runout....405
Pilot Bearing....406
Flywheel (Manual Transmission)....406
Flywheel and Flexplate Assembly (Automatic Transmission)....407
Radial Shaft Ring Seal....407
Lifting Eyes....408
Flywheel Housing....408
Cleaning and Inspection....410
All Components....410
Flywheel and Flexplate Assemblies....410
Recondition....410
Flywheel....410
Installation....412
Flywheel Housing....412
Lifting Eyes....413
Radial Shaft Ring Seal....414
Flywheel Assembly (Manual Transmission)....414
Pilot Bearing (Flywheel)....415
Flywheel and Flexplate Assembly (Automatic Transmission)....415
Table of Contents....418
Exploded Views....420
Oil Pan (Front Sump Shown, Rear Sump Similar, Typical)....420
Oil Pickup Tube - Front Sump (Typical)....421
Removal....422
Oil Pan....422
Oil Pickup Tube ? Front Sump....423
Oil Recovery....424
Oil Pickup Tube ? Rear Sump....425
Cleaning and Inspection....426
Oil Pan....426
Oil Pickup Tube....426
Installation....427
Oil Pickup Tube ? Front Sump....427
Oil Pickup Tube ? Rear Sump....427
Oil Recovery....428
Oil Pan....431
Table of Contents....434
Exploded Views....436
Oil Pump....436
Front Timing Gears (Typical)....437
Rear Timing Gears....438
Removal....439
Preliminary Checks....439
Oil Pump....440
Front Crank Gears....441
Rear Timing Gears....442
Cleaning and Inspection....444
Timing Gears....444
Oil Pump....444
Installation....445
Rear Timing Gears....445
Front Timing Gears....447
Oil Pump....447
Table of Contents....450
Exploded Views....452
Piston and Connecting Rod (Typical) and Cylinder Sleeve....452
Removal....454
Preliminary Checks....454
Piston and Connecting Rod....455
Piston Disassembly....456
Cylinder Sleeves....457
Cleaning and Inspection....458
Cleaning....458
Piston Inspection....458
Piston Ring Inspection....459
Connecting Rod Inspection....459
Connecting Rod Bore Check....460
Piston Pin Inspection....461
Cylinder Sleeve Inspection....461
Installation....463
Cylinder Sleeves....463
Piston Assembly....463
Piston and Connecting Rod....464
Engine Run-in Procedure....466
Table of Contents....470
Exploded View....472
Crankcase and Crankshaft....472
Removal....473
Preliminary Checks....474
Crankshaft....474
Piston Cooling Jets....475
Cleaning, Inspection and Testing....476
Crankcase....476
Crankshaft Measurement....476
Main Bearings Measurement....477
Piston Cooling Jets....478
Installation....479
Piston Cooling Jets....479
Crankshaft....479
Table of Contents....484
Abbreviations and Acronyms....486
Abbreviations and Acronyms....486
Table of Contents....490
Terminology....492
Terms....492
Table of Contents....502
Fuel System....504
Air Inlet Duct and Exhaust Manifolds....504
Engine Brake....504
Cylinder Head, Camshaft and Valve Train....504
Flywheel and Flywheel Housing....504
Oil Pump, Low Mount Fan Drive, and Timing Gears....505
Power Cylinders....505
Crankcase and Crankshaft....507
Table of Contents....508
General Torque....510
Bolt Identification....510
General Torque Guidelines....511
Standard Torque Charts....512
Using a Torque Wrench Extension....513
Special Torques....514
Mounting Engine on Stand....514
Engine Electrical....514
Cold Start Assist....515
Aftertreatment System....515
Exhaust Back Pressure Control....516
Turbochargers....516
Air Compressor and Power Steering/Fuel Pump....517
Fuel System....518
Oil Module Assembly....519
Exhaust Gas Recirculation (EGR) System....519
Air Inlet Duct and Exhaust Manifolds....520
Front Cover, High Mount Fan Drive, Cooling System, Related Components....520
Engine Brake....521
Cylinder Head, Camshaft and Valve Train....522
Flywheel and Flywheel Housing....523
Oil Pan and Oil Suction Tube....524
Oil Pump and Timing Gears....524
Power Cylinders....524
Crankcase and Crankshaft....525
Table of Contents....526
Special Tools....528
Contact Information....528
Mounting Engine on Stand....528
Engine Electrical....528
Aftertreatment System....528
Exhaust Back Pressure Control....528
Turbochargers....529
Air Compressor and Power Steering....529
Fuel System....530
Oil Cooler, Filter Housing and Crankcase Ventilation....530
Exhaust Gas Recirculation (EGR) System....531
Air Inlet Throttle Duct and Exhaust Manifold....531
Front Cover, Fan Drive, Cooling System and Related Components....531
MaxxForce Engine Brake by Jacobs....531
Cylinder Head, Camshaft and Valve Train....532
Flywheel and Flywheel Housing....532
Oil Pump, Fan Drive and Timing Gears....533
Power Cylinders....533
Crankcase and Crankshaft....533
Special Tools ....534
Essential Tools....534
tables....6
Summary of Changes....6
MaxxForce? 11 and 13 Diesel Engines....17
Mounting Engine on Stand....69
Mounting Engine on Stand....69
Engine Electrical....115
Engine Electrical....115
Cold Start Assist....126
Aftertreatment System....147
Aftertreatment System....147
Exhaust Back Pressure Control....159
Exhaust Back Pressure Control....159
Turbochargers....190
Turbochargers....190
Air Compressor and Power Steering/Fuel Pump....204
Air Compressor....204
Fuel System....251
Fuel System....252
Fuel System....253
Oil Module Assembly....269
Oil Cooler....269
EGR System....305
EGR System....305
Exhaust Manifolds....318
Air Intake Throttle Duct and Exhaust Manifolds....318
Air Intake Throttle Duct and Exhaust Manifolds....318
Front Cover, Fan Drive, Cooling System and Related Components....349
Front Cover, Fan Drive, Cooling System and Related Components....349
Engine Brake....365
Engine Brake....365
Engine Brake....365
Cylinder Head, Camshaft and Valve Train....397
Cylinder Head, Camshaft and Valve Train....397
Cylinder Head, Camshaft and Valve Train....398
Flywheel and Flywheel Housing....417
Flywheel and Flywheel Housing....417
Flywheel and Flywheel Housing....417
Oil Pan Components....433
Oil Pump and Timing Gears....449
Oil Pump and Timing Gears....449
Oil Pump and Timing Gears....449
Power Cylinders....467
Power Cylinders....468
Power Cylinders....468
Crankcase and Crankshaft....482
Crankcase and Crankshaft....482
Crankcase and Crankshaft....482
Fuel System....504
Exhaust Manifolds....504
Engine Brake....504
Cylinder Head, Camshaft and Valve Train....504
Flywheel and Flywheel Housing....504
Oil Pump, Low Mount Fan Drive, and Timing Gears....505
Power Cylinders....505
Crankcase and Crankshaft....507
Standard Torque Values - Class 10.9 Metric Flange Head Bolts and Studs....512
Thread Diameter (mm)....512
Thread Pitch (mm)....512
Torque....512
Mounting Engine on Stand....514
Engine Electrical....514
Cold Start Assist....515
Aftertreatment System....515
Exhaust Back Pressure Control....516
Turbochargers....516
Air Compressor and Power Steering/Fuel Pump....517
Fuel System....518
Oil Module Assembly....519
EGR System....519
Air Intake Throttle Duct and Exhaust Manifolds....520
Front Cover, Fan Drive, Cooling System and Related Components....521
Engine Brake....521
Cylinder Head, Camshaft and Valve Train....522
Flywheel and Flywheel Housing....523
Oil Pan Components....524
Oil Pump and Timing Gears....524
Power Cylinders....524
Crankcase and Crankshaft....525
Mounting Engine on Stand....528
Engine Electrical....528
Aftertreatment System....528
Exhaust Back Pressure Control....528
Turbochargers....529
Air Compressor and Power Steering....529
Fuel System....530
Oil Cooler, Filter Housing and Crankcase Ventilation....530
EGR System....531
Air Inlet Throttle Duct and Exhaust Manifold....531
Front Cover, Fan Drive, Cooling System and Related Components....531
MaxxForce Engine Brake by Jacobs....531
Cylinder Head, Camshaft and Valve Train....532
Flywheel and Flywheel Housing....532
Oil Pump, Fan Drive and Timing Gears....533
Power Cylinders....533
Crankcase and Crankshaft....533
0000001682 - MaxxForce 11 and 13 Engine Service Manual (2014-03)....543
toc....545
Summary of Changes....545
Safety Terminology....551
Safety Instructions....551
Work Area....551
Safety Equipment....551
Protective Measures....551
Vehicle....551
Engine....551
Fire Prevention....551
Batteries....551
Compressed Air....552
Tools....552
Fluids Under Pressure....552
Fuel....552
Removal of Tools, Parts, and Equipment....552
Table of Contents....553
Engine Identification....555
Engine Serial Number....555
Engine Serial Number Examples....555
Engine Serial Number Codes....555
Engine Emission Label ....555
Engine Accessory Labels and Identification Plates....556
Engine Specifications....556
Heavy Duty On Board Diagnostics (HD-OBD)....558
Engine Description....558
Optional Equipment....559
Chassis Mounted Equipment....559
Engine Component Locations....560
Air Management System....564
Airflow....565
Turbochargers....566
Air Control Valve (ACV)....567
Boost Control....567
Low-Pressure Charge Air Cooler (LPCAC)....567
High-Pressure Charge Air Cooler (HPCAC)....567
High-Pressure Boost Pressure (HPBP) Sensor ....568
High-Pressure Boost Temperature (HPBT) Sensor ....568
Low-Pressure Boost Pressure (LPBP) Sensor and Low-Pressure Boost Temperature (LPBT) Sensor ....568
Exhaust Gas Recirculation (EGR) System....569
EGR System Overview....570
EGR Flow....570
EGR System Control....570
EGRV Control....570
EGR ? Open Loop....571
EGR ? Closed Loop ....571
EGR Flow Cooling....571
Aftertreatment (AFT) System....572
Diesel Particulate Filter (DPF)....573
Diesel Oxidation Catalyst (DOC)....573
Aftertreatment (AFT) System Conditions and Responses....573
Downstream Fuel Injection....574
Downstream Injection (DSI) Unit....575
Hydrocarbon Injector (HCI) Assembly....575
Crankcase Oil Separator....576
Fuel Management System....578
Fuel System....578
Fuel Flow....579
Low-Pressure Fuel System....580
Chassis Mounted Filter/Water Separator....580
Fuel Primer Pump Assembly....580
Low-Pressure (LP) Fuel Pump....581
Fuel Filter Assembly....581
High-Pressure Fuel System....582
High-Pressure (HP) Pump....583
Fuel Pressure Control Valve (FPCV)....583
Fuel Rail....583
Fuel Rail Pressure (FRP) Sensor....583
Pressure Limiting Valve....583
Injectors....583
Inlet Air Heater System....583
Inlet Air Heater System Components....583
Inlet Air Heater Fuel Igniter (IAHFI)....583
Inlet Air Heater Relay (IAHR)....584
Inlet Air Heater Fuel Solenoid (IAHFS) Valve....584
Inlet Air Heater System Operation....584
Oil Flow and Components....585
Crankcase Oil Separator....587
Remote Mounted Centrifugal Oil Filter (Optional)....588
Engine Cooling System....589
Cooling System Flow....589
Thermostat Operation....590
Coolant Control Valve (CCV) operation....591
Coolant Flow Valve (CFV)....591
Coolant Mixer Valve (CMV)....591
Engine Brake System....592
Engine Brake Control System Components....592
Engine Brake System Operation....594
Electronic Control System....595
Electronic Control System Components....595
Operation and Function....595
Reference Voltage (VREF)....595
Signal Conditioner....595
Microprocessor....595
Diagnostic Trouble Codes....595
Microprocessor Memory....595
ROM....595
RAM....595
Actuator Control....596
Actuators....596
Coolant Control Valve (CCV)....596
Exhaust Back Pressure Valve (EBPV) Control....596
Exhaust Gas Recirculation (EGR) Valve ....596
Air Control Valve (ACV)....596
Inlet Air Heater Relay (IAHR)....596
Inlet Air Heater Fuel Solenoid (IAHFS) Valve....597
Engine Throttle Valve (ETV)....597
Fuel Pressure Control Valve (FPCV)....597
Aftertreatment Fuel Doser (AFTFD)....597
Aftertreatment Shutoff Valve (AFTSV)....597
Engine and Vehicle Sensors....597
Thermistor Sensors....597
Aftertreatment Temperature Sensors....598
Engine Coolant Temperature (ECT) Sensors....598
Engine Oil Temperature (EOT) Sensor....598
Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....598
Charge Air Cooler Outlet Temp (CACOT) Sensor....598
Intake Manifold Temperature (IMT) Sensor....598
Exhaust Gas Recirculation Temperature (EGRT) Sensor....599
Ambient Air Temperature (AAT) Sensor....599
Variable Capacitance Sensors....599
DPF Differential Pressure (DPFDP) Sensor....599
Engine Fuel Pressure (EFP) Sensor....599
Engine Oil Pressure (EOP) Sensor....599
Fuel Rail Pressure (FRP) Sensor....599
Intake Manifold Pressure (IMP) Sensor....600
Aftertreatment Fuel Inlet (AFTFI) Sensor....600
Aftertreatment Fuel Pressure 2 (AFP2) sensor....600
Turbocharger 1 Turbine Outlet Pressure (TC1TOP)....600
Magnetic Pickup Sensors....600
Crankshaft Position (CKP) Sensor....600
Camshaft Position (CMP) Sensor....601
Vehicle Speed Sensor (VSS)....601
Crankcase Oil Separator Speed (CCOSS) sensor....601
Potentiometer Sensors....601
Accelerator Pedal Position (APP)....601
Switches....602
Driveline Disengagement Switch (DDS)....602
Engine Coolant Level (ECL) Switch....602
Oil Level Sensor (OLS)....602
Additional Sensors....603
Oxygen Sensor (O2S)....603
Humidity Sensor (HS)....603
Table of Contents....605
Mounting Engine....607
Engine Cleaning....607
Mounting Engine on Stand....607
Table of Contents....613
Electronic Component Location....615
Electronic Components ? Right Front....615
Electronic Components ? Left Rear....616
Description of Engine Sensors, Valves and Actuators....617
Crankshaft Position (CKP) Sensor....617
Camshaft Position (CMP) Sensor....617
Engine Coolant Temperature (ECT) Sensors....617
Engine Oil Temperature (EOT) Sensor....618
Engine Oil Pressure (EOP) Sensor....618
Crankcase Oil Separator Speed (CCOSS) Sensor....618
Fuel Delivery Pressure (FDP) Sensor....619
Fuel Pressure Control Valve (FPCV)....619
Mass Air Flow (MAF) Sensor....619
Humidity / Inlet Air Temperature (IAT) Sensor....620
Charge Air Cooler Outlet Temperature (CACOT) Sensor....620
Intake Manifold Pressure (IMP) Sensor....620
Fuel Rail Pressure (FRP) Sensor....621
Intake Manifold Temperature (IMT) Sensor....621
Oxygen Sensor (O2S)....621
Engine Throttle Valve (ETV)....622
Coolant Control Valve (CCV)....622
Air Control Valve (ACV) Assembly....622
Exhaust Gas Recirculation (EGR) Valve....623
Exhaust Gas Recirculation Temperature (EGRT) Sensor....623
Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....624
Removal....625
Warnings and Cautions....625
Crankshaft Position (CKP) Sensor....625
Camshaft Position (CMP) Sensor....626
Engine Coolant Temperature 1 (ECT1) Sensor....626
Engine Coolant Temperature 2 (ECT2) Sensor....626
Engine Oil Temperature (EOT) Sensor....627
Engine Oil Pressure (EOP) Sensor....627
Crankcase Oil Separator Speed (CCOSS) Sensor....628
Fuel Delivery Pressure (FDP) Sensor....628
Fuel Pressure Control Valve (FPCV)....628
Mass Air Flow (MAF) Sensor (If equipped)....629
Humidity / Intake Air Temperature (IAT) Sensor....629
Charger Air Cooler Outlet Temperature (CACOT) Sensor....630
Intake Manifold Pressure (IMP) Sensor....630
Fuel Rail Pressure (FRP) Sensor....631
Intake Manifold Temperature (IMT) Sensor....631
Oxygen Sensor (O2S)....631
Engine Throttle Valve (ETV)....632
Coolant Control Valve (CCV)....632
Air Control Valve (ACV)....633
Exhaust Gas Recirculation (EGR) Valve....633
Exhaust Gas Recirculation Temperature (EGRT) Sensor....634
Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....634
Wiring Harness ECM Connections....634
Engine Injector (Wiring) Harness....635
Engine Sensor (Wiring) Harness....637
Engine Control Module (ECM) and Support....640
Cleaning and Inspection....641
Engine Injection and Engine Sensor Wiring Harnesses....641
Sensors and Valves....641
Engine Control Module (ECM)....641
Installation....642
Engine Control Module (ECM) and Support....642
Engine Sensor (Wiring) Harness....643
Engine Injector (Wiring) Harness....646
Wiring Harness ECM Connections....648
Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....648
Exhaust Gas Recirculation Temperature (EGRT) Sensor....649
Exhaust Gas Recirculation (EGR) Valve....649
Air Control Valve (ACV)....650
Coolant Control Valve (CCV)....650
Engine Throttle Valve (ETV)....651
Oxygen Sensor (O2S)....651
Intake Manifold Temperature (IMT) Sensor....652
Fuel Rail Pressure (FRP) Sensor....652
Intake Manifold Pressure (IMP) Sensor....652
Charger Air Cooler Outlet Temperature (CACOT) Sensor....653
Humidity / Inlet Air Temperature (IAT) Sensor....653
Mass Air Flow (MAF) Sensor (If equipped)....654
Fuel Pressure Control Valve (FPCV)....654
Fuel Delivery Pressure (FDP) Sensor....654
Crankcase Oil Separator Speed (CCOSS) Sensor....655
Engine Oil Pressure (EOP) Sensor....655
Engine Oil Temperature (EOT) Sensor....656
Engine Coolant Temperature 2 (ECT2) Sensor....656
Engine Coolant Temperature 1 (ECT1) Sensor....657
Camshaft Position (CMP) Sensor....657
Crankshaft Position (CKP) Sensor....658
Table of Contents....661
Exploded View....663
Inlet Air Heater Components....663
Removal....664
Relay Assembly....664
Inlet Air Heater Fuel Igniter (IAHFI) and Fuel Supply Inlet Air Heater Hose....665
Fuel Solenoid Valve and Fuel Supply Solenoid Hose....666
Installation....668
Fuel Solenoid Valve and Fuel Supply Solenoid Hose....668
Inlet Air Heater Fuel Igniter (IAHFI) and Fuel Supply Inlet Air Heater Hose....670
Relay Assembly....671
Table of Contents....673
Illustrations....675
Catalyst and Aftertreatment System Fuel Supply Components....675
Removal....678
Supply Fuel After Filter Hose and Tubes....678
Downstream Injection (DSI) Unit....681
Pre-Diesel Oxidation Catalyst (PDOC)....682
HCI Coolant Supply Tube Assembly....683
HCI Coolant Return Tube Assembly ....684
Hydrocarbon Injector (HCI) / Aftertreatment Fuel Injector (AFI) Assembly....685
Cleaning and Inspection....687
Hydrocarbon Injector (HCI) / Aftertreatment Fuel Injector (AFI) Cleaning....687
Exhaust Back Pressure Valve Housing Cleaning....687
Installation....688
Downstream Injection (DSI) Unit....688
Hydrocarbon Injector (HCI) / Aftertreatment Fuel Injector (AFI) Assembly....689
HCI Coolant Return Tube Assembly....691
HCI Coolant Supply Tube Assembly....691
Pre-Diesel Oxidation Catalyst (PDOC) ....692
HCI Fuel Tube Assembly ....693
Table of Contents....697
Exploded Views....699
Control System....699
Removal....700
Warnings....700
Air Control Valve (ACV)....701
Exhaust Back Pressure Valve Actuator and TC1 Turbine Outlet Pressure Sensor Tubes....702
Exhaust Back Pressure Valve Assembly....703
Installation....704
Exhaust Back Pressure Valve Assembly....704
Air Control Valve (ACV)....705
Exhaust Back Pressure Valve Actuator and TC1 Turbine Outlet Pressure Sensor Tubes....706
Table of Contents....711
Exploded Views....713
Turbochargers and Charge Air Cooler Assembly....713
Coolant Tube, Coolant Hoses and Low-Pressure Charge Air Cooler (LPCAC)....714
Turbocharger Oil Supply Tube and Support Bracket....715
Turbocharger Oil Return Tubes....716
Air Inlets, Wastegate High-Pressure Actuator, and Air Control Valve....717
Turbochargers....718
Individual Component Removal....719
Overview....719
High-Pressure (HP) Turbocharger Center Section....720
Overview....720
Removal (Complete Engine Teardown)....725
High-Pressure (HP) Wastegate Hose....725
Low-Pressure Charge Air Cooler (LPCAC)....726
Low-Pressure Charge Air Cooler (LPCAC) Coolant Tube and Hoses....727
High-Pressure (HP) Compressor Out Duct and Air Inlet Duct....729
High-Pressure Turbocharger Air Supply Duct....729
Turbocharger Oil Return and Oil Supply Tubes....730
Overview....730
Turbocharger Heat Shields....732
Turbocharger Support Bracket....732
High-Pressure (HP) Turbocharger Wastegate Actuator....733
Turbocharger Mounting....733
Disassembly....735
Turbochargers....735
Cleaning, Inspection, and Testing....736
Turbochargers and Related Parts Cleaning....736
High-Pressure (HP) Turbocharger Turbine Housing Cleaning....736
Turbocharger Inspection....736
Low-Pressure Charge Air Cooler (LPCAC) Pressure Test ? correction....737
High-Pressure Charge Air Cooler (HPCAC) Pressure Test....738
High-Pressure Charge Air Cooler (HPCAC) Cleaning....742
Back-Flush With Water and EGR Cleaning Fluid:....745
Forward-Flush With Water and EGR Cleaning Fluid:....746
Back-Flush With Water:....746
Forward-Flush With Water:....746
Installation....748
Turbocharger Mounting....748
Turbocharger Support Bracket....750
High-Pressure (HP) Turbocharger Wastegate Actuator....751
Turbocharger Heat Shields....751
Turbocharger Oil Return and Oil Supply Tubes....752
Overview....752
High-Pressure Turbocharger Air Supply Duct....754
High-Pressure (HP) Compressor Out Duct and Air Inlet Duct....754
Low-Pressure Charge Air Cooler (LPCAC) Coolant Tube and Hoses....755
Low-Pressure Charge Air Cooler (LPCAC)....757
High-Pressure (HP) Wastegate Hose....758
Table of Contents....761
Exploded Views....763
Power Steering and One-Cylinder Air Compressor....763
Power Steering and Two-Cylinder Air Compressor....764
Removal....765
Power Steering Pressure Tubes....765
Power Steering Elbows....766
Power Steering Pump....767
Air Compressor Coolant Hoses....767
Air Compressor....768
Cleaning....768
All components....768
Installation....769
Air Compressor ....769
Air Compressor Coolant Hoses....769
Power Steering Pump....770
Power Steering Elbows....771
Power Steering Pressure Tubes....771
Table of Contents....775
Exploded Views....777
High-pressure Fuel Lines....777
Fuel Supply and Drain (Return) Lines....778
Fuel Filter Housing Assembly....779
High-pressure Fuel Pump and Drive Housing....780
Removal....781
High-pressure Fuel Lines....782
Injector and Fuel Drain (Return) Lines....784
Fuel Rail Assembly....784
Fuel Primer Pump Assembly....785
Fuel Supply and Drain (Return) Lines....785
Fuel Primer Pump Assembly....788
Fuel Filter Housing Assembly....788
Fuel Filter Stand Pipe Replacement....789
Radial Shaft Seal....790
Fuel Pressure Control Valve (FPCV)....791
Piston Overflow Valve (KUEV)....791
High-pressure Fuel Pump (HPFP) and Drive Housing....792
Fuel Injectors....797
Cleaning and Inspection....800
Low-pressure and High-pressure Fuel System Components....800
Fuel Injector Bore....800
Fuel Injector Harness....800
Installation....801
Fuel Injectors....801
High-Pressure Fuel Pump (HPFP) and Drive Housing....806
Radial Shaft Seal....810
Piston Overflow Valve (KUEV)....811
Fuel Pressure Control Valve (FPCV)....811
Fuel Filter Housing Assembly....812
Fuel Primer Pump Assembly....813
Fuel Supply and Drain (Return) Lines....813
Fuel Rail Assembly....816
Injector and Fuel Drain (Return) Lines....816
High-pressure Fuel Lines....817
Filter and Fuel Strainer Element....819
Fuel System Priming....819
Fuel System Priming Tool Method....819
Hand Primer Pump Method....824
Table of Contents....829
Exploded Views....831
Oil Module Assembly....831
Oil Module....832
Removal....833
Oil Filter Cover and Filter....833
Oil Centrifuge....834
Oil Module Assembly....835
Oil Cooler....837
Oil Pressure Relief Valve....838
Cleaning, Inspection and Testing....839
Oil Cooler....839
Oil Cooler Leak Test....839
Extension Tubes....839
Oil Centrifuge....839
Installation....840
Oil Pressure Relief Valve....840
Oil Cooler....840
Oil Module Assembly....841
Oil Centrifuge....843
Oil Filter Cover and Filter....843
Table of Contents....847
Exploded Views....849
EGR Coolant Manifold and Elbow....849
Removal....854
Coolant Manifold....854
Coolant Elbow ....855
EGR Cooler Bracket....855
EGR Outlet Tubes....856
EGR Module Cover....856
Heat Protection (Cylinders 4-6) Shield....857
EGR Inlet Tubes....857
Heat Protection EGR Shield....858
EGR Dual Flap Valve....859
EGR Cooler Assembly....860
Disassembly and Assembly of EGR Cooler....861
EGR Cooler High-Temperature or Low-Temperature Side Replacement....861
Cleaning, Inspection and Testing....867
EGR System Components Cleaning....867
EGR Cooler Assembly Cleaning....867
EGR Cooler Assembly Leak Test....874
Installation....875
EGR Cooler Assembly....875
EGR Dual Flap Valve....875
Heat Protection EGR Shield....877
EGR Inlet Tubes....877
Heat Protection (Cylinders 4-6) Shield....878
EGR Module Cover....879
EGR Outlet Tubes....879
EGR Cooler Bracket....880
Coolant Elbow....880
Coolant Manifold....881
Table of Contents....883
Exploded Views....885
Exhaust Manifold....885
Air Intake Throttle Horizontal Duct....886
Air Intake Throttle Vertical Duct....887
Removal....888
Exhaust Manifold Heat Shield....889
Front Exhaust Manifold Cuff Assembly....889
Rear Exhaust Manifold Cuff Assembly....891
Exhaust Manifold....893
Air Intake Throttle Duct....893
Cleaning, Inspection and Testing....895
Air Intake Throttle Duct and Exhaust Manifolds....895
Manifold Warp Test for Exhaust Manifolds....895
Installation....896
Air Intake Throttle Duct....896
Exhaust Manifold....896
Front Exhaust Manifold Cuff Assembly....898
Rear Exhaust Manifold Cuff Assembly....901
Exhaust Manifold Heat Shield....903
Table of Contents....905
Exploded Views....907
High Mount Fan Drive System and Vibration Damper....907
Accessory Drive System (Typical)....908
Thermostat Assembly and Coolant Outlet Manifold (Low Mount Fan)....909
Thermostat Assembly and Coolant Outlet Manifold (High Mount Fan)....910
Water Pump Assembly, Coolant Control Valve (CCV), Water Distribution Housing, Thermostat Housing and EGR Cooler Return Manifold....911
Front Belt-Driven Fan Cover (High Mount Fan)....912
Front Gear-driven Fan Cover (Low Mount Fan)....913
Fan Low Mount Drive (Typical)....914
Removal....915
Pulley (High Mount Fan)....915
Tensioner Bracket (High Mount Fan)....916
High Mount Fan Drive....916
Coolant Outlet Manifold and Thermostat Assembly....917
Automatic Belt Tensioner and Idler Pulleys....918
Water Pump Assembly and Pulley....918
Vibration Damper....919
Coolant Control Valve (CCV) Assembly....920
Thermostat Housing....920
Water Distribution Housing....921
Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal....922
Front Belt- or Gear-Driven Fan Cover....922
Radial Shaft Seal (Fan Low Mount Drive)....923
Fan Low Mount Drive Assembly....923
Cleaning, Inspection and Testing....924
Installation....925
Fan Low Mount Drive Assembly....925
Radial Shaft Seal (Fan Low Mount Drive)....925
Front Belt- or Gear-Driven Fan Cover....926
Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal....926
Water Distribution Housing....927
Thermostat Housing....927
Coolant Control Valve (CCV) Assembly....928
Vibration Damper....929
Water Pump Assembly and Pulley....930
Automatic Belt Tensioner and Idler Pulley....930
Coolant Outlet Manifold and Thermostat Assembly....931
High Mount Fan Drive....932
Tensioner Bracket (High Mount Fan)....933
Pulley (High Mount Fan)....933
Table of Contents....935
Exploded Views....937
MaxxForce? Engine Brake Housing Assembly....938
Engine Injector Wiring Harness With Engine Brake Solenoid Leads....939
Removal....940
Engine Brake Housing Assembly....940
Disassembly....941
Solenoid....941
Control Valve....941
Master Piston....942
Slave Piston....942
Cleaning and Inspection....944
Solenoid Assembly Check....944
Assembly....945
Slave Piston....945
Master Piston....946
Control Valve....947
Solenoid....947
Installation....949
Engine Brake Housing Assembly....949
Engine Brake Lash Adjustment....949
Table of Contents....951
Exploded Views....953
Valve Cover and Base....953
Rocker Arm Assembly And Valve Bridges (Non-Brake)....954
Camshaft and Cylinder Head Idler Gear....955
Cylinder Head....956
Periodic Service....957
Crankshaft Rotation Procedure....957
Cylinder No. 1 TDC Procedure....957
Valve Overlap Procedure....958
Valve Lash Adjustment Procedure....959
Removal....961
Upper Valve Cover and Base....961
Rocker Arm Assembly (Non-Brake Engine)....962
Camshaft....963
Cylinder Head....966
Cylinder Head Idler Gear....968
Cleaning, Inspection, and Testing....970
Cylinder Head and Crankcase Components....970
Camshaft Bearings....970
Fuel Injector Bore....971
Valves Leak Test....971
Installation....973
Cylinder Head Idler Gear....973
Cylinder Head....974
Camshaft....979
Rocker Arm Assembly (Non-Brake Engine)....981
Upper Valve Cover and Base....983
Table of Contents....987
Exploded Views....989
Flywheel Housing and Flywheel (Manual Transmission)....989
Flywheel and Flexplate Assembly (Automatic Transmission)....990
Rear Engine Mounts....991
Removal....992
Preliminary Checks and Measurements....992
Flywheel Assembly (Manual Transmission)....992
Flywheel Surface Runout....992
Pilot Bearing....993
Flywheel (Manual Transmission)....993
Flywheel and Flexplate Assembly (Automatic Transmission)....994
Radial Shaft Ring Seal....994
Lifting Eyes....995
Flywheel Housing....995
Cleaning and Inspection....997
All Components....997
Flywheel and Flexplate Assemblies....997
Recondition....997
Flywheel....997
Installation....999
Flywheel Housing....999
Lifting Eyes....1000
Radial Shaft Ring Seal....1001
Flywheel Assembly (Manual Transmission)....1001
Pilot Bearing (Flywheel)....1002
Flywheel and Flexplate Assembly (Automatic Transmission)....1002
Table of Contents....1005
Exploded Views....1007
Oil Pan (Front Sump Shown, Rear Sump Similar, Typical)....1007
Oil Pickup Tube - Front Sump (Typical)....1008
Removal....1009
Oil Pan....1009
Oil Pickup Tube ? Front Sump....1010
Oil Recovery....1011
Oil Pickup Tube ? Rear Sump....1012
Cleaning and Inspection....1013
Oil Pan....1013
Oil Pickup Tube....1013
Installation....1014
Oil Pickup Tube ? Front Sump....1014
Oil Pickup Tube ? Rear Sump....1014
Oil Recovery....1015
Oil Pan....1018
Table of Contents....1021
Exploded Views....1023
Oil Pump....1023
Front Timing Gears (Typical)....1024
Rear Timing Gears....1025
Removal....1026
Preliminary Checks....1026
Oil Pump....1027
Front Crank Gears....1028
Rear Timing Gears....1029
Cleaning and Inspection....1031
Timing Gears....1031
Oil Pump....1031
Installation....1032
Rear Timing Gears....1032
Front Timing Gears....1034
Oil Pump....1034
Table of Contents....1037
Exploded Views....1039
Piston and Connecting Rod (Typical) and Cylinder Sleeve....1039
Removal....1041
Preliminary Checks....1041
Piston and Connecting Rod....1042
Piston Disassembly....1043
Cylinder Sleeves....1044
Cleaning and Inspection....1045
Cleaning....1045
Piston Inspection....1045
Piston Ring Inspection....1046
Connecting Rod Inspection....1046
Connecting Rod Bore Check....1047
Piston Pin Inspection....1048
Cylinder Sleeve Inspection....1048
Installation....1050
Cylinder Sleeves....1050
Piston Assembly....1050
Piston and Connecting Rod....1051
Engine Run-in Procedure....1054
Table of Contents....1057
Exploded View....1059
Crankcase and Crankshaft....1059
Removal....1060
Preliminary Checks....1061
Crankshaft....1061
Piston Cooling Jets....1062
Cleaning, Inspection and Testing....1063
Crankcase....1063
Crankshaft Measurement....1063
Main Bearings Measurement....1064
Piston Cooling Jets....1065
Installation....1066
Piston Cooling Jets....1066
Crankshaft....1066
Table of Contents....1071
Abbreviations and Acronyms....1073
Table of Contents....1077
Terminology....1079
Terms....1079
Table of Contents....1089
Fuel System....1091
Air Inlet Duct and Exhaust Manifolds....1091
Engine Brake....1091
Cylinder Head, Camshaft and Valve Train....1091
Flywheel and Flywheel Housing....1091
Oil Pump, Low Mount Fan Drive, and Timing Gears....1092
Power Cylinders....1092
Crankcase and Crankshaft....1094
Table of Contents....1095
General Torque....1097
Bolt Identification....1097
General Torque Guidelines....1098
Standard Torque Charts....1099
Using a Torque Wrench Extension....1100
Special Torques....1101
Mounting Engine on Stand....1101
Engine Electrical....1101
Inlet Air Heater....1102
Aftertreatment System....1102
Exhaust Back Pressure Control....1103
Turbochargers....1103
Air Compressor and Power Steering/Fuel Pump....1104
Fuel System....1105
Oil Module Assembly....1106
Exhaust Gas Recirculation (EGR) System....1106
Air Inlet Duct and Exhaust Manifolds....1107
Front Cover, High Mount Fan Drive, Cooling System, Related Components....1107
Engine Brake....1108
Cylinder Head, Camshaft and Valve Train....1109
Flywheel and Flywheel Housing....1110
Oil Pan and Oil Suction Tube....1111
Oil Pump and Timing Gears....1111
Power Cylinders....1111
Crankcase and Crankshaft....1112
Table of Contents....1113
Special Tools....1115
Contact Information....1115
Mounting Engine on Stand....1115
Engine Electrical....1115
Aftertreatment System....1115
Exhaust Back Pressure Control....1115
Turbochargers....1116
Air Compressor and Power Steering....1116
Fuel System....1117
Oil Cooler, Filter Housing and Crankcase Ventilation....1117
Exhaust Gas Recirculation (EGR) System....1118
Air Inlet Throttle Duct and Exhaust Manifold....1118
Front Cover, Fan Drive, Cooling System and Related Components....1118
MaxxForce Engine Brake by Jacobs....1118
Cylinder Head, Camshaft and Valve Train....1119
Flywheel and Flywheel Housing....1119
Oil Pump, Fan Drive and Timing Gears....1120
Power Cylinders....1120
Crankcase and Crankshaft....1120
Special Tools ....1121
Essential Tools....1121
Table of Contents....1129
Description....1131
tables....950
Engine Brake....950
Cylinder Head, Camshaft and Valve Train....985
Flywheel and Flywheel Housing....1004
Oil Pump and Timing Gears....1036
Power Cylinders....1055
Crankcase and Crankshaft....1069
Fuel System....1091
Exhaust Manifolds....1091
Engine Brake....1091
Cylinder Head, Camshaft and Valve Train....1091
Flywheel and Flywheel Housing....1091
Oil Pump, Low Mount Fan Drive, and Timing Gears....1092
Power Cylinders....1092
Crankcase and Crankshaft....1094
Standard Torque Values - Class 10.9 Metric Flange Head Bolts and Studs....1099
Thread Diameter (mm)....1099
Thread Pitch (mm)....1099
Torque....1099
Mounting Engine on Stand....1101
Engine Electrical....1101
Inlet Air Heater....1102
Aftertreatment System....1102
Exhaust Back Pressure Control....1103
Turbochargers....1103
Air Compressor and Power Steering/Fuel Pump....1104
Fuel System....1105
Oil Module Assembly....1106
EGR System....1106
Air Intake Throttle Duct and Exhaust Manifolds....1107
Front Cover, Fan Drive, Cooling System and Related Components....1108
Engine Brake....1108
Cylinder Head, Camshaft and Valve Train....1110
Flywheel and Flywheel Housing....1110
Oil Pan Components....1111
Oil Pump and Timing Gears....1111
Power Cylinders....1111
Crankcase and Crankshaft....1112
Mounting Engine on Stand....1115
Engine Electrical....1115
Aftertreatment System....1115
Exhaust Back Pressure Control....1115
Turbochargers....1116
Air Compressor and Power Steering....1116
Fuel System....1117
Oil Cooler, Filter Housing and Crankcase Ventilation....1117
EGR System....1118
Air Inlet Throttle Duct and Exhaust Manifold....1118
Front Cover, Fan Drive, Cooling System and Related Components....1118
MaxxForce Engine Brake by Jacobs....1118
Cylinder Head, Camshaft and Valve Train....1119
Flywheel and Flywheel Housing....1119
Oil Pump, Fan Drive and Timing Gears....1120
Power Cylinders....1120
Crankcase and Crankshaft....1120
0000001682 - MaxxForce 11 and 13 Engine Service Manual (2015-06)....1134
toc....1136
Table of Contents....1136
Safety Terminology....1140
Safety Instructions....1140
Work Area....1140
Safety Equipment....1140
Protective Measures....1140
Vehicle....1140
Engine....1141
Fire Prevention....1141
Batteries....1141
Compressed Air....1141
Tools....1141
Fluids Under Pressure....1142
Fuel....1142
Removal of Tools, Parts, and Equipment....1142
Table of Contents....1144
Engine Identification....1146
Engine Serial Number....1146
Engine Serial Number Examples....1146
Engine Serial Number Codes....1146
Engine Emission Label ....1147
Engine Accessory Labels and Identification Plates....1148
Engine Specifications....1149
Heavy Duty On Board Diagnostics (HD-OBD)....1151
Engine Description....1151
Optional Equipment....1152
Chassis Mounted Equipment....1152
Engine Component Locations....1154
Air Management System....1158
Airflow....1159
Turbochargers....1160
Air Control Valve (ACV)....1162
Boost Control....1163
Low-Pressure Charge Air Cooler (LPCAC)....1164
High-Pressure Charge Air Cooler (HPCAC)....1165
High-Pressure Boost Pressure (HPBP) Sensor ....1166
High-Pressure Boost Temperature (HPBT) Sensor ....1167
Low-Pressure Boost Pressure (LPBP) Sensor and Low-Pressure Boost Temperature (LPBT) Sensor ....1168
Exhaust Gas Recirculation (EGR) System....1169
EGR System Overview....1170
EGR Flow....1170
EGR System Control....1170
EGRV Control....1171
EGR ? Open Loop....1172
EGR ? Closed Loop ....1172
EGR Flow Cooling....1172
Aftertreatment (AFT) System....1173
Diesel Particulate Filter (DPF)....1174
Diesel Oxidation Catalyst (DOC)....1174
Aftertreatment (AFT) System Conditions and Responses....1174
Downstream Fuel Injection....1175
Downstream Injection (DSI) Unit....1176
Hydrocarbon Injector (HCI) Assembly....1176
Crankcase Oil Separator....1177
Fuel Management System....1179
Fuel System....1179
Fuel Flow....1180
Low-Pressure Fuel System....1181
Chassis Mounted Filter/Water Separator....1181
Fuel Primer Pump Assembly....1181
Low-Pressure (LP) Fuel Pump....1182
Fuel Filter Assembly....1182
High-Pressure Fuel System....1183
High-Pressure (HP) Pump....1184
Fuel Pressure Control Valve (FPCV)....1184
Fuel Rail....1184
Fuel Rail Pressure (FRP) Sensor....1184
Pressure Limiting Valve....1184
Injectors....1184
Inlet Air Heater System....1185
Inlet Air Heater System Components....1185
Inlet Air Heater Fuel Igniter (IAHFI)....1185
Inlet Air Heater Relay (IAHR)....1186
Inlet Air Heater Fuel Solenoid (IAHFS) Valve....1186
Inlet Air Heater System Operation....1187
Oil Flow and Components....1188
Crankcase Oil Separator....1190
Remote Mounted Centrifugal Oil Filter (Optional)....1191
Engine Cooling System....1192
Cooling System Flow....1192
Thermostat Operation....1194
Coolant Control Valve (CCV) operation....1195
Coolant Flow Valve (CFV)....1195
Coolant Mixer Valve (CMV)....1195
Engine Brake System....1196
Engine Brake Control System Components....1196
Engine Brake System Operation....1198
Electronic Control System....1199
Electronic Control System Components....1199
Operation and Function....1199
Reference Voltage (VREF)....1199
Signal Conditioner....1199
Microprocessor....1199
Diagnostic Trouble Codes....1199
Microprocessor Memory....1199
ROM....1200
RAM....1200
Actuator Control....1201
Actuators....1202
Coolant Control Valve (CCV)....1202
Exhaust Back Pressure Valve (EBPV) Control....1202
Exhaust Gas Recirculation (EGR) Valve ....1202
Air Control Valve (ACV)....1202
Inlet Air Heater Relay (IAHR)....1203
Inlet Air Heater Fuel Solenoid (IAHFS) Valve....1204
Engine Throttle Valve (ETV)....1204
Fuel Pressure Control Valve (FPCV)....1204
Aftertreatment Fuel Doser (AFTFD)....1205
Aftertreatment Shutoff Valve (AFTSV)....1205
Engine and Vehicle Sensors....1206
Thermistor Sensors....1206
Aftertreatment Temperature Sensors....1207
Engine Coolant Temperature (ECT) Sensors....1207
Engine Oil Temperature (EOT) Sensor....1207
Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....1208
Charge Air Cooler Outlet Temp (CACOT) Sensor....1208
Intake Manifold Temperature (IMT) Sensor....1208
Exhaust Gas Recirculation Temperature (EGRT) Sensor....1208
Ambient Air Temperature (AAT) Sensor....1208
Variable Capacitance Sensors....1208
DPF Differential Pressure (DPFDP) Sensor....1209
Engine Fuel Pressure (EFP) Sensor....1209
Engine Oil Pressure (EOP) Sensor....1209
Fuel Rail Pressure (FRP) Sensor....1209
Intake Manifold Pressure (IMP) Sensor....1210
Aftertreatment Fuel Inlet (AFTFI) Sensor....1210
Aftertreatment Fuel Pressure 2 (AFP2) sensor....1210
Turbocharger 1 Turbine Outlet Pressure (TC1TOP)....1210
Magnetic Pickup Sensors....1211
Crankshaft Position (CKP) Sensor....1211
Camshaft Position (CMP) Sensor....1211
Vehicle Speed Sensor (VSS)....1212
Crankcase Oil Separator Speed (CCOSS) sensor....1212
Potentiometer Sensors....1212
Accelerator Pedal Position (APP)....1213
Switches....1213
Driveline Disengagement Switch (DDS)....1213
Engine Coolant Level (ECL) Switch....1213
Oil Level Sensor (OLS)....1214
Additional Sensors....1215
Oxygen Sensor (O2S)....1215
Humidity Sensor (HS)....1215
Table of Contents....1216
Mounting Engine....1218
Engine Cleaning....1218
Mounting Engine on Stand....1219
Table of Contents....1228
Oil Fill Tube Assembly....1230
Oil Fill Tube Assembly Leak Inspection....1230
Overview....1230
Tools Required....1230
Equipment Condition....1230
Inspection Procedure....1231
Expected Outcome....1232
Oil Fill Tube Assembly Removal....1233
Overview....1233
Equipment Condition....1233
Special Tools Required....1233
Torque Specifications....1233
Procedure....1234
Oil Fill Tube Adapter Mount Cleaning and Inspection....1236
Oil Fill Tube Assembly Installation....1237
Procedure....1237
Table of Contents....1240
Electronic Component Location....1242
Electronic Components ? Right Front....1242
Electronic Components ? Left Rear....1243
Description of Engine Sensors, Valves and Actuators....1244
Crankshaft Position (CKP) Sensor....1244
Camshaft Position (CMP) Sensor....1245
Engine Coolant Temperature (ECT) Sensors....1246
Engine Oil Temperature (EOT) Sensor....1247
Engine Oil Pressure (EOP) Sensor....1248
Crankcase Oil Separator Speed (CCOSS) Sensor....1249
Fuel Delivery Pressure (FDP) Sensor....1250
Fuel Pressure Control Valve (FPCV)....1251
Mass Air Flow (MAF) Sensor....1252
Humidity / Inlet Air Temperature (IAT) Sensor....1253
Charge Air Cooler Outlet Temperature (CACOT) Sensor....1254
Intake Manifold Pressure (IMP) Sensor....1255
Fuel Rail Pressure (FRP) Sensor....1256
Intake Manifold Temperature (IMT) Sensor....1257
Oxygen Sensor (O2S)....1258
Engine Throttle Valve (ETV)....1259
Coolant Control Valve (CCV)....1260
Air Control Valve (ACV) Assembly....1261
Exhaust Gas Recirculation (EGR) Valve....1262
Exhaust Gas Recirculation Temperature (EGRT) Sensor....1263
Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....1264
Removal....1265
Warnings and Cautions....1265
Crankshaft Position (CKP) Sensor....1266
Camshaft Position (CMP) Sensor....1267
Engine Coolant Temperature 1 (ECT1) Sensor....1268
Engine Coolant Temperature 2 (ECT2) Sensor....1269
Engine Oil Temperature (EOT) Sensor....1270
Engine Oil Pressure (EOP) Sensor....1271
Crankcase Oil Separator Speed (CCOSS) Sensor....1272
Fuel Delivery Pressure (FDP) Sensor....1273
Fuel Pressure Control Valve (FPCV)....1274
Mass Air Flow (MAF) Sensor (If equipped)....1275
Humidity / Intake Air Temperature (IAT) Sensor....1276
Charger Air Cooler Outlet Temperature (CACOT) Sensor....1277
Intake Manifold Pressure (IMP) Sensor....1278
Fuel Rail Pressure (FRP) Sensor....1279
Intake Manifold Temperature (IMT) Sensor....1280
Oxygen Sensor (O2S)....1281
Engine Throttle Valve (ETV)....1282
Coolant Control Valve (CCV)....1283
Air Control Valve (ACV)....1284
Exhaust Gas Recirculation (EGR) Valve....1285
Exhaust Gas Recirculation Temperature (EGRT) Sensor....1286
Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....1287
Wiring Harness ECM Connections....1288
Engine Injector (Wiring) Harness....1289
Engine Sensor (Wiring) Harness....1291
Engine Control Module (ECM) and Support....1294
Cleaning and Inspection....1296
Engine Injection and Engine Sensor Wiring Harnesses....1296
Sensors and Valves....1297
Engine Control Module (ECM)....1297
Installation....1298
Engine Control Module (ECM) and Support....1298
Engine Sensor (Wiring) Harness....1300
Engine Injector (Wiring) Harness....1303
Wiring Harness ECM Connections....1306
Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....1308
Exhaust Gas Recirculation Temperature (EGRT) Sensor....1309
Exhaust Gas Recirculation (EGR) Valve....1310
Air Control Valve (ACV)....1311
Coolant Control Valve (CCV)....1312
Engine Throttle Valve (ETV)....1313
Oxygen Sensor (O2S)....1314
Intake Manifold Temperature (IMT) Sensor....1315
Fuel Rail Pressure (FRP) Sensor....1316
Intake Manifold Pressure (IMP) Sensor....1317
Charger Air Cooler Outlet Temperature (CACOT) Sensor....1318
Humidity / Inlet Air Temperature (IAT) Sensor....1319
Mass Air Flow (MAF) Sensor (If equipped)....1320
Fuel Pressure Control Valve (FPCV)....1321
Fuel Delivery Pressure (FDP) Sensor....1322
Crankcase Oil Separator Speed (CCOSS) Sensor....1323
Engine Oil Pressure (EOP) Sensor....1324
Engine Oil Temperature (EOT) Sensor....1325
Engine Coolant Temperature 2 (ECT2) Sensor....1326
Engine Coolant Temperature 1 (ECT1) Sensor....1327
Camshaft Position (CMP) Sensor....1328
Crankshaft Position (CKP) Sensor....1329
Table of Contents....1332
Exploded View....1334
Inlet Air Heater Components....1334
Removal....1335
Relay Assembly....1335
Inlet Air Heater Fuel Igniter (IAHFI) and Fuel Supply Inlet Air Heater Hose....1337
Fuel Solenoid Valve and Fuel Supply Solenoid Hose....1339
Installation....1342
Fuel Solenoid Valve and Fuel Supply Solenoid Hose....1342
Inlet Air Heater Fuel Igniter (IAHFI) and Fuel Supply Inlet Air Heater Hose....1345
Relay Assembly....1347
Table of Contents....1350
Illustrations....1352
Catalyst and Aftertreatment System Fuel Supply Components....1352
Removal....1355
Supply Fuel After Filter Hose and Tubes....1356
Downstream Injection (DSI) Unit....1361
Pre-Diesel Oxidation Catalyst (PDOC)....1363
HCI Coolant Supply Tube Assembly....1365
HCI Coolant Return Tube Assembly ....1367
Hydrocarbon Injector (HCI) / Aftertreatment Fuel Injector (AFI) Assembly....1369
Cleaning and Inspection....1373
Hydrocarbon Injector (HCI) / Aftertreatment Fuel Injector (AFI) Cleaning....1373
Exhaust Back Pressure Valve Housing Cleaning....1375
Installation....1376
Downstream Injection (DSI) Unit....1376
Hydrocarbon Injector (HCI) / Aftertreatment Fuel Injector (AFI) Assembly....1379
HCI Coolant Return Tube Assembly....1382
HCI Coolant Supply Tube Assembly....1383
Pre-Diesel Oxidation Catalyst (PDOC) ....1384
HCI Fuel Tube Assembly ....1386
Table of Contents....1390
Exploded Views....1392
Control System....1392
Removal....1393
Warnings....1393
Air Control Valve (ACV)....1394
Exhaust Back Pressure Valve Actuator and TC1 Turbine Outlet Pressure Sensor Tubes....1396
Exhaust Back Pressure Valve Assembly....1398
Installation....1399
Exhaust Back Pressure Valve Assembly....1399
Air Control Valve (ACV)....1402
Exhaust Back Pressure Valve Actuator and TC1 Turbine Outlet Pressure Sensor Tubes....1404
Table of Contents....1410
Exploded Views....1412
Turbochargers and Charge Air Cooler Assembly....1412
Coolant Tube, Coolant Hoses and Low-Pressure Charge Air Cooler (LPCAC)....1413
Turbocharger Oil Supply Tube and Support Bracket....1414
Turbocharger Oil Return Tubes....1415
Air Inlets, Wastegate High-Pressure Actuator, and Air Control Valve....1416
Turbochargers....1417
Cleaning Procedure....1418
Turbocharger Cleaning Procedure....1418
Turbocharger Cleaning Procedure....1418
Overview....1418
Special Tools Required....1419
Equipment Condition....1419
Removal Procedure....1420
Individual Component Removal....1428
Overview....1428
High-Pressure (HP) Turbocharger Center Section....1429
Overview....1429
Removal (Complete Engine Teardown)....1434
High-Pressure (HP) Wastegate Hose....1435
Low-Pressure Charge Air Cooler (LPCAC)....1436
Low-Pressure Charge Air Cooler (LPCAC) Coolant Tube and Hoses....1438
High-Pressure (HP) Compressor Out Duct and Air Inlet Duct....1442
High-Pressure Turbocharger Air Supply Duct....1443
Turbocharger Oil Return and Oil Supply Tubes....1444
Overview....1444
Turbocharger Heat Shields....1448
Turbocharger Support Bracket....1449
High-Pressure (HP) Turbocharger Wastegate Actuator....1450
Turbocharger Mounting....1451
Disassembly....1453
Turbochargers....1453
Cleaning, Inspection, and Testing....1454
Turbochargers and Related Parts Cleaning....1454
High-Pressure (HP) Turbocharger Turbine Housing Cleaning....1455
Turbocharger Inspection....1456
Low-Pressure Charge Air Cooler (LPCAC) Pressure Test ? correction....1457
High-Pressure Charge Air Cooler (HPCAC) Pressure Test....1460
High-Pressure Charge Air Cooler (HPCAC) Cleaning....1467
Back-Flush With Water and EGR Cleaning Fluid:....1472
Forward-Flush With Water and EGR Cleaning Fluid:....1473
Back-Flush With Water:....1474
Forward-Flush With Water:....1474
Installation....1476
Turbocharger Mounting....1476
Turbocharger Support Bracket....1480
High-Pressure (HP) Turbocharger Wastegate Actuator....1481
Turbocharger Heat Shields....1482
Turbocharger Oil Return and Oil Supply Tubes....1483
Overview....1483
High-Pressure Turbocharger Air Supply Duct....1487
High-Pressure (HP) Compressor Out Duct and Air Inlet Duct....1488
Low-Pressure Charge Air Cooler (LPCAC) Coolant Tube and Hoses....1489
Low-Pressure Charge Air Cooler (LPCAC)....1493
High-Pressure (HP) Wastegate Hose....1495
Table of Contents....1498
Exploded Views....1500
Power Steering and One-Cylinder Air Compressor....1500
Power Steering and Two-Cylinder Air Compressor....1501
Removal....1502
Power Steering Pressure Tubes....1502
Power Steering Elbows....1504
Power Steering Pump....1505
Air Compressor Coolant Hoses....1506
Air Compressor....1507
Cleaning....1508
All components....1508
Installation....1509
Air Compressor ....1509
Air Compressor Coolant Hoses....1510
Power Steering Pump....1511
Power Steering Elbows....1512
Power Steering Pressure Tubes....1513
Table of Contents....1516
Exploded Views....1518
High-pressure Fuel Lines....1518
Fuel Supply and Drain (Return) Lines....1519
Fuel Filter Housing Assembly....1520
High-pressure Fuel Pump and Drive Housing....1521
Removal....1522
High-pressure Fuel Lines....1523
Injector and Fuel Drain (Return) Lines....1528
Fuel Rail Assembly....1529
Fuel Primer Pump Assembly....1530
Fuel Supply and Drain (Return) Lines....1531
Fuel Primer Pump Assembly....1536
Fuel Filter Housing Assembly....1537
Fuel Filter Stand Pipe Replacement....1539
Radial Shaft Seal....1540
Fuel Pressure Control Valve (FPCV)....1542
Piston Overflow Valve (KUEV)....1543
High-pressure Fuel Pump (HPFP) and Drive Housing....1545
Fuel Injectors....1553
Cleaning and Inspection....1559
Low-pressure and High-pressure Fuel System Components....1559
Fuel Injector Bore....1559
Fuel Injector Harness....1559
Installation....1560
Fuel Injectors....1560
High-Pressure Fuel Pump (HPFP) and Drive Housing....1569
Radial Shaft Seal....1576
Piston Overflow Valve (KUEV)....1578
Fuel Pressure Control Valve (FPCV)....1579
Fuel Filter Housing Assembly....1580
Fuel Primer Pump Assembly....1582
Fuel Supply and Drain (Return) Lines....1583
Fuel Rail Assembly....1588
Injector and Fuel Drain (Return) Lines....1589
High-pressure Fuel Lines....1590
Filter and Fuel Strainer Element....1594
Fuel System Priming....1595
Fuel System Priming Tool Method....1595
Hand Primer Pump Method....1603
Table of Contents....1608
Exploded Views....1610
Oil Module Assembly....1610
Oil Module....1611
Removal....1612
Oil Filter Cover and Filter....1613
Oil Centrifuge....1614
Oil Module Assembly....1616
Oil Cooler....1620
Oil Pressure Relief Valve....1622
Cleaning, Inspection and Testing....1623
Oil Cooler....1623
Oil Cooler Leak Test....1625
Extension Tubes....1627
Oil Centrifuge....1627
Installation....1628
Oil Pressure Relief Valve....1628
Oil Cooler....1629
Oil Module Assembly....1631
Oil Centrifuge....1634
Oil Filter Cover and Filter....1636
Table of Contents....1638
Exploded Views....1640
EGR Coolant Manifold and Elbow....1640
Removal....1645
Coolant Manifold....1646
Coolant Elbow ....1647
EGR Cooler Bracket....1648
EGR Outlet Tubes....1649
EGR Module Cover....1650
Heat Protection (Cylinders 4-6) Shield....1651
EGR Inlet Tubes....1652
Heat Protection EGR Shield....1654
EGR Dual Flap Valve....1655
EGR Cooler Assembly....1658
Disassembly and Assembly of EGR Cooler....1659
EGR Cooler High-Temperature or Low-Temperature Side Replacement....1659
Cleaning, Inspection and Testing....1665
EGR System Components Cleaning....1665
EGR Cooler Assembly Cleaning....1666
EGR Cooler Assembly Leak Test....1678
Installation....1679
EGR Cooler Assembly....1679
EGR Dual Flap Valve....1680
Heat Protection EGR Shield....1684
EGR Inlet Tubes....1685
Heat Protection (Cylinders 4-6) Shield....1687
EGR Module Cover....1688
EGR Outlet Tubes....1689
EGR Cooler Bracket....1690
Coolant Elbow....1691
Coolant Manifold....1692
Table of Contents....1694
Exploded Views....1696
Exhaust Manifold....1696
Air Intake Throttle Horizontal Duct....1697
Air Intake Throttle Vertical Duct....1698
Removal....1699
Exhaust Manifold Heat Shield....1700
Front Exhaust Manifold Cuff Assembly....1701
Rear Exhaust Manifold Cuff Assembly....1705
Exhaust Manifold....1708
Air Intake Throttle Duct....1709
Cleaning, Inspection and Testing....1711
Air Intake Throttle Duct and Exhaust Manifolds....1711
Manifold Warp Test for Exhaust Manifolds....1712
Installation....1713
Air Intake Throttle Duct....1713
Exhaust Manifold....1715
Front Exhaust Manifold Cuff Assembly....1718
Rear Exhaust Manifold Cuff Assembly....1723
Exhaust Manifold Heat Shield....1727
Table of Contents....1730
Exploded Views....1732
High Mount Fan Drive System and Vibration Damper....1732
Accessory Drive System (Typical)....1733
Thermostat Assembly and Coolant Outlet Manifold (Low Mount Fan)....1734
Thermostat Assembly and Coolant Outlet Manifold (High Mount Fan)....1735
Water Pump Assembly, Coolant Control Valve (CCV), Water Distribution Housing, Thermostat Housing and EGR Cooler Return Manifold....1736
Front Belt-Driven Fan Cover (High Mount Fan)....1737
Front Gear-driven Fan Cover (Low Mount Fan)....1738
Fan Low Mount Drive (Typical)....1739
Removal....1740
Pulley (High Mount Fan)....1740
Tensioner Bracket (High Mount Fan)....1742
High Mount Fan Drive....1743
Coolant Outlet Manifold and Thermostat Assembly....1744
Automatic Belt Tensioner and Idler Pulleys....1746
Water Pump Assembly and Pulley....1747
Vibration Damper....1748
Coolant Control Valve (CCV) Assembly....1750
Thermostat Housing....1751
Water Distribution Housing....1754
Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal....1755
Front Belt- or Gear-Driven Fan Cover....1756
Radial Shaft Seal (Fan Low Mount Drive)....1757
Fan Low Mount Drive Assembly....1758
Cleaning, Inspection and Testing....1759
Installation....1761
Fan Low Mount Drive Assembly....1761
Radial Shaft Seal (Fan Low Mount Drive)....1762
Front Belt- or Gear-Driven Fan Cover....1763
Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal....1764
Water Distribution Housing....1765
Thermostat Housing....1766
Coolant Control Valve (CCV) Assembly....1768
Vibration Damper....1769
Water Pump Assembly and Pulley....1771
Automatic Belt Tensioner and Idler Pulley....1772
Coolant Outlet Manifold and Thermostat Assembly....1773
High Mount Fan Drive....1775
Tensioner Bracket (High Mount Fan)....1777
Pulley (High Mount Fan)....1778
Table of Contents....1780
Exploded Views....1782
MaxxForce? Engine Brake Housing Assembly....1783
Engine Injector Wiring Harness With Engine Brake Solenoid Leads....1784
Removal....1785
Engine Brake Housing Assembly....1785
Disassembly....1787
Solenoid....1787
Control Valve....1788
Master Piston....1789
Slave Piston....1790
Cleaning and Inspection....1793
Solenoid Assembly Check....1793
Assembly....1795
Slave Piston....1795
Master Piston....1798
Control Valve....1799
Solenoid....1800
Installation....1802
Engine Brake Housing Assembly....1802
Engine Brake Lash Adjustment....1803
Table of Contents....1806
Exploded Views....1808
Valve Cover and Base....1808
Rocker Arm Assembly And Valve Bridges (Non-Brake)....1810
Camshaft and Cylinder Head Idler Gear....1811
Cylinder Head....1812
Periodic Service....1813
Crankshaft Rotation Procedure....1813
Cylinder No. 1 TDC Procedure....1815
Valve Overlap Procedure....1817
Valve Lash Adjustment Procedure....1818
Removal....1821
Upper Valve Cover and Base....1821
Rocker Arm Assembly (Non-Brake Engine)....1823
Camshaft....1825
Cylinder Head....1831
Cylinder Head Idler Gear....1834
Cleaning, Inspection, and Testing....1835
Cylinder Head and Crankcase Components....1835
Camshaft Bearings....1836
Fuel Injector Bore....1837
Valves Leak Test....1838
Installation....1841
Cylinder Head Idler Gear....1841
Cylinder Head....1844
Camshaft....1849
Rocker Arm Assembly (Non-Brake Engine)....1854
Upper Valve Cover and Base....1858
Table of Contents....1864
Exploded Views....1866
Flywheel Housing and Flywheel (Manual Transmission)....1866
Flywheel and Flexplate Assembly (Automatic Transmission)....1867
Rear Engine Mounts....1868
Removal....1869
Preliminary Checks and Measurements....1869
Flywheel Assembly (Manual Transmission)....1869
Flywheel Surface Runout....1869
Pilot Bearing....1871
Flywheel (Manual Transmission)....1872
Flywheel and Flexplate Assembly (Automatic Transmission)....1873
Radial Shaft Ring Seal....1874
Lifting Eyes....1875
Flywheel Housing....1876
Cleaning and Inspection....1878
All Components....1878
Flywheel and Flexplate Assemblies....1878
Recondition....1879
Flywheel....1879
Installation....1881
Flywheel Housing....1881
Lifting Eyes....1884
Radial Shaft Ring Seal....1885
Flywheel Assembly (Manual Transmission)....1886
Pilot Bearing (Flywheel)....1888
Flywheel and Flexplate Assembly (Automatic Transmission)....1889
Table of Contents....1892
Exploded Views....1894
Oil Pan (Front Sump Shown, Rear Sump Similar, Typical)....1894
Oil Pickup Tube - Front Sump (Typical)....1895
Oil Fill Tube Assembly....1896
Removal....1897
Oil Pan....1897
Oil Pickup Tube ? Front Sump....1900
Oil Recovery....1901
Oil Pickup Tube ? Rear Sump....1903
Oil Fill Tube Assembly Removal....1904
Overview....1904
Equipment Condition....1904
Special Tools Required....1904
Procedure....1904
Cleaning and Inspection....1906
Oil Pan....1906
Oil Pickup Tube....1906
Oil Fill Tube Adapter Mount Cleaning and Inspection....1907
Installation....1908
Oil Pickup Tube ? Front Sump....1908
Oil Pickup Tube ? Rear Sump....1909
Oil Recovery....1911
Oil Pan....1915
Oil Fill Tube Assembly Installation....1918
Torque Specifications....1918
Procedure....1918
Table of Contents....1922
Exploded Views....1924
Oil Pump....1924
Front Timing Gears (Typical)....1925
Rear Timing Gears....1926
Removal....1927
Preliminary Checks....1927
Oil Pump....1930
Front Crank Gears....1932
Rear Timing Gears....1933
Cleaning and Inspection....1935
Timing Gears....1935
Oil Pump....1935
Installation....1936
Rear Timing Gears....1936
Front Timing Gears....1939
Oil Pump....1940
Table of Contents....1944
Exploded Views....1946
Piston and Connecting Rod (Typical) and Cylinder Sleeve....1946
Removal....1948
Preliminary Checks....1948
Piston and Connecting Rod....1950
Piston Disassembly....1953
Cylinder Sleeves....1954
Cleaning and Inspection....1955
Cleaning....1955
Piston Inspection....1956
Piston Ring Inspection....1958
Connecting Rod Inspection....1959
Connecting Rod Bore Check....1961
Piston Pin Inspection....1962
Cylinder Sleeve Inspection....1964
Installation....1966
Cylinder Sleeves....1966
Piston Assembly....1967
Piston and Connecting Rod....1969
Engine Run-in Procedure....1974
Table of Contents....1978
Exploded View....1980
Crankcase and Crankshaft....1980
Removal....1981
Preliminary Checks....1983
Crankshaft....1984
Piston Cooling Jets....1986
Cleaning, Inspection and Testing....1987
Crankcase....1987
Crankshaft Measurement....1988
Main Bearings Measurement....1990
Piston Cooling Jets....1992
Installation....1993
Piston Cooling Jets....1993
Crankshaft....1994
Table of Contents....2000
Abbreviations and Acronyms....2002
Table of Contents....2010
Terminology....2012
Terms....2012
Table of Contents....2026
Fuel System....2028
Air Inlet Duct and Exhaust Manifolds....2028
Engine Brake....2028
Cylinder Head, Camshaft and Valve Train....2028
Flywheel and Flywheel Housing....2028
Oil Pump, Low Mount Fan Drive, and Timing Gears....2029
Power Cylinders....2029
Crankcase and Crankshaft....2031
Table of Contents....2032
General Torque....2034
Bolt Identification....2034
General Torque Guidelines....2035
Standard Torque Charts....2036
Using a Torque Wrench Extension....2037
Special Torques....2038
Mounting Engine on Stand....2038
Engine Electrical....2038
Inlet Air Heater....2039
Aftertreatment System....2039
Exhaust Back Pressure Control....2040
Turbochargers....2040
Air Compressor and Power Steering/Fuel Pump....2041
Fuel System....2042
Oil Module Assembly....2043
Exhaust Gas Recirculation (EGR) System....2043
Air Inlet Duct and Exhaust Manifolds....2044
Front Cover, High Mount Fan Drive, Cooling System, Related Components....2044
Engine Brake....2045
Cylinder Head, Camshaft and Valve Train....2046
Flywheel and Flywheel Housing....2047
Oil Pan and Oil Suction Tube....2048
Oil Pump and Timing Gears....2048
Power Cylinders....2048
Crankcase and Crankshaft....2049
Table of Contents....2050
Special Tools....2052
Contact Information....2052
Mounting Engine on Stand....2052
Engine Electrical....2052
Aftertreatment System....2052
Exhaust Back Pressure Control....2052
Turbochargers....2053
Air Compressor and Power Steering....2053
Fuel System....2054
Oil Cooler, Filter Housing and Crankcase Ventilation....2054
Exhaust Gas Recirculation (EGR) System....2055
Air Inlet Throttle Duct and Exhaust Manifold....2055
Front Cover, Fan Drive, Cooling System and Related Components....2055
MaxxForce Engine Brake by Jacobs....2055
Cylinder Head, Camshaft and Valve Train....2056
Flywheel and Flywheel Housing....2056
Oil Pump, Fan Drive and Timing Gears....2057
Power Cylinders....2057
Crankcase and Crankshaft....2057
Special Tools ....2058
Essential Tools....2058
Table of Contents....2072
Description....2074
tables....1804
Engine Brake....1804
Cylinder Head, Camshaft and Valve Train....1861
Flywheel and Flywheel Housing....1891
Oil Pump and Timing Gears....1942
Power Cylinders....1975
Crankcase and Crankshaft....1998
Fuel System....2028
Exhaust Manifolds....2028
Engine Brake....2028
Cylinder Head, Camshaft and Valve Train....2028
Flywheel and Flywheel Housing....2028
Oil Pump, Low Mount Fan Drive, and Timing Gears....2029
Power Cylinders....2029
Crankcase and Crankshaft....2031
Standard Torque Values - Class 10.9 Metric Flange Head Bolts and Studs....2036
Thread Diameter (mm)....2036
Thread Pitch (mm)....2036
Torque....2036
Mounting Engine on Stand....2038
Engine Electrical....2038
Inlet Air Heater....2039
Aftertreatment System....2039
Exhaust Back Pressure Control....2040
Turbochargers....2040
Air Compressor and Power Steering/Fuel Pump....2041
Fuel System....2042
Oil Module Assembly....2043
EGR System....2043
Air Intake Throttle Duct and Exhaust Manifolds....2044
Front Cover, Fan Drive, Cooling System and Related Components....2045
Engine Brake....2045
Cylinder Head, Camshaft and Valve Train....2047
Flywheel and Flywheel Housing....2047
Oil Pan Components....2048
Oil Pump and Timing Gears....2048
Power Cylinders....2048
Crankcase and Crankshaft....2049
Mounting Engine on Stand....2052
Engine Electrical....2052
Aftertreatment System....2052
Exhaust Back Pressure Control....2052
Turbochargers....2053
Air Compressor and Power Steering....2053
Fuel System....2054
Oil Cooler, Filter Housing and Crankcase Ventilation....2054
EGR System....2055
Air Inlet Throttle Duct and Exhaust Manifold....2055
Front Cover, Fan Drive, Cooling System and Related Components....2055
MaxxForce Engine Brake by Jacobs....2055
Cylinder Head, Camshaft and Valve Train....2056
Flywheel and Flywheel Housing....2056
Oil Pump, Fan Drive and Timing Gears....2057
Power Cylinders....2057
Crankcase and Crankshaft....2057
0000001741 - MaxxForce 11 and 13 Engine Diagnostic Manual (2013-02)....2077
toc....2079
Table of Contents....2079
Safety Terminology....2083
Safety Instructions....2083
Work Area....2083
Safety Equipment....2083
Protective Measures....2083
Vehicle....2083
Engine....2083
Fire Prevention....2083
Batteries....2083
Compressed Air....2084
Tools....2084
Fluids Under Pressure....2084
Fuel....2084
Removal of Tools, Parts, and Equipment....2084
Table of Contents....2085
Engine Identification....2087
Engine Serial Number....2087
Engine Serial Number Examples....2087
Engine Serial Number Codes....2087
Engine Emission Label ....2087
Engine Accessory Labels and IdentificationPlates....2088
Engine Specifications....2088
Heavy Duty On Board Diagnostics (HD-OBD)....2090
Engine Description....2090
Optional Equipment....2091
Chassis Mounted Equipment....2091
Engine Component Locations....2092
Air Management System....2096
Airflow....2097
Turbochargers....2098
Air Control Valve (ACV)....2099
Boost Control....2099
Low Pressure Charge Air Cooler (LPCAC)....2100
High Pressure Charge Air Cooler (HPCAC)....2100
High Pressure Boost Pressure (HPBP) Sensor ....2100
High Pressure Boost Temperature (HPBT) Sensor ....2100
Low Pressure Boost Pressure (LPBP) and Low Pressure Boost Temperature (LPBT) Sensors ....2100
Exhaust Gas Recirculation (EGR) System....2101
EGR System Overview....2102
EGR Flow....2102
EGR System Control....2102
EGRV Control....2102
EGR ? Open Loop....2103
EGR ? Closed Loop ....2103
EGR Flow Cooling....2103
Aftertreatment (AFT) System....2104
Diesel Particulate Filter (DPF)....2105
Diesel Oxidation Catalyst (DOC)....2105
Aftertreatment (AFT) System Conditions and Responses....2105
Downstream Fuel Injection....2106
Downstream Injection (DSI) Unit....2107
Aftertreatment Fuel Injector (AFI)....2107
Crankcase Oil Separator....2108
Fuel Management System....2110
Fuel System Components....2110
Fuel Flow....2111
Low Pressure Fuel System....2112
Chassis Mounted Filter/Water Separator....2112
Fuel Primer Pump Assembly....2112
Low Pressure (LP) Fuel Pump....2113
Fuel Filter Assembly....2113
High Pressure Fuel System....2114
High Pressure (HP) Pump....2115
Fuel Pressure Control Valve (FPCV)....2115
Fuel Rail....2115
Fuel Rail Pressure (FRP) Sensor....2115
Rail Pressure Limiting Valve....2115
Injectors....2115
Cold Start Assist System....2115
Cold Start Assist System Components....2115
Cold Start Fuel Igniter (CSFI)....2115
Cold Start Relay (CSR)....2116
Cold Start Fuel Solenoid (CSFS) Valve....2116
Cold Start Assist System Operation....2116
Oil Flow and Components....2117
Crankcase Oil Separator....2119
Remote Mounted Centrifugal Oil Filter (Optional)....2120
Engine Cooling System....2121
Cooling System Flow....2121
Thermostat Operation....2122
Coolant Control Valve (CCV) operation....2123
Coolant Flow Valve (CFV)....2123
Coolant Mixer Valve (CMV)....2123
Engine Brake System....2124
Engine Brake Control System Components....2124
Engine Brake System Description....2125
Engine Brake System Operation....2125
Electronic Control System....2126
Electronic Control System Components....2126
Operation and Function....2126
Reference Voltage (VREF)....2126
Signal Conditioner....2126
Microprocessor....2126
Diagnostic Trouble Codes....2126
Microprocessor Memory....2126
ROM....2126
RAM....2126
Actuator Control....2127
Actuators....2127
Coolant Control Valve (CCV)....2127
Exhaust Back Pressure Valve (EBPV) Control....2127
Exhaust Gas Recirculation (EGR) Valve ....2127
Air Control Valve (ACV)....2127
Cold Start Relay (CSR)....2127
Cold Start Fuel Solenoid (CSFS) Valve....2128
Engine Throttle Valve (ETV)....2128
Fuel Pressure Control Valve (FPCV)....2128
Aftertreatment Fuel Doser (AFTFD)....2128
Aftertreatment Fuel Shutoff Valve (AFTFSV)....2128
Engine and Vehicle Sensors....2128
Thermistor Sensors....2128
Aftertreatment Temperature Sensors....2129
Engine Coolant Temperature (ECT) Sensors....2129
Engine Oil Temperature (EOT) Sensor....2129
Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....2129
Charge Air Cooler Outlet Temp (CACOT) Sensor....2129
Intake Manifold Temperature (IMT) Sensor....2129
Exhaust Gas Recirculation Temperature (EGRT) Sensor....2130
Ambient Air Temperature (AAT) Sensor....2130
Variable Capacitance Sensors....2130
DPF Differential Pressure (DPFDP) Sensor....2130
Fuel Delivery Pressure (FDP) Sensor....2130
Engine Oil Pressure (EOP) Sensor....2130
Fuel Rail Pressure (FRP) Sensor....2130
Intake Manifold Pressure (IMP) Sensor....2131
Aftertreatment Fuel Inlet Sensor (AFTFIS) ....2131
Aftertreatment Fuel Pressure 2 (AFTFP2) sensor....2131
Turbocharger 1 Turbine Outlet Pressure (TC1TOP)....2131
Magnetic Pickup Sensors....2131
Crankshaft Position (CKP) Sensor....2131
Camshaft Position (CMP) Sensor....2132
Vehicle Speed Sensor (VSS)....2132
Crankcase Oil Separator Speed (CCOSS) sensor....2132
Potentiometer Sensors....2132
Accelerator Pedal Position (APP)....2132
Switches....2133
Driveline Disengagement Switch (DDS)....2133
Engine Coolant Level (ECL) Switch....2133
Oil Level Sensor (OLS)....2133
Additional Sensors....2133
Oxygen Sensor (O2S)....2133
Humidity Sensor (HS)....2133
Table of Contents....2135
Standard Electronic Control Features....2137
Aftertreatment (AFT) System....2137
Cold Ambient Protection (CAP)....2137
Cold Start Assist....2137
Coolant Temperature Compensation (CTC)....2137
Data Plate....2137
Electronic Speedometer and Tachometer....2138
Engine Crank Inhibit (ECI)....2138
Engine Electronic Governor Control....2138
Engine Fan Control (EFC)....2138
Event Logging System ....2138
Fast Idle Advance....2138
J1939 Datalink ....2139
Password Protection....2139
Service Diagnostics....2139
Trip Reporting....2139
Vehicle Setup....2139
Optional Electronic Control Features....2140
Cruise Control....2140
Driver Reward....2140
MaxxForce? Engine Brake....2140
Engine Warning Protection System (EWPS)....2140
Gear Down Protection (GDP)....2140
Idle Shutdown Timer (IST)....2141
Progressive Shift....2141
Power Take Off (PTO) - In Cab....2141
Power Take Off (PTO) - Remote....2141
Service Interval....2142
Traction Control....2142
Up-Shift Indicator....2142
Road Speed Limiter....2142
Table of Contents....2143
Session Files....2145
Diagnostic Trouble Code (DTC)....2145
Suspect Parameter Number (SPN) ....2145
Failure Mode Indicator (FMI)....2145
Pending....2145
Active....2145
Previously Active....2145
Freeze Frame Data....2145
ECM Programmable Features ....2146
Connecting EST with ServiceMaxx? Software to Engine....2146
Service Bay Tests....2146
Engine Off Tests....2146
Actuator Test....2146
Continuous Monitor Test....2146
DPF Servicing....2146
Relative Compression Test....2147
Engine Running Tests....2147
Air Management Test....2147
High Pressure Pump Test....2148
Cylinder Cutout Test....2149
Onboard Filter Cleanliness Test....2149
Service Tool Procedures....2150
Engine Off Procedures....2150
Cold Start Assist ....2150
Oxygen Sensor Calibration....2150
Injector Quantity Adjustment....2150
Engine Running Procedures....2150
Engine Fan....2150
Table of Contents....2151
Coolant System....2153
Coolant Loss....2153
Symptom....2153
Possible Causes....2153
Tools....2153
Procedure....2153
Coolant Overflow....2154
Symptom....2154
Possible Causes....2154
Tools....2154
Procedure....2155
Coolant Leak to Exhaust....2156
Symptoms....2156
Possible Causes....2156
Tools....2156
Aftertreatment Fuel Injector (AFI) Coolant Leak Inspection....2157
EGR Cooler Leak Inspection....2157
Coolant Leak to Fuel ....2158
Symptom....2158
Possible Causes....2158
Tools....2158
Procedure....2158
Coolant Leak to Intake....2158
Symptom....2158
Possible Causes....2158
Tools....2158
Procedure....2159
Coolant Leak to Lube Oil....2159
Symptom....2159
Possible Causes....2159
Tools....2159
Lube Oil Contamination Inspection....2159
Cylinder Head Leak Test....2161
Procedure....2161
Coolant Over-Temperature....2161
Symptom....2161
Possible Causes....2161
Tools....2161
Coolant Over-Temperature Conditions Inspection....2161
Coolant Over-Temperature ? Engine Cooling....2163
Procedure....2163
Cooling System Components....2164
Cooling System Flow....2165
Thermostat Operation....2165
Coolant Control Valve (CCV) and Coolant Mixer Valve (CMV) Operation....2166
Coolant Mixer Valve (CMV) Operation....2167
Procedure....2167
Lubrication System....2169
Visual Oil Level Inspection....2169
Incorrect Maintenance ....2169
Dilution from Coolant....2169
Power Steering Fluid Leak to Lube Oil....2169
Symptom....2169
Possible Causes....2169
Procedure....2169
Lube Oil to Coolant....2169
Symptom....2169
Possible Causes....2169
Tools....2169
Procedure....2170
Lube Oil to Intake....2170
Symptom....2170
Possible Causes....2170
Procedure....2170
Lube Oil to Exhaust....2170
Symptom....2170
Possible Causes....2170
Procedure....2170
Low Oil Pressure....2171
Symptom....2171
Possible Causes....2171
Tools....2171
Procedure....2172
Fuel System....2174
Excessive Fuel Consumption....2174
Symptom....2174
Possible Causes....2174
Operator effects....2174
Application effects....2174
Chassis effects....2174
Engine effects....2174
Procedure....2174
Fuel in Coolant....2175
Symptom....2175
Possible Causes....2175
Tools....2175
Procedure....2175
Fuel in Lube Oil....2176
Symptom....2176
Possible Causes....2176
Tools....2176
Procedure....2176
Fuel to Intake....2177
Symptom....2177
Possible Causes....2177
Procedure....2177
Fuel to Exhaust....2177
Symptom....2177
Possible Causes....2177
Tools....2177
Procedure....2177
Fuel Pressure and Aeration....2177
Symptom....2177
Possible Cause....2177
Procedure....2178
Water in Fuel....2178
Symptoms....2178
Possible Causes....2178
Tools....2178
Procedure....2178
Priming the Fuel System....2179
Procedure....2179
Engine Brake System....2180
Engine Brake Inspection....2180
Symptom....2180
Possible Causes....2180
Tools....2180
Preliminary Steps....2180
Engine Brake does not Turn on/Slow to Turn On....2181
Engine Brake does not Turn Off/Slow to Turn Off....2181
Engine Fails to Start....2181
Engine Brake Weak in Effect or Low on Engine Brake Power....2182
Engine Brake Slow to Operate or Weak in Effect....2182
Oil Pressure Dropping Below Minimum Required for Engine Brake Operation....2183
One or More Cylinders Fail to Stop Braking or Engine Stalls....2183
Engine Misses or Loses Power....2183
Table of Contents....2185
Diagnostics Form EGED-475....2187
Diagnostics Form Vehicle Information and Complaint Page....2188
Required Test Procedures....2189
1. Initial Key ON Check....2189
Purpose....2189
Tools....2189
Procedure....2189
2. Visual Inspection....2189
Purpose....2189
Tools....2189
Engine Oil....2189
Engine Coolant Level....2190
Electrical System....2190
Intake Air....2190
Charge Air Cooler (CAC) System....2190
Exhaust System....2191
Air Tanks....2191
Fuel Level....2191
Fuel Line Routing and Condition....2191
Primary Fuel Filter Inspection....2191
Fuel Quality Check....2193
Purpose....2193
Tools....2193
Procedure....2193
3. Electronic Service Tool (EST) Connection and Data Recording....2194
Purpose....2194
Tools....2194
Procedure....2194
4. Check for Diagnostic Trouble Codes (DTCs)....2197
Purpose....2197
Tools....2197
Procedure....2197
5. Engine Cranking....2198
Purpose....2198
Tools....2198
Procedure....2198
Special Test Procedures....2199
Fuel System....2199
Low-pressure Fuel System....2200
Fuel System Priming....2201
Purpose....2201
Tools....2201
Procedure....2201
Fuel Delivery Pressure (FDP) Test....2202
Purpose....2202
Tools....2202
Procedure....2202
Fuel Dead Head Test....2203
Purpose....2203
Tools....2203
Procedure....2203
Fuel Aeration Test....2204
Purpose....2205
Tools....2205
Procedure....2205
Aeration Test Point 1....2205
Aeration Test Point 2....2205
Fuel Restriction Test....2206
Purpose....2207
Tools....2207
Procedure....2207
Restriction Test Point 1....2207
Restriction Test Point 2....2207
Restriction Test Point 3....2207
High-pressure Fuel System....2208
Fuel Rail Pressure (FRP) Circuit Test....2208
Purpose....2208
Tools....2208
Procedure....2208
High-pressure Pump Inlet Pressure Test....2209
Purpose....2209
Tools....2209
Procedure....2209
Fuel Rail Pressure (FRP) Return Flow Test....2210
Purpose....2210
Tools....2210
Procedure....2210
Fuel Rail Pressure (FRP) Leak Isolation....2211
Purpose....2211
Tools....2211
Procedure....2211
HP Pump Fuel Return Pressure Test....2212
Purpose....2212
Tools....2212
Procedure....2212
HP Pump Return Flow Test....2212
Purpose....2212
Tools....2212
Procedure....2212
Cold Start Assist System....2213
Cold Start Assist System Test....2213
Purpose....2213
Tools....2213
Procedure....2213
Cold Start Fuel Igniter (CSFI) Test....2214
Purpose....2214
Tools....2214
Procedure....2214
Fuel Supply at Cold Start Fuel Solenoid (CSFS) Test....2215
Purpose....2215
Tools....2215
Procedure....2215
Fuel Supply at Cold Start Fuel Igniter (CSFI) Test....2216
Purpose....2216
Tools....2216
Procedure....2216
Table of Contents....2217
Diagnostics Form EGED-530....2219
Diagnostics Form Vehicle Information and Complaint Page....2220
Required Test Procedures....2221
1. Initial Key ON Check....2221
Purpose....2221
Tools....2221
Procedure....2221
2. Visual Inspection....2221
Purpose....2221
Tools....2221
Engine Oil....2221
Engine Coolant Level....2222
Electrical System....2222
Intake Air....2223
Charge Air Cooler (CAC) System....2223
Exhaust System....2223
Vehicle Air Tanks....2223
Fuel Level....2223
Primary Fuel Filter Inspection....2223
Fuel Quality Check....2225
Purpose....2225
Tools....2225
Procedure....2225
3. Electronic Service Tool (EST) Connection and Data Recording....2226
Purpose....2226
Tools....2226
Procedure....2226
4. Check for Diagnostic Trouble Codes (DTCs)....2229
Purpose....2229
Tools....2229
Procedure....2229
5. Engine Low Idle to High Idle....2230
Purpose....2230
Tools....2230
Procedure....2230
6. KOER Air Management Test....2232
Purpose....2232
Tools....2232
Procedure....2232
7. Road Test (Full load to highway speed)....2232
Purpose....2232
Tools....2232
Procedure....2232
Special Test Procedures....2234
Air Control Valve (ACV) Tests....2234
Purpose....2234
Tools....2234
Exhaust Back Pressure Valve (EBPV) ....2234
Turbocharger 2 Wastegate Control (TC2WC)....2235
Fuel System....2236
Low-pressure Fuel System....2237
Fuel Delivery Pressure (FDP) Test....2238
Purpose....2238
Tools....2238
Procedure....2238
Fuel Dead Head Test....2239
Purpose....2239
Tools....2239
Procedure....2239
Fuel Aeration and Restriction Tests....2241
Aeration Test....2241
Purpose....2242
Tools....2242
Aeration Test Point 1....2242
Procedure....2242
Aeration Test Point 2....2242
Restriction Test....2243
Purpose....2244
Tools....2244
Procedure....2244
Test Point 1....2244
Test Point 2....2244
Test Point 3....2244
High-pressure Fuel System....2245
High-pressure Pump Inlet Pressure Test....2246
Purpose....2246
Tools....2246
Procedure....2246
Fuel Rail Pressure (FRP) Return Flow Test....2247
Purpose....2247
Tools....2247
Procedure....2247
Fuel Rail Pressure (FRP) Leak Isolation....2248
Purpose....2248
Tools....2248
Procedure....2248
HP Pump Fuel Return Pressure Test....2249
Purpose....2249
Tools....2249
Procedure....2249
Crankcase Oil Breather Separator Test....2250
Purpose....2250
Tools....2250
Procedure....2250
Crankcase Pressure Test....2250
Purpose....2250
Tools....2250
Procedure....2250
Cylinder Performance Test ? Step 1....2252
Relative Compression Test....2252
Purpose....2252
Tools....2252
Procedure....2252
Possible Causes....2252
Cylinder Performance Test ? Step 2....2253
Cylinder Cutout Test....2253
Purpose....2253
Tools....2253
Possible Causes....2253
Procedure....2253
Injector Replacement....2254
Purpose....2254
Tools....2254
Procedure....2254
Fuel Pressure Control Valve (FPCV) Test....2255
Purpose....2255
Tools....2255
Procedure....2255
Charge Air Cooler (CAC) Pressure Test....2255
Procedure....2255
Table of Contents....2257
How to Use This Section....2259
Diagnostic Trouble Codes (DTCs) and Sub-section Diagnostics Page Locations....2259
Diagnostics Form EGED-500 Usage....2269
Diagnostics Form Example ....2269
HD-OBD System Description....2270
Diagnostic Procedure Process With Examples....2273
Pin-grip Inspection....2273
Circuit Diagnostics....2279
AAT Sensor (Ambient Air Temperature)....2279
Tools Required....2279
Pinpoint Diagnostics With ServiceMaxx? Software....2280
AFT (Aftertreatment) System....2282
Overview....2287
Tools Required....2287
SPN 3251 FMI 0 - DPFDP excessively HIGH (Plugged filter)....2292
Fault Overview....2292
Malfunction Indicator Lamp (MIL) Reaction....2292
Associated Faults....2292
Drive Cycle to Determine Fault Status....2292
SPN 3251 FMI 21 - DPFDP excessively LOW (Sensor/circuit fault or missing DPF)....2298
Fault Overview....2298
Malfunction Indicator Lamp (MIL) Reaction....2298
Associated Faults....2298
Drive Cycle to Determine Fault Status....2298
SPN 3471 FMI 1 - Fuel Pressure 1 Below Desired....2301
Fault Overview....2301
Malfunction Indicator Lamp (MIL) Reaction....2301
Associated Faults....2301
Drive Cycle to Determine Fault Status....2301
SPN 3471 FMI 7 - Fuel Doser Valve not responding as expected....2307
Fault Overview....2307
Malfunction Indicator Lamp (MIL) Reaction....2307
Associated Faults....2307
Drive Cycle to Determine Fault Status....2307
SPN 3719 FMI 0 - DPF Soot Load ? Highest (level 3 / 3)....2314
Fault Overview....2314
Malfunction Indicator Lamp (MIL) Reaction....2314
Associated Faults....2314
Drive Cycle to Determine Fault Status....2314
SPN 3720 FMI 0 - DPF Ash load at maximum limit....2319
Fault Overview....2319
Malfunction Indicator Lamp (MIL) Reaction....2319
Associated Faults....2319
Drive Cycle to Determine Fault Status....2319
SPN 5298 FMI 2 - Reduced DOC Efficiency ? De-Rate....2324
Fault Overview....2324
Malfunction Indicator Lamp (MIL) Reaction....2324
Associated Faults....2324
Drive Cycle to Determine Fault Status....2324
AFT System Indicators....2331
Regen Inhibitors....2337
Normal DPF Inlet....2341
Normal DPF Outlet....2342
Plugged DPF Inlet....2343
DPF Contaminated with Coolant....2344
DPF Contaminated with Oil....2345
DPF Outlet Leaking Soot....2346
External Damage to DPF....2347
DPF Ceramic Filter Brick Measurement....2348
AFTFD (Aftertreatment Fuel Doser)....2349
Tools Required....2350
AFTFIS (Aftertreatment Fuel Inlet Sensor)....2352
Tools Required....2353
Pinpoint Diagnostics With ServiceMaxx? software....2353
Aftertreatment Fuel Pressure 2 Sensor (AFTFP2)....2356
Tools Required....2357
Pinpoint Diagnostics With ServiceMaxx? Software....2357
Aftertreatment Fuel Shutoff Valve (AFTFSV)....2359
Tools Required....2359
AMS (Air Management System)....2362
Tools Required....2363
SPN 2659 FMI 20 - EGR High Flow Rate Detected....2366
Fault Overview....2366
Malfunction Indicator Lamp (MIL) Reaction....2366
Associated Faults....2366
Drive Cycle to Determine Fault Status....2366
APP Sensor (Accelerator Pedal Position)....2369
Overview....2369
Tools Required....2370
Pinpoint Diagnostics With ServiceMaxx? software....2371
CACOT Sensor (Charge Air Cooler Outlet Temperature)....2374
Tools Required....2374
Pinpoint Diagnostics With ServiceMaxx? Software....2375
CCOSS Sensor (Crankcase Oil Separator Speed)....2377
Tools Required....2377
Pinpoint Crankcase Oil Separator: Not spinning fault....2377
CCS (Cruise Control System)....2379
Function....2379
CCS Operation....2379
CCS Pinpoint Diagnostics ? With ServiceMaxx? Software....2379
CFV (Coolant Flow Valve)....2380
CKP Sensor (Crankshaft Position)....2383
Tools Required....2383
CMP Sensor (Camshaft Position)....2385
Tools Required....2385
CMV (Coolant Mixer Valve)....2387
Tools Required....2387
CSFI (Cold Start Fuel Igniter)....2389
Tools Required....2389
CSFS (Cold Start Fuel Solenoid)....2394
Tools Required....2394
Cylinder Balance....2396
Tools Required....2397
Cylinder Balance Operation....2397
Pinpoint Diagnostics With ServiceMaxx? software....2398
DOCIT Sensor (Diesel Oxidation Catalyst Inlet Temperature)....2399
Tools Required....2399
Pinpoint Diagnostics With ServiceMaxx? Software....2400
DOCOT Sensor (Diesel Oxidation Catalyst Outlet Temperature)....2402
Tools Required....2402
Pinpoint Diagnostics With ServiceMaxx? Software....2403
DPFDP Sensor (Diesel Particulate Filter Differential Pressure)....2405
Tools Required....2405
Pinpoint Diagnostics With ServiceMaxx? Software....2406
DPFOT Sensor (Diesel Particulate Filter Outlet Temperature)....2408
Tools Required....2408
Pinpoint Diagnostics With ServiceMaxx? Software....2409
DPF System (Diesel Particulate Filter)....2411
Tools Required....2412
SPN 3936 FMI 10 - DPF Thermal Management Mode Failed to Raise DOC-In Temp as Expected....2413
Fault Overview....2413
Malfunction Indicator Lamp (MIL) Reaction....2413
Associated Faults....2413
Drive Cycle to Determine Fault Status....2413
SPN 3936 FMI 20 - High Regen Frequency....2417
Fault Overview....2417
Malfunction Indicator Lamp (MIL) Reaction....2417
Associated Faults....2417
Drive Cycle to Determine Fault Status....2417
EBPV (Exhaust Back Pressure Valve)....2424
Tools Required....2424
ECB1 (Engine Compression Brake 1)....2427
Tools Required....2427
ECB2 (Engine Compression Brake 2)....2429
Tools Required....2429
ECL Switch (Engine Coolant Level)....2431
Tools Required....2431
Pinpoint Diagnostics With ServiceMaxx? Software....2431
ECM Power (Engine Control Module)....2433
Tools Required....2433
ECM Power Output (Engine Control Module)....2435
Tools Required....2435
ECM (Engine Control Module)Self-Diagnostics....2439
Tools Required....2439
Crank Sensor Relearn Procedure....2441
Tools Required....2441
Function....2441
ECS (Engine Coolant System)....2442
Tools Required....2442
ECT1 Sensor (Engine Coolant Temperature 1)....2443
Tools Required....2443
Pinpoint Diagnostics With ServiceMaxx? Software....2443
ECT2 Sensor (Engine Coolant Temperature 2)....2445
Tools Required....2445
Pinpoint Diagnostics With ServiceMaxx? Software....2445
Engine Fan Control (EFC) ? Two Speed and Variable....2448
Tools Required....2449
Function Two-Speed EFC....2449
Function Variable EFC....2449
EFC ? Two Speed Sensor Circuit Operation....2449
EFC ? Variable Sensor Circuit Operation....2449
EGRT Sensor (Exhaust Gas Recirculation Temperature)....2451
Tools Required....2451
Pinpoint Diagnostics With ServiceMaxx? Software....2452
EGR (Exhaust Gas Recirculation) Valve....2454
Tools Required....2455
Pinpoint Diagnostics With ServiceMaxx? Software....2455
Exhaust Gas Recirculation (EGR) System Monitor....2458
Tools Required....2458
SPN 3058 FMI 0 - Engine Did Not Go Into Open Loop EGR Control When Expected....2459
Fault Overview....2459
Malfunction Indicator Lamp (MIL) Reaction....2459
Associated Faults....2459
SPN 3058 FMI 10 - Engine Did Not Go Into Closed Loop EGR Control When Expected....2462
Fault Overview....2462
Malfunction Indicator Lamp (MIL) Reaction....2462
Associated Faults....2462
EOL Sensor (Engine Oil Level)....2465
Tools Required....2465
Pinpoint Diagnostics With ServiceMaxx? Software....2466
EOP Sensor (Engine Oil Pressure)....2468
Tools Required....2468
Pinpoint Diagnostics With ServiceMaxx? Software....2468
EOT Sensor (Engine Oil Temperature)....2470
Tools Required....2470
Pinpoint Diagnostics With ServiceMaxx? Software....2470
ETV (Engine Throttle Valve)....2472
Tools Required....2472
Pinpoint Diagnostics With ServiceMaxx? Software....2473
EWPS (Engine Warning Protection System) ....2475
Function....2476
EWPS Programmable Parameters....2477
Tools Required....2477
FDP Sensor (Fuel Delivery Pressure)....2478
Tools Required....2478
Pinpoint Diagnostics With ServiceMaxx? Software....2479
FPCV (Fuel Pressure Control Valve)....2481
Tools Required....2481
Pinpoint Diagnostics With ServiceMaxx? Software....2481
FRP Sensor (Fuel Rail Pressure)....2483
Overview....2484
Tools Required....2484
Pinpoint Diagnostics With ServiceMaxx? Software....2485
SPN 157 - FMI 20 FRP signal Drifted HIGH....2488
Fault Overview....2488
Malfunction Indicator Lamp (MIL) Reaction....2488
Associated Faults....2488
Drive Cycle....2488
SPN 157 - FMI 21 FRP signal Drifted LOW....2491
Fault Overview....2491
Malfunction Indicator Lamp (MIL) Reaction....2491
Associated Faults....2491
Drive Cycle....2491
FRP (Fuel Rail Pressure) System....2494
Tools Required....2494
Pinpoint Diagnostics With ServiceMaxx? Software....2495
Hard Brake Monitor....2497
HS (Humidity Sensor) / AIT (Air Inlet Temperature Sensor)....2498
Tools Required....2498
Pinpoint Diagnostics With ServiceMaxx? Software....2499
IMP (Intake Manifold Pressure)....2502
Overview....2503
Tools Required....2503
Pinpoint Diagnostics With ServiceMaxx? Software....2504
SPN 102 - FMI 10 IMP - Boost Slow Response....2506
Malfunction Indicator Lamp (MIL) Reaction....2506
Associated Faults....2506
Drive Cycle....2506
IMT Sensor (Intake Manifold Temperature)....2511
Tools Required....2511
Pinpoint Diagnostics With ServiceMaxx? Software....2511
INJ (Injector) Circuits....2514
Tools Required....2515
IST (Idle Shutdown Timer) System (Clean Low Idle)....2521
IST (Clean Low Idle)....2521
IST (Idle Shutdown Timer) System (Federal - Optional)....2522
IST (Federal - Optional) Sensor Circuit Operation....2522
J1939 Data Link Communications....2523
Tools Required....2523
MAF Sensor (Mass Air Flow)....2525
Function....2525
MIL (Malfunction Indicator Lamp)....2526
O2S (Oxygen Sensor)....2527
Tools Required....2528
Function....2528
O2S Sensor Circuit Operation....2528
Pinpoint Diagnostics With ServiceMaxx? Software....2529
Service Interval Messages....2532
Service Interval Messages Operation....2532
Stand Alone Real Time (SART) Clock....2533
Tools Required....2533
TC1TOP Sensor (Turbocharger 1 Turbine Outlet Pressure)....2535
Tools Required....2535
Pinpoint Diagnostics With ServiceMaxx? Software....2535
TC1WC (Turbocharger 1 Wastegate Control)....2539
Tools Required....2539
TC2WC (Turbocharger 2 Wastegate Control)....2541
Tools Required....2541
TC2CIS (Turbocharger 2 Compressor Inlet Sensor)....2543
Tools Required....2543
Pinpoint Diagnostics With ServiceMaxx? Software....2544
TOSS / VSS (Transmission Output Shaft Speed / Vehicle Speed Sensor) Sensor....2547
Overview....2549
Tools Required....2549
Pinpoint Diagnostics With ServiceMaxx? Software....2550
SPN 191 FMI 1 TOSS / VSS not detected while vehicle moving....2552
Malfunction Indicator Lamp (MIL) Reaction....2553
Drive Cycle to Determine Fault Status....2553
VREF (Voltage Reference)....2556
Tools Required....2557
WIF Sensor (Water In Fuel)....2562
Tools Required....2562
Pinpoint Diagnostics With ServiceMaxx? Software....2563
WIFL (Water In Fuel Lamp)....2565
Overview....2565
Tools Required....2565
SPN 97 - FMI 3 - WIFL short to PWR....2566
SPN 97 - FMI 4 - WIFL short to GND....2567
SPN 97 - FMI 5 - WIFL open / load circuit....2569
WTSL (Wait to Start Lamp)....2571
Overview....2571
Tools Required....2571
SPN 1081 - FMI 3 - WTSL circuit short to PWR....2572
Malfunction Indicator Lamp (MIL) Reaction....2572
SPN 1081 - FMI 4 - WTSL circuit short to GND....2574
Malfunction Indicator Lamp (MIL) Reaction....2574
SPN 1081 - FMI 5- WTSL open load / circuit....2576
Malfunction Indicator Lamp (MIL) Reaction....2576
Sensor and Actuator Locations....2578
Engine Mounted Components....2578
AFT System....2580
Engine Compression Brake Locations....2581
Vehicle Mounted Components....2582
Ambient Air Temperature Sensor....2582
Table of Contents....2583
Electrical Tools....2585
180-Pin Breakout Box....2585
3-Banana Plug Harness....2585
500 Ohm Resistor Harness....2586
Big Bore Terminal Test Probe Kit....2586
Digital Multimeter (DMM)....2586
EXP-1000 HD by Midtronics....2587
EZ-Tech? Electronic Service Tool (EST)....2587
ServiceMaxx? Software....2587
MaxxForce? 11 and 13 Engine Tool Kit....2588
NAVCoM Interface Kit....2588
Breakout Harness 4485A (APP)....2588
Breakout Harness 4602 (AFTFSV)....2589
Breakout Harness 4735A (O2S)....2589
Breakout Harness 4760A (DOCIT, DOCOT, DPFOT, and EGRT)....2589
Breakout Harness 4761A (DPFDP)....2589
Breakout Harness 4827 (CSFS, ECT1, ECT2, EOL, and EOT)....2590
Breakout Harness 4828 (AFTFD and FPCV)....2590
Breakout Harness 4829 (FRP)....2590
Breakout Harness 4830 (AFTFIS, HS/AIT, and TC2CIS)....2590
Breakout Harness 4844 (EFAN)....2591
Breakout Harness 4850 (IMP)....2591
Breakout Harness 4870 (CMV)....2591
Breakout Harness 4871 (AAT and CFV)....2591
Breakout Harness 4881 (FDP)....2592
Breakout Harness 4882 (EOP)....2592
Breakout Harness 4883 (IMT)....2592
Breakout Harness 4885 (CSR)....2592
Breakout Harness 4951 (CCOSS)....2593
Breakout Harness 4993 (CACOT)....2593
Breakout Harness 6002 (WIF)....2593
Breakout Harness 6003 (EBPV, TC1TOP, TC1WC, and TC2WC)....2593
Breakout Harness 6004 (ECB)....2594
Breakout Harness 6016 (ETV and EGR Valve)....2594
Breakout Harness 6021 (CKP and CMP)....2594
Breakout Harness 6027 (AFTFP2)....2594
Mechanical Tools....2595
Air Cap, Fuel Cap and Plug Kit....2595
Air Compressor Coolant Line Release Tool....2595
Air Intake Guard....2595
Blow-by Test Tool....2596
Clean Fuel Source Tool....2596
Cold Start Solenoid Test Adapter Kit....2597
Digital Manometer....2597
EGR Cooler Leak Detection Test Kit....2598
Engine Brake Kit....2598
Fuel Block Off Tool....2598
Fuel Injector Cups....2598
Fuel Inlet Restriction and Aeration Tool....2599
Fuel Line Coupler....2599
Fuel Line Disconnect Tool 11.8 mm....2599
Fuel Line Disconnect Tool 16 mm....2599
Fuel Pressure Gauge....2600
High Pressure Rail Plugs....2600
High Pressure Return Line Tester....2601
Pressure Test Kit....2602
Radiator Pressure Test Kit....2602
Slack Tube? Manometer....2603
UV Leak Detection Kit....2604
Vacuum Analyzer and Fuel Pump Tester....2604
Table of Contents....2605
Abbreviations and Acronyms....2607
Abbreviations and Acronyms....2607
Table of Contents....2613
Terminology....2615
Terms....2615
Table of Contents....2625
All Ratings....2627
MaxxForce? 11 (10.5 L)....2633
330 hp @ 1700 rpm....2633
370 hp @ 1700 rpm....2634
390 hp @ 1700 rpm....2635
MaxxForce? 13 (12.4 L)....2636
410 hp @ 1700 rpm....2636
430 hp @ 1700 rpm....2637
475 hp @ 1700 rpm....2638
Table of Contents....2639
Signal Values....2641
Table of Contents....2649
Description....2651
tables....2081
Technical Service Literature....2081
MaxxForce? 11 and 13 Diesel Engines....2088
Engine Brake Solenoid Specifications....2181
Engine Brake Oil Pressure Requirements....2183
Normal fuel return flow with number of connected injectors....2248
Example....2275
Example....2276
Example....2277
Example....2278
SPN 171 FMI 2 ? AAT signal does not agree with other sensors....2280
Sensor Circuit Check With ServiceMaxx? Software....2281
Connector Voltage Check Without ServiceMaxx? Software....2281
Harness Resistance Check....2281
SPN 3251 FMI 14 ? DPFDP sensor pressure hoses reversed....2288
SPN 3480 FMI 0 ? AFTFP1 too high while dosing....2288
SPN 3480 FMI 1 ? AFTFP1 too low while dosing....2288
SPN 3481 FMI 7 ? Incorrect dosing pressure, multiple events....2288
SPN 3556 FMI 0 ? AFT Fuel Pressure 2 Excessively High....2289
SPN 3556 FMI 1 ? AFT Fuel Pressure 2 Below Desired....2289
SPN 3556 FMI 7 ? AFT Fuel Injector not responding as expected....2289
SPN 3719 FMI 15 ? DPF Soot Load - Lowest (level 1/3)....2289
SPN 3719 FMI 16 ? DPF Soot Load - Moderate (level 2/3)....2289
SPN 4077 FMI 0 ? AFTFP2 too high while dosing....2290
SPN 4077 FMI 1 ? AFTFP2 too low while dosing....2290
SPN 4766 FMI 10 ? DPF Regeneration feedback fault....2290
SPN 4766 FMI 20 ? DOC Outlet Temp above maximum desired....2290
SPN 4766 FMI 21 ? DOC Outlet Temp below minimum desired....2291
SPN 5319 FMI 31 ? DPF incomplete Regeneration....2291
Entry Conditions for a Rolling Regen....2333
Entry Conditions for a Parked Regen....2334
Sensor Compare Checks....2336
Exhaust Restriction Test....2336
Check Rolling Regen Inhibitors....2338
Check Parked Regen Inhibitors....2339
Parked Regen Checks....2340
Connector Voltage Check ? AFTFD Disconnected....2350
Operational Voltage Check....2351
Actuator Resistance Check....2351
Harness Resistance Check....2351
Sensor Circuit Check....2354
Pinpoint Diagnostics Without ServiceMaxx? Software....2354
Harness Resistance Check....2355
Sensor Circuit Check....2358
Pinpoint Diagnostics Without ServiceMaxx? Software....2358
Harness Resistance Check....2358
Connector Voltage Check ? AFTFSV Disconnected....2360
Operational Voltage Check....2360
Actuator Resistance Check....2360
Harness Resistance Check....2361
SPN 102 FMI 16 ? Intake Manifold Pressure Overboost ....2364
SPN 102 FMI 18 ? Intake Manifold Pressure Underboost....2364
SPN 1173 FMI 16 ? TC2CIT signal above desired (Interstage CAC under cooling)....2364
SPN 2630 FMI 16 ? CACOT Undercooling....2365
SPN 2659 FMI 21 ? EGR Low Flow Rate detected....2365
Sensor Circuit Check....2372
Pinpoint Diagnostics Without ServiceMaxx? Software....2372
Harness Resistance Check....2373
Operational Voltage Check....2373
SPN 2630 FMI 2 ? CACOT signal does not agree with other sensors....2375
Sensor Circuit Check With ServiceMaxx? Software....2376
Connector Voltage Check Without ServiceMaxx? Software....2376
Harness Resistance Check....2376
Sensor Resistance Check....2378
Connector Voltage Check Without ServiceMaxx? software....2378
Harness Resistance Check....2378
Programmable Parameters....2379
Switch Checks....2380
Connector Voltage Check....2381
Operational Voltage Check....2381
Actuator Resistance Check....2381
Harness Resistance Check....2382
Sensor Resistance Check....2383
Harness Resistance Check....2384
Operational Checks....2384
Sensor Resistance Check....2385
Harness Resistance Check....2386
Operational Checks....2386
SPN 636 FMI 2 ? CMP and CKP Synchronization Error....2386
Connector Voltage Check....2388
Operational Voltage Check....2388
Actuator Resistance Check....2388
Harness Resistance Check....2388
Cold Soak Sensor Compare Check With ServiceMaxx? Software....2390
SPN 626 FMI 18 ? Cold Start Assist fault: Lack of heat in the Intake Manifold ....2390
Voltage Check on CSFI - Actuator Test....2390
Amperage Draw Check - Actuator Test....2390
Voltage Checks on Relay Connector....2391
Voltage Checks on Relay - Actuator Test....2392
CSFI Resistance Check....2393
Harness Resistance Check....2393
Connector Voltage Check ? CSFS Disconnected....2395
Operational Voltage Check....2395
Actuator Resistance Check....2395
Harness Resistance Check....2395
SPN 4765 FMI 2 ? DOCIT signal does not agree with other exhaust sensors....2400
Sensor Circuit Check With ServiceMaxx? Software....2401
Connector Voltage Check Without ServiceMaxx? Software....2401
Harness Resistance Check....2401
SPN 4766 FMI 2 ? DOCOT signal does not agree with other exhaust sensors....2403
Sensor Circuit Check With ServiceMaxx? Software....2404
Connector Voltage Check Without ServiceMaxx? Software....2404
Harness Resistance Check....2404
SPN 3251 FMI 2 ? DPFDP above or below desired level....2406
Sensor Circuit Check With ServiceMaxx? Software....2407
Connector Voltage Check Without ServiceMaxx? Software....2407
Harness Resistance Check....2407
SPN 3246 FMI 2 ? DPFOT signal does not agree with other exhaust sensors....2409
Sensor Circuit Check With ServiceMaxx? Software....2410
Connector Voltage Check Without ServiceMaxx? Software....2410
Harness Resistance Check....2410
Connector Voltage Check ? EBPV Disconnected....2425
Operational Voltage Check....2425
Actuator Resistance Check....2425
Harness Resistance Check....2426
Connector Voltage Check ? ECB1 Disconnected....2428
Operational Voltage Check....2428
Actuator Resistance Check....2428
Harness Resistance Check....2428
Connector Voltage Check ? ECB2 Disconnected....2430
Operational Voltage Check....2430
Actuator Resistance Check....2430
Harness Resistance Check....2430
SPN 111 FMI 1 ? Low Engine Coolant level....2432
Connector Voltage Check....2432
Harness Resistance Check....2432
SPN 158 FMI 15- ECM Switched voltage too HIGH....2434
SPN 158 FMI 17- ECM Switched voltage too LOW....2434
Voltage Checks at ECM....2434
Voltage Checks for SPN 3597 FMI 4 ? ECM Power Output 1....2436
Voltage Checks for SPN 3598 FMI 4 ? ECM Power Output 2....2436
Voltage Checks for SPN 3599 FMI 4 ? ECM Power Output 3....2437
Harness Resistance Check for SPN 3597 FMI 4 ? ECM Power Output 1....2437
Harness Resistance Check for SPN 3598 FMI 4 ? ECM Power Output 2....2438
Harness Resistance Check for SPN 3599 FMI 4 ? ECM Power Output 3....2438
SPN 108 FMI 3- BARO signal Out of Range HIGH....2439
SPN 108 FMI 4 - BARO signal Out of Range LOW....2439
SPN 628 FMI 12 - ECM Memory Error....2440
SPN 629 FMI 2- ECM Error- Level 2 Monitoring....2440
SPN 629 FMI 8 - Engine Off timer fault....2440
SPN 629 FMI 12 - ECM Internal chip Error....2440
SPN 629 FMI 14 - ECM Internal component....2440
SPN 1110 FMI 1 ? ECM Detects Fueling Without Demand....2440
Cold Soak Sensor Compare Check With ServiceMaxx? Software....2442
Sensor Circuit Check With ServiceMaxx? Software....2444
Connector Voltage Check Without ServiceMaxx? Software....2444
Harness Resistance Check....2444
SPN 4076 FMI 16 ? ECT2 signal does not agree with other sensors (Cold soak)....2446
Sensor Circuit Check With ServiceMaxx? Software....2446
Connector Voltage Check Without ServiceMaxx? Software....2446
Harness Resistance Check....2447
Voltage Check at Single or Two-Speed EFC Connector - Actuator Test....2450
Harness Resistance Check....2450
SPN 412 FMI 2 ? EGRT signal does not agree with other sensors....2452
Sensor Circuit Check With ServiceMaxx? Software....2453
Connector Voltage Check Without ServiceMaxx? Software....2453
Harness Resistance Check....2453
SPN 27 FMI 7 ? EGRP does not agree with commanded position....2456
Connector Voltage Check ? EGR Valve Disconnected....2456
Operational Voltage Check....2456
Harness Resistance Check....2457
Sensor Circuit Check With ServiceMaxx? Software....2466
Connector Voltage Check Without ServiceMaxx? Software....2467
Harness Resistance Check....2467
Sensor Circuit Check....2469
Connector Voltage Check....2469
Harness Resistance Check....2469
Sensor Circuit Check With ServiceMaxx? Software....2471
Pinpoint Diagnostics Without ServiceMaxx? Software....2471
Harness Resistance Check....2471
Connector Voltage Check ? ETV Disconnected....2473
Operational Voltage Check....2474
Harness Resistance Check....2474
SPN 94 FMI 0 ? Fuel pressure above maximum....2479
Sensor Circuit Check With ServiceMaxx? Software....2480
Connector Voltage Check Without ServiceMaxx? Software....2480
Harness Resistance Check....2480
Connector Voltage Check ? FPCV Disconnected....2482
Operational Voltage Check....2482
Harness Resistance Check....2482
Sensor Circuit Check With ServiceMaxx? Software....2486
Connector Voltage Check Without ServiceMaxx? Software....2487
Harness Resistance Check....2487
SPN 157 FMI 0 - FRP relief valve opening fault....2495
SPN 157 FMI 14 - FRP Relief Valve failure....2495
SPN 3055 FMI 0 - FRP exceeded maximum....2495
SPN 3055 FMI 15 - FRP below minimum with maximum command....2495
SPN 3055 FMI 16 - FRP not as expected ? Run High pressure pump test....2496
SPN 3055 FMI 17 - FRP above maximum with minimum command....2496
SPN 172 FMI 2 ? AIT signal does not agree with other sensors....2499
Sensor Circuit Check With ServiceMaxx? Software....2500
Connector Voltage Check Without ServiceMaxx? Software....2500
Harness Resistance Check....2501
Sensor Circuit Check With ServiceMaxx? Software....2505
Connector Voltage Check Without ServiceMaxx? Software....2505
Harness Resistance Check....2505
Cold Soak Sensor Compare Check With ServiceMaxx? Software....2512
SPN 105 FMI 2 ? IMT signal does not agree with other sensors....2512
SPN 105 FMI 18 ? IMT signal not responding as expected....2512
Sensor Circuit Check With ServiceMaxx? Software....2513
Connector Voltage Check Without ServiceMaxx? Software....2513
Harness Resistance Check....2513
Injector 1 ? Resistance Checks Through Harness and Injector....2515
Injector 2 ? Resistance Checks Through Harness and Injector....2516
Injector 3 ? Resistance Checks Through Harness and Injector....2517
Injector 4 ? Resistance Checks Through Harness and Injector....2518
Injector 5 ? Resistance Checks Through Harness and Injector....2519
Injector 6 ? Resistance Checks Through Harness and Injector....2520
Connector Voltage Check....2524
EST Communication Check....2524
Harness Resistance Check....2524
SPN 724 FMI 20 ? O2S adaptation above maximum limit / SPN 724 FMI 21 ? O2S adaptation below minimum limit....2529
Connector Voltage Check Without ServiceMaxx? Software....2530
Harness Resistance Check....2531
Pinpoint O2S System Fault ....2531
SPN 3223 FMI 1? O2S heater temperature below minimum....2531
SPN 3223 FMI 17 ? O2S heater temperature below minimum at low battery PWR....2531
O2S Calibration Procedure ? Using ServiceMaxx? Software....2531
Connector Voltage Check....2533
Harness Resistance Check....2534
SPN 5541 FMI 2 ? TC1TOP signal does not agree with BARO....2536
Sensor Circuit Check With ServiceMaxx? Software....2536
Connector Voltage Check Without ServiceMaxx? Software....2537
Harness Resistance Check....2538
Connector Voltage Check ? TC1WC Disconnected....2540
Operational Voltage Check....2540
Actuator Resistance Check....2540
Harness Resistance Check....2540
Connector Voltage Check ? TC2WC Disconnected....2542
Operational Voltage Check....2542
Actuator Resistance Check....2542
Harness Resistance Check....2542
SPN 1173 FMI 2 ? TC2CIT signal does not agree with other sensors....2544
Sensor Circuit Check....2545
Pinpoint Diagnostics Without ServiceMaxx? Software....2545
Harness Resistance Check....2546
SPN 84 FMI 2 - Vehicle speed anti-tampering fault....2550
TOSS / VSS Connector Voltage Check Without ServiceMaxx? Software....2550
TOSS / VSS Sensor Continuity Check Without ServiceMaxx? Software....2550
Harness Resistance Check....2551
TOSS / VSS Operational Check Without ServiceMaxx? Software....2551
SPN 191 FMI 2 TOSS / VSS signal erratic, intermittent, or incorrect....2552
SPN 191 FMI 3 TOSS / VSS signal out of range HIGH....2552
SPN 191 FMI 4 TOSS / VSS signal out of range LOW....2552
SPN 191 FMI 16 TOSS / VSS reading higher then limit....2553
Voltage Checks for SPN 3509 FMI 14 ? VREF1....2557
Voltage Checks for SPN 3510 FMI 14 ? VREF2....2558
Voltage Checks for SPN 3511 FMI 14 ? VREF3....2558
Voltage Checks for SPN 3512 FMI 14 ? VREF4....2559
Voltage Checks for SPN 3513 FMI 14 ? VREF5....2559
Voltage Checks for SPN 3514 FMI 14 ? VREF6....2560
Harness Resistance Check for SPN 3509 FMI 14 ? VREF1....2560
Harness Resistance Check for SPN 3510 FMI 14 ? VREF2....2560
Harness Resistance Check for SPN 3511 FMI 14 ? VREF3....2560
Harness Resistance Check for SPN 3512 FMI 14 ? VREF4....2561
Harness Resistance Check for SPN 3513 FMI 14 ? VREF5....2561
Harness Resistance Check for SPN 3514 FMI 14 ? VREF6....2561
Voltage Check....2563
Connector Resistance Check to GND....2564
Harness Resistance Check....2564
Key-On Engine-Off....2627
Engine Cranking....2627
Low Idle, no load, stabilized engine operating temperature....2628
High Idle, no load, stabilized engine operating temperature....2629
Full load, rated speed on dynamometer, stabilized engine operating temperature....2629
Component Specifications....2630
Actuator Output State....2631
Cold Start Assist System....2632
Crankcase Pressure....2632
EBPV Rod Extension....2632
TC2WC Rod Extension....2632
0000001741 - MaxxForce 11 and 13 Engine Diagnostic Manual (2014-04)....2654
toc....2656
Table of Contents....2656
Safety Terminology....2660
Safety Instructions....2660
Work Area....2660
Safety Equipment....2660
Protective Measures....2660
Vehicle....2660
Engine....2660
Fire Prevention....2660
Batteries....2661
Compressed Air....2661
Tools....2661
Fluids Under Pressure....2661
Fuel....2661
Removal of Tools, Parts, and Equipment....2661
Table of Contents....2662
Engine Identification....2664
Engine Serial Number....2664
Engine Serial Number Examples....2664
Engine Serial Number Codes....2664
Engine Emission Label ....2664
Engine Accessory Labels and IdentificationPlates....2665
Engine Specifications....2665
Heavy Duty On Board Diagnostics (HD-OBD)....2667
Engine Description....2667
Optional Equipment....2668
Chassis Mounted Equipment....2668
Engine Component Locations....2669
Air Management System....2673
Airflow....2674
Turbochargers....2675
Air Control Valve (ACV)....2676
Boost Control....2676
Low Pressure Charge Air Cooler (LPCAC)....2677
High Pressure Charge Air Cooler (HPCAC)....2677
High Pressure Boost Pressure (HPBP) Sensor ....2677
High Pressure Boost Temperature (HPBT) Sensor ....2677
Low Pressure Boost Pressure (LPBP) and Low Pressure Boost Temperature (LPBT) Sensors ....2677
Exhaust Gas Recirculation (EGR) System....2678
EGR System Overview....2679
EGR Flow....2679
EGR System Control....2679
EGRV Control....2679
EGR ? Open Loop....2680
EGR ? Closed Loop ....2680
EGR Flow Cooling....2680
Aftertreatment (AFT) System....2681
Diesel Particulate Filter (DPF)....2682
Diesel Oxidation Catalyst (DOC)....2682
Aftertreatment (AFT) System Conditions and Responses....2682
Downstream Fuel Injection....2683
Downstream Injection (DSI) Unit....2684
Aftertreatment Fuel Injector (AFI)....2684
Crankcase Oil Separator....2685
Fuel Management System....2687
Fuel System Components....2687
Fuel Flow....2688
Low Pressure Fuel System....2689
Chassis Mounted Filter/Water Separator....2689
Fuel Primer Pump Assembly....2689
Low Pressure (LP) Fuel Pump....2690
Fuel Filter Assembly....2690
High Pressure Fuel System....2691
High Pressure (HP) Pump....2692
Fuel Pressure Control Valve (FPCV)....2692
Fuel Rail....2692
Fuel Rail Pressure (FRP) Sensor....2692
Rail Pressure Limiting Valve....2692
Injectors....2692
Inlet Air Heater System....2692
Inlet Air Heater System Components....2692
Inlet Air Heater Fuel Igniter (IAHFI)....2692
Inlet Air Heater Relay (IAHR)....2693
Inlet Air Heater Fuel Solenoid (IAHFS) Valve....2693
Inlet Air Heater System Operation....2693
Oil Flow and Components....2694
Crankcase Oil Separator....2696
Remote Mounted Centrifugal Oil Filter (Optional)....2697
Engine Cooling System....2698
Cooling System Flow....2698
Thermostat Operation....2699
Coolant Control Valve (CCV) assembly operation....2700
Coolant Flow Valve (CFV)....2700
Coolant Mixer Valve (CMV)....2700
Engine Brake System....2701
Engine Brake Control System Components....2701
Engine Brake System Description....2702
Engine Brake System Operation....2702
Electronic Control System....2703
Electronic Control System Components....2703
Operation and Function....2703
Reference Voltage (VREF)....2703
Signal Conditioner....2703
Microprocessor....2703
Diagnostic Trouble Codes....2703
Microprocessor Memory....2703
ROM....2703
RAM....2703
Actuator Control....2704
Actuators....2704
Coolant Control Valve (CCV)....2704
Exhaust Back Pressure Valve (EBPV) Control....2704
Exhaust Gas Recirculation (EGR) Valve ....2704
Air Control Valve (ACV)....2704
Inlet Air Heater Relay (IAHR)....2704
Inlet Air Heater Fuel Solenoid (IAHFS) Valve....2705
Engine Throttle Valve (ETV)....2705
Fuel Pressure Control Valve (FPCV)....2705
Aftertreatment Fuel Doser (AFTFD)....2705
Aftertreatment Fuel Shutoff Valve (AFTFSV)....2705
Engine and Vehicle Sensors....2705
Thermistor Sensors....2705
Aftertreatment Temperature Sensors....2706
Engine Coolant Temperature (ECT) Sensors....2706
Engine Oil Temperature (EOT) Sensor....2706
Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....2706
Charge Air Cooler Outlet Temp (CACOT) Sensor....2706
Intake Manifold Temperature (IMT) Sensor....2706
Exhaust Gas Recirculation Temperature (EGRT) Sensor....2707
Ambient Air Temperature (AAT) Sensor....2707
Variable Capacitance Sensors....2707
DPF Differential Pressure (DPFDP) Sensor....2707
Fuel Delivery Pressure (FDP) Sensor....2707
Engine Oil Pressure (EOP) Sensor....2707
Fuel Rail Pressure (FRP) Sensor....2707
Intake Manifold Pressure (IMP) Sensor....2708
Aftertreatment Fuel Inlet Sensor (AFTFIS) ....2708
Aftertreatment Fuel Pressure 2 (AFTFP2) sensor....2708
Turbocharger 1 Turbine Outlet Pressure (TC1TOP)....2708
Magnetic Pickup Sensors....2708
Crankshaft Position (CKP) Sensor....2709
Camshaft Position (CMP) Sensor....2709
Vehicle Speed Sensor (VSS)....2709
Crankcase Oil Separator Speed (CCOSS) sensor....2709
Potentiometer Sensors....2709
Accelerator Pedal Position (APP)....2709
Switches....2710
Driveline Disengagement Switch (DDS)....2710
Engine Coolant Level (ECL) Switch....2710
Oil Level Sensor (OLS)....2710
Additional Sensors....2710
Oxygen Sensor (O2S)....2710
Humidity Sensor (HS)....2710
Table of Contents....2712
Standard Electronic Control Features....2714
Aftertreatment (AFT) System....2714
Cold Ambient Protection (CAP)....2714
Inlet Air Heater....2714
Coolant Temperature Compensation (CTC)....2714
Data Plate....2714
Electronic Speedometer and Tachometer....2715
Engine Crank Inhibit (ECI)....2715
Engine Electronic Governor Control....2715
Engine Fan Control (EFC)....2715
Event Logging System ....2715
Fast Idle Advance....2715
J1939 Datalink ....2716
Password Protection....2716
Service Diagnostics....2716
Trip Reporting....2716
Vehicle Setup....2716
Optional Electronic Control Features....2717
Cruise Control....2717
Driver Reward....2717
MaxxForce? Engine Brake....2717
Engine Warning Protection System (EWPS)....2717
Gear Down Protection (GDP)....2717
Idle Shutdown Timer (IST)....2718
Progressive Shift....2718
Power Take Off (PTO) - In Cab....2718
Power Take Off (PTO) - Remote....2718
Service Interval....2719
Traction Control....2719
Up-Shift Indicator....2719
Road Speed Limiter....2719
Table of Contents....2720
Session Files....2722
Diagnostic Trouble Code (DTC)....2722
Suspect Parameter Number (SPN) ....2722
Failure Mode Indicator (FMI)....2722
Pending....2722
Active....2722
Previously Active....2722
Freeze Frame Data....2722
ECM Programmable Features ....2723
Connecting EST with ServiceMaxx? Software to Engine....2723
Service Bay Tests....2723
Engine Off Tests....2723
Actuator Test....2723
Continuous Monitor Test....2723
DPF Servicing....2723
Relative Compression Test....2724
Engine Running Tests....2724
Air Management Test....2724
High Pressure Pump Test....2725
Cylinder Cutout Test....2726
Multi-Cylinder Cutout Test....2727
Hot Run Sensor Comparison Test....2729
Purpose....2729
Tools Required....2729
Onboard Filter Cleanliness Test....2731
Service Tool Procedures....2732
Engine Off Procedures....2732
Inlet Air Heater....2732
Oxygen Sensor Calibration....2732
Injector Quantity Adjustment....2732
Engine Running Procedures....2732
Engine Fan....2732
Table of Contents....2734
Coolant System....2736
Coolant Loss....2736
Symptom....2736
Possible Causes....2736
Tools....2736
Procedure....2736
Coolant Overflow....2737
Symptom....2737
Possible Causes....2737
Tools....2737
Procedure....2738
Coolant Leak to Exhaust....2739
Symptoms....2739
Possible Causes....2739
Tools....2739
Aftertreatment Fuel Injector (AFI) Coolant Leak Inspection....2740
EGR Cooler Leak Inspection....2740
Coolant Leak to Fuel ....2741
Symptom....2741
Possible Causes....2741
Tools....2741
Procedure....2741
Coolant Leak to Intake....2741
Symptom....2741
Possible Causes....2741
Tools....2741
Procedure....2742
Coolant Leak to Lube Oil....2742
Symptom....2742
Possible Causes....2742
Tools....2742
Lube Oil Contamination Inspection....2742
Cylinder Head Leak Test....2744
Procedure....2744
Coolant Over-Temperature....2744
Symptom....2744
Possible Causes....2744
Tools....2744
Coolant Over-Temperature Conditions Inspection....2744
Coolant Over-Temperature ? Engine Cooling....2746
Procedure....2746
Cooling System Components....2747
Cooling System Flow....2748
Thermostat Operation....2748
Coolant Control Valve (CCV) Assembly and Coolant Mixer Valve (CMV) Operation....2749
Coolant Control Valve (CCV) Test....2750
Lubrication System....2752
Visual Oil Level Inspection....2752
Incorrect Maintenance ....2752
Dilution from Coolant....2752
Power Steering Fluid Leak to Lube Oil....2752
Symptom....2752
Possible Causes....2752
Procedure....2752
Lube Oil to Coolant....2752
Symptom....2752
Possible Causes....2752
Tools....2752
Procedure....2753
Lube Oil to Intake....2753
Symptom....2753
Possible Causes....2753
Procedure....2753
Lube Oil to Exhaust....2753
Symptom....2753
Possible Causes....2753
Procedure....2753
Low Oil Pressure....2754
Symptom....2754
Possible Causes....2754
Tools....2754
Procedure....2755
Fuel System....2757
Excessive Fuel Consumption....2757
Symptom....2757
Possible Causes....2757
Operator effects....2757
Application effects....2757
Chassis effects....2757
Engine effects....2757
Procedure....2757
Fuel in Coolant....2758
Symptom....2758
Possible Causes....2758
Tools....2758
Procedure....2758
Fuel in Lube Oil....2759
Symptom....2759
Possible Causes....2759
Tools....2759
Procedure....2759
Fuel to Intake....2760
Symptom....2760
Possible Causes....2760
Procedure....2760
Fuel to Exhaust....2760
Symptom....2760
Possible Causes....2760
Tools....2760
Procedure....2760
Fuel Pressure and Aeration....2760
Symptom....2760
Possible Cause....2760
Procedure....2761
Water in Fuel....2761
Symptoms....2761
Possible Causes....2761
Tools....2761
Procedure....2761
Priming the Fuel System....2762
Procedure....2762
Engine Brake System....2764
Engine Brake Inspection....2764
Symptom....2764
Possible Causes....2764
Tools....2764
Preliminary Steps....2764
Engine Brake does not Turn on/Slow to Turn On....2765
Engine Brake does not Turn Off/Slow to Turn Off....2765
Engine Fails to Start....2765
Engine Brake Weak in Effect or Low on Engine Brake Power....2766
Engine Brake Slow to Operate or Weak in Effect....2766
Oil Pressure Dropping Below Minimum Required for Engine Brake Operation....2767
One or More Cylinders Fail to Stop Braking or Engine Stalls....2767
Engine Misses or Loses Power....2767
Table of Contents....2768
Diagnostics Form EGED-475....2770
Diagnostics Form Vehicle Information and Complaint Page....2771
Required Test Procedures....2773
1. Initial Key ON Check....2773
Purpose....2773
Tools....2773
Procedure....2773
2. Visual Inspection....2773
Purpose....2773
Tools....2773
Engine Oil....2773
Engine Coolant Level....2774
Electrical System....2774
Intake Air....2774
Charge Air Cooler (CAC) System....2774
Exhaust System....2775
Air Tanks....2775
Fuel Level....2775
Fuel Line Routing and Condition....2775
Primary Fuel Filter Inspection....2775
Fuel Quality Check....2777
Purpose....2777
Tools....2777
Procedure....2777
3. Electronic Service Tool (EST) Connection and Data Recording....2778
Purpose....2778
Tools....2778
Procedure....2778
4. Check for Diagnostic Trouble Codes (DTCs)....2781
Purpose....2781
Tools....2781
Procedure....2781
5. Engine Cranking....2782
Purpose....2782
Tools....2782
Procedure....2782
Special Test Procedures....2783
Fuel System....2783
Low-pressure Fuel System....2784
Fuel System Priming....2785
Purpose....2785
Tools....2785
Procedure....2785
Fuel Delivery Pressure (FDP) Test....2786
Purpose....2786
Tools....2786
Procedure....2786
Fuel Dead Head Test....2787
Purpose....2787
Tools....2787
Procedure....2787
Fuel Aeration Test....2788
Purpose....2789
Tools....2789
Procedure....2789
Aeration Test Point 1....2789
Aeration Test Point 2....2789
Fuel Restriction Test....2790
Purpose....2791
Tools....2791
Procedure....2791
Restriction Test Point 1....2791
Restriction Test Point 2....2791
Restriction Test Point 3....2791
High-pressure Fuel System....2792
Fuel Rail Pressure (FRP) Circuit Test....2792
Purpose....2792
Tools....2792
Procedure....2792
High-pressure Pump Inlet Pressure Test....2793
Purpose....2793
Tools....2793
Procedure....2793
Fuel Rail Pressure (FRP) Return Flow Test....2794
Purpose....2794
Tools....2794
Fuel Rail Pressure (FRP) Return Flow Test Part 1....2794
Fuel Rail Pressure (FRP) Return Flow Test Part 2....2794
Fuel Rail Pressure (FRP) Leak Isolation....2795
Purpose....2795
Tools....2795
Procedure....2795
HP Pump Fuel Return Pressure Test....2796
Purpose....2796
Tools....2796
Procedure....2796
HP Pump Return Flow Test....2796
Purpose....2796
Tools....2796
Procedure....2796
Inlet Air Heater System....2797
Inlet Air Heater System Test....2797
Purpose....2797
Tools....2797
Procedure....2797
Inlet Air Heater Fuel Igniter (IAHFI) Test....2798
Purpose....2798
Tools....2798
Procedure....2798
Fuel Supply at Inlet Air Heater Fuel Solenoid (IAHFS) Test....2799
Purpose....2799
Tools....2799
Procedure....2799
Fuel Supply at Inlet Air Heater Fuel Igniter (IAHFI) Test....2800
Purpose....2800
Tools....2800
Procedure....2800
Table of Contents....2802
Diagnostics Form EGED-530....2804
Diagnostics Form Vehicle Information and Complaint Page....2805
Required Test Procedures....2807
1. Initial Key ON Check....2807
Purpose....2807
Tools....2807
Procedure....2807
2. Visual Inspection....2807
Purpose....2807
Tools....2807
Engine Oil....2808
Engine Coolant Level....2808
Electrical System....2808
Intake Air....2809
Charge Air Cooler (CAC) System....2809
Exhaust System....2809
Vehicle Air Tanks....2809
Fuel Level....2809
Primary Fuel Filter Inspection....2809
Fuel Quality Check....2811
Purpose....2811
Tools....2811
Procedure....2811
3. Electronic Service Tool (EST) Connection and Data Recording....2812
Purpose....2812
Tools....2812
Procedure....2812
4. Check for Diagnostic Trouble Codes (DTCs)....2815
Purpose....2815
Tools....2815
Procedure....2815
5. Engine Low Idle to High Idle....2816
Purpose....2816
Tools....2816
Procedure....2816
6. KOER Air Management Test....2818
Purpose....2818
Tools....2818
Procedure....2818
7. Road Test (Full load to highway speed)....2818
Purpose....2818
Tools....2818
Procedure....2818
Special Test Procedures....2820
Air Control Valve (ACV) Tests....2820
Purpose....2820
Tools....2820
Exhaust Back Pressure Valve (EBPV)....2820
Turbocharger 2 Wastegate Control (TC2WC)....2821
Fuel System....2822
Low-pressure Fuel System....2823
Fuel Delivery Pressure (FDP) Test....2824
Purpose....2824
Tools....2824
Procedure....2824
Fuel Dead Head Test....2825
Purpose....2825
Tools....2825
Procedure....2825
Fuel Aeration and Restriction Tests....2827
Aeration Test....2827
Purpose....2828
Tools....2828
Aeration Test Point 1....2828
Procedure....2828
Aeration Test Point 2....2828
Restriction Test....2829
Purpose....2830
Tools....2830
Procedure....2830
Test Point 1....2830
Test Point 2....2830
Test Point 3....2830
High-pressure Fuel System....2831
High-pressure Pump Inlet Pressure Test....2832
Purpose....2832
Tools....2832
Procedure....2832
Fuel Rail Pressure (FRP) Return Flow Test....2833
Purpose....2833
Tools....2833
Fuel Rail Pressure (FRP) Return Flow Test Part 1....2833
Fuel Rail Pressure (FRP) Return Flow Test Part 2....2833
Fuel Rail Pressure (FRP) Leak Isolation....2834
Purpose....2834
Tools....2834
Procedure....2834
HP Pump Fuel Return Pressure Test....2835
Purpose....2835
Tools....2835
Procedure....2835
Crankcase Oil Breather Separator Test....2836
Purpose....2836
Tools....2836
Procedure....2836
Crankcase Pressure Test....2836
Purpose....2836
Tools....2836
Procedure....2836
Cylinder Performance Test ? Step 1....2838
Relative Compression Test....2838
Purpose....2838
Tools....2838
Procedure....2838
Possible Causes....2838
Cylinder Performance Test ? Step 2....2839
Cylinder Cutout Test....2839
Purpose....2839
Tools....2839
Possible Causes....2839
Procedure....2839
Injector Replacement....2840
Purpose....2840
Tools....2840
Procedure....2840
Fuel Pressure Control Valve (FPCV) Test....2841
Purpose....2841
Tools....2841
Procedure....2841
Charge Air Cooler (CAC) Pressure Test....2841
Procedure....2841
Table of Contents....2842
Diagnostic Trouble Codes (DTCs) and Sub-section Diagnostics Page Locations....2844
Diagnostics Form 0000002941 Usage....2854
Diagnostics Form Example ....2854
HD-OBD System Description....2855
Diagnostic Procedure Process With Examples....2858
Pin-grip Inspection....2858
Circuit Diagnostics....2864
AAT Sensor (Ambient Air Temperature)....2864
Overview....2864
Tools Required....2865
SPN 171 FMI 2 - AAT signal erratic, intermittent, or incorrect....2866
Fault Overview....2866
Malfunction Indicator Lamp (MIL) Reaction....2866
Associated Faults....2866
Fault Facts....2866
Drive Cycle to Determine Fault Status....2866
Possible Causes....2867
SPN 171 FMI 3- AAT Signal Out of Range HIGH....2869
Fault Overview....2869
Malfunction Indicator Lamp (MIL) Reaction....2869
Drive Cycle to Determine Fault Status....2869
Possible Causes....2869
SPN 171 FMI 4- AAT Signal Out of Range LOW....2872
Fault Overview....2872
Malfunction Indicator Lamp (MIL) Reaction....2872
Drive Cycle to Determine Fault Status....2872
Possible Causes....2872
AFT (Aftertreatment) System....2874
Overview....2881
Tools Required....2881
SPN 3251 FMI 0 - DPFDP excessively HIGH (Restricted filter)....2882
Fault Overview....2882
Malfunction Indicator Lamp (MIL) Reaction....2882
Associated Faults....2882
Drive Cycle to Determine Fault Status....2882
DPFDP sensor pressure hoses reversed....2888
SPN 3251 FMI 21 - DPFDP excessively LOW (Sensor/circuit fault or missing DPF)....2889
Fault Overview....2889
Malfunction Indicator Lamp (MIL) Reaction....2889
Associated Faults....2889
Drive Cycle to Determine Fault Status....2889
SPN 3471 FMI 1 - Fuel Pressure 1 Below Desired....2892
Fault Overview....2892
Malfunction Indicator Lamp (MIL) Reaction....2892
Associated Faults....2892
Drive Cycle to Determine Fault Status....2892
SPN 3471 FMI 7 - Fuel Doser Valve not responding as expected....2897
Fault Overview....2897
Malfunction Indicator Lamp (MIL) Reaction....2897
Associated Faults....2897
Drive Cycle to Determine Fault Status....2897
SPN 3480 FMI 0 - AFTFP1 too high while dosing....2903
Fault Overview....2903
Malfunction Indicator Lamp (MIL) Reaction....2903
Associated Faults....2903
Drive Cycle to Determine Fault Status....2903
SPN 3480 FMI 1- AFTFP1 too low while dosing....2907
Fault Overview....2907
Malfunction Indicator Lamp (MIL) Reaction....2907
Associated Faults....2907
Drive Cycle to Determine Fault Status....2907
SPN 3481 FMI 7 - Incorrect dosing pressure, multiple events....2911
Fault Overview....2911
Malfunction Indicator Lamp (MIL) Reaction....2911
Associated Faults....2911
Drive Cycle to Determine Fault Status....2911
SPN 3556 FMI 0 - AFT Fuel Pressure 2 excessively high....2915
Fault Overview....2915
Malfunction Indicator Lamp (MIL) Reaction....2915
Associated Faults....2915
Drive Cycle to Determine Fault Status....2915
SPN 3556 FMI 1- AFT Fuel Pressure 2 below desired....2919
Fault Overview....2919
Malfunction Indicator Lamp (MIL) Reaction....2919
Associated Faults....2919
Drive Cycle to Determine Fault Status....2919
SPN 3556 FMI 7 - AFT Fuel Injector not responding as expected....2923
Fault Overview....2923
Malfunction Indicator Lamp (MIL) Reaction....2923
Associated Faults....2923
Drive Cycle to Determine Fault Status....2923
SPN 3750 FMI 31 - DPF Regen inhibited due to low exhaust temperatures....2928
Fault Overview....2928
Malfunction Indicator Lamp (MIL) Reaction....2928
Associated Faults....2928
Drive Cycle to Determine Fault Status....2928
Fault Facts....2928
Possible Causes....2928
SPN 4077 FMI 0 - AFTFP2 too high while dosing....2930
Fault Overview....2930
Malfunction Indicator Lamp (MIL) Reaction....2930
Associated Faults....2930
Drive Cycle to Determine Fault Status....2930
SPN 4077 FMI 1 - AFTFP2 too low while dosing....2934
Fault Overview....2934
Malfunction Indicator Lamp (MIL) Reaction....2934
Associated Faults....2934
Drive Cycle to Determine Fault Status....2934
SPN 4766 FMI 10 - DPF Regeneration feedback fault....2938
Fault Overview....2938
Malfunction Indicator Lamp (MIL) Reaction....2938
Associated Faults....2938
Drive Cycle to Determine Fault Status....2938
SPN 4766 FMI 20 - DOC Outlet Temp above maximum desired....2945
Fault Overview....2945
Malfunction Indicator Lamp (MIL) Reaction....2945
Associated Faults....2945
Drive Cycle to Determine Fault Status....2945
SPN 4766 FMI 21 - DOC Outlet Temp below minimum desired....2951
Fault Overview....2951
Malfunction Indicator Lamp (MIL) Reaction....2951
Associated Faults....2951
Drive Cycle to Determine Fault Status....2951
SPN 5298 FMI 2 - Reduced DOC Efficiency ? De-Rate....2957
Fault Overview....2957
Malfunction Indicator Lamp (MIL) Reaction....2957
Associated Faults....2957
Drive Cycle to Determine Fault Status....2957
SPN 5319 FMI 31 - DPF Incomplete Regeneration....2964
Fault Overview....2964
Malfunction Indicator Lamp (MIL) Reaction....2964
Associated Faults....2965
Fault Facts....2965
Drive Cycle to Determine Fault Status....2965
Possible Causes....2965
Aftertreatment System Overview....2969
Types of Regens....2969
Regen Inhibitors....2975
Overview....2975
Normal DPF Inlet....2979
Normal DPF Outlet....2980
Restricted DPF Inlet....2981
DPF Contaminated with Coolant....2982
DPF Contaminated with Oil....2983
DPF Outlet Leaking Soot....2984
External Damage to DPF....2985
DPF Ceramic Filter Brick Measurement....2986
AFTFD (Aftertreatment Fuel Doser)....2987
Tools Required....2988
AFTFIS (Aftertreatment Fuel Inlet Sensor)....2990
Overview....2991
Tools Required....2991
3480 FMI 2 - AFTFP1 signal erratic, intermittent or incorrect....2993
Fault Overview....2993
Malfunction Indicator Lamp (MIL) Reaction....2993
Associated Faults....2993
Drive Cycle to Determine Fault Status....2993
Possible Causes....2994
3480 FMI 3 - AFTFP1 Signal Out of Range HIGH....2995
Fault Overview....2995
Malfunction Indicator Lamp (MIL) Reaction....2995
Associated Faults....2995
Fault Facts....2995
Drive Cycle to Determine Fault Status....2995
Possible Causes....2996
3480 FMI 4 - AFTFP1 Signal Out of Range LOW....2998
Fault Overview....2998
Malfunction Indicator Lamp (MIL) Reaction....2998
Associated Faults....2998
Fault Facts....2998
Drive Cycle to Determine Fault Status....2998
Possible Causes....2999
Pinpoint Diagnostics With ServiceMaxx? software....3001
AFTFP2 (Aftertreatment Fuel Pressure 2 Sensor)....3003
Tools Required....3004
Pinpoint Diagnostics With ServiceMaxx? Software....3004
AFTFSV (Aftertreatment Fuel Shutoff Valve)....3006
Tools Required....3006
3482 FMI 3 - AFT Fuel Shutoff Valve short to PWR (Open or High Resistance)....3008
Fault Overview....3008
Malfunction Indicator Lamp (MIL) Reaction....3008
Drive Cycle to Determine Fault Status....3008
Possible Causes....3009
3482 FMI 4- AFT Fuel Shutoff Valve short to GND....3011
Fault Overview....3011
Malfunction Indicator Lamp (MIL) Reaction....3011
Drive Cycle to Determine Fault Status....3011
Possible Causes....3011
AMS (Air Management System)....3013
Tools Required....3014
SPN 2659 FMI 20 - EGR High Flow Rate Detected....3017
Fault Overview....3017
Malfunction Indicator Lamp (MIL) Reaction....3017
Associated Faults....3017
Drive Cycle to Determine Fault Status....3018
APP Sensor (Accelerator Pedal Position)....3020
Overview....3020
Tools Required....3021
Pinpoint Diagnostics With ServiceMaxx? software....3022
CACOT Sensor (Charge Air Cooler Outlet Temperature)....3025
Overview....3026
Tools Required....3026
Pinpoint Diagnostics With ServiceMaxx? Software....3027
SPN 2630 FMI 16 - CACOT Undercooling....3030
Fault Overview....3030
Malfunction Indicator Lamp (MIL) Reaction....3030
Associated Faults....3030
Drive Cycle to Determine Fault Status....3030
Possible Causes....3031
CCOSS Sensor (Crankcase Oil Separator Speed)....3033
Tools Required....3033
Pinpoint Crankcase Oil Separator: Not spinning fault....3033
CCS (Cruise Control System)....3035
Function....3035
CCS Operation....3035
CCS Pinpoint Diagnostics ? With ServiceMaxx? Software....3035
CFV (Coolant Flow Valve)....3037
CKP Sensor (Crankshaft Position)....3039
Overview....3040
Tools Required....3040
SPN 637 FMI 8 - CKP signal noise....3042
Fault Overview....3042
Malfunction Indicator Lamp (MIL) Reaction....3042
Drive Cycle to Determine Fault Status....3042
Possible Causes....3042
SPN 637 FMI 10 - CKP signal inactive....3046
Fault Overview....3046
Malfunction Indicator Lamp (MIL) Reaction....3046
Drive Cycle to Determine Fault Status....3046
Possible Causes....3046
CMP Sensor (Camshaft Position)....3050
Overview....3052
Tools Required....3052
SPN 636 FMI 2 - CMP and CKP Synchronization Error....3054
Fault Overview....3054
Malfunction Indicator Lamp (MIL) Reaction....3054
Drive Cycle to Determine Fault Status....3054
Possible Causes....3054
SPN 636 FMI 8 - CMP signal noise....3058
Fault Overview....3058
Malfunction Indicator Lamp (MIL) Reaction....3058
Drive Cycle to Determine Fault Status....3058
Possible Causes....3058
SPN 636 FMI 10 - CMP signal inactive....3062
Fault Overview....3062
Malfunction Indicator Lamp (MIL) Reaction....3062
Drive Cycle to Determine Fault Status....3062
Possible Causes....3062
CMV (Coolant Mixer Valve)....3066
Tools Required....3066
IAHFI (Inlet Air Heater Fuel Igniter)....3068
Overview....3069
Tools Required....3069
5548 FMI 4- Inlet Air Heater Fuel Ignitor short to GND....3070
Fault Overview....3070
Malfunction Indicator Lamp (MIL) Reaction....3070
Drive Cycle to Determine Fault Status....3070
Possible Causes....3070
Cold Soak Sensor Compare Check With ServiceMaxx? Software....3073
IAHFS (Inlet Air Heater Fuel Solenoid)....3078
Tools Required....3078
Cylinder Balance....3081
Overview....3085
Tools Required....3085
SPN 651 FMI 13- Injector 1 programmable parameter error....3086
Fault Overview....3086
Malfunction Indicator Lamp (MIL) Reaction....3086
Drive Cycle to Determine Fault Status....3086
Possible Causes....3086
SPN 651 FMI 16- Injector 1 Fuel quantity/timing high error....3088
Fault Overview....3088
Malfunction Indicator Lamp (MIL) Reaction....3088
Associated Faults....3088
Drive Cycle to Determine Fault Status....3088
Possible Causes....3088
SPN 651 FMI 18- Injector 1 Fuel quantity/timing low error....3090
Fault Overview....3090
Malfunction Indicator Lamp (MIL) Reaction....3090
Associated Faults....3090
Drive Cycle to Determine Fault Status....3090
Possible Causes....3090
SPN 652 FMI 13- Injector 2 programmable parameter error....3092
Fault Overview....3092
Malfunction Indicator Lamp (MIL) Reaction....3092
Drive Cycle to Determine Fault Status....3092
Possible Causes....3092
SPN 652 FMI 16- Injector 2 Fuel quantity/timing high error....3094
Fault Overview....3094
Malfunction Indicator Lamp (MIL) Reaction....3094
Associated Faults....3094
Drive Cycle to Determine Fault Status....3094
Possible Causes....3094
SPN 652 FMI 18- Injector 2 Fuel quantity/timing low error....3096
Fault Overview....3096
Malfunction Indicator Lamp (MIL) Reaction....3096
Associated Faults....3096
Drive Cycle to Determine Fault Status....3096
Possible Causes....3096
SPN 653 FMI 13- Injector 3 programmable parameter error....3098
Fault Overview....3098
Malfunction Indicator Lamp (MIL) Reaction....3098
Drive Cycle to Determine Fault Status....3098
Possible Causes....3098
SPN 653 FMI 16- Injector 3 Fuel quantity/timing high error....3100
Fault Overview....3100
Malfunction Indicator Lamp (MIL) Reaction....3100
Associated Faults....3100
Drive Cycle to Determine Fault Status....3100
Possible Causes....3100
SPN 653 FMI 18- Injector 3 Fuel quantity/timing low error....3102
Fault Overview....3102
Malfunction Indicator Lamp (MIL) Reaction....3102
Associated Faults....3102
Drive Cycle to Determine Fault Status....3102
Possible Causes....3102
SPN 654 FMI 13- Injector 4 programmable parameter error....3104
Fault Overview....3104
Malfunction Indicator Lamp (MIL) Reaction....3104
Drive Cycle to Determine Fault Status....3104
Possible Causes....3104
SPN 654 FMI 16- Injector 1 Fuel quantity/timing high error....3106
Fault Overview....3106
Malfunction Indicator Lamp (MIL) Reaction....3106
Associated Faults....3106
Drive Cycle to Determine Fault Status....3106
Possible Causes....3106
SPN 654 FMI 18- Injector 4 Fuel quantity/timing low error....3108
Fault Overview....3108
Malfunction Indicator Lamp (MIL) Reaction....3108
Associated Faults....3108
Drive Cycle to Determine Fault Status....3108
Possible Causes....3108
SPN 655 FMI 13- Injector 5 programmable parameter error....3110
Fault Overview....3110
Malfunction Indicator Lamp (MIL) Reaction....3110
Drive Cycle to Determine Fault Status....3110
Possible Causes....3110
SPN 655 FMI 16- Injector 5 Fuel quantity/timing high error....3112
Fault Overview....3112
Malfunction Indicator Lamp (MIL) Reaction....3112
Associated Faults....3112
Drive Cycle to Determine Fault Status....3112
Possible Causes....3112
SPN 655 FMI 18- Injector 5 Fuel quantity/timing low error....3114
Fault Overview....3114
Malfunction Indicator Lamp (MIL) Reaction....3114
Associated Faults....3114
Drive Cycle to Determine Fault Status....3114
Possible Causes....3114
SPN 656 FMI 13- Injector 6 programmable parameter error....3116
Fault Overview....3116
Malfunction Indicator Lamp (MIL) Reaction....3116
Drive Cycle to Determine Fault Status....3116
Possible Causes....3116
SPN 656 FMI 16- Injector 6 Fuel quantity/timing high error....3118
Fault Overview....3118
Malfunction Indicator Lamp (MIL) Reaction....3118
Associated Faults....3118
Drive Cycle to Determine Fault Status....3118
Possible Causes....3118
SPN 656 FMI 18- Injector 6 Fuel quantity/timing low error....3120
Fault Overview....3120
Malfunction Indicator Lamp (MIL) Reaction....3120
Associated Faults....3120
Drive Cycle to Determine Fault Status....3120
Possible Causes....3120
SPN 1322 FMI 31- Misfire- Multiple Cylinders....3122
Fault Overview....3122
Malfunction Indicator Lamp (MIL) Reaction....3122
Associated Faults....3122
Drive Cycle to Determine Fault Status....3122
Possible Causes....3122
SPN 1323 FMI 31- Misfire- Cylinder 1....3126
Fault Overview....3126
Malfunction Indicator Lamp (MIL) Reaction....3126
Associated Faults....3126
Drive Cycle to Determine Fault Status....3126
Possible Causes....3126
SPN 1324 FMI 31- Misfire- Cylinder 2....3129
Fault Overview....3129
Malfunction Indicator Lamp (MIL) Reaction....3129
Associated Faults....3129
Drive Cycle to Determine Fault Status....3129
Possible Causes....3129
SPN 1325 FMI 31- Misfire- Cylinder 3....3132
Fault Overview....3132
Malfunction Indicator Lamp (MIL) Reaction....3132
Associated Faults....3132
Drive Cycle to Determine Fault Status....3132
Possible Causes....3132
SPN 1326 FMI 31- Misfire- Cylinder 4....3135
Fault Overview....3135
Malfunction Indicator Lamp (MIL) Reaction....3135
Associated Faults....3135
Drive Cycle to Determine Fault Status....3135
Possible Causes....3135
SPN 1327 FMI 31- Misfire- Cylinder 5....3138
Fault Overview....3138
Malfunction Indicator Lamp (MIL) Reaction....3138
Associated Faults....3138
Drive Cycle to Determine Fault Status....3138
Possible Causes....3138
SPN 1328 FMI 31- Misfire- Cylinder 6....3141
Fault Overview....3141
Malfunction Indicator Lamp (MIL) Reaction....3141
Associated Faults....3141
Drive Cycle to Determine Fault Status....3141
Possible Causes....3141
DOCIT Sensor (Diesel Oxidation Catalyst Inlet Temperature)....3144
Overview....3145
Tools Required....3145
SPN 4765 FMI 2 DOCIT signal does not agree with other exhaust sensors....3147
Fault Overview....3147
Malfunction Indicator Lamp (MIL) Reaction....3147
Associated Faults....3147
Drive Cycle to Determine Fault Status....3147
Possible Causes....3148
SPN 4765 FMI 3 DOCIT signal Out of Range HIGH....3150
Fault Overview....3150
Malfunction Indicator Lamp (MIL) Reaction....3150
Drive Cycle to Determine Fault Status....3150
Possible Causes....3150
SPN 4765 FMI 4 DOCIT signal Out of Range LOW....3153
Fault Overview....3153
Malfunction Indicator Lamp (MIL) Reaction....3153
Drive Cycle to Determine Fault Status....3153
Possible Causes....3153
SPN 4765 FMI 20 - DOCIT signal drifted HIGH....3155
Fault Overview....3155
Malfunction Indicator Lamp (MIL) Reaction....3155
Associated Faults....3155
Drive Cycle to Determine Fault Status....3155
SPN 4765 FMI 21 - DOCIT signal drifted LOW....3157
Fault Overview....3157
Malfunction Indicator Lamp (MIL) Reaction....3157
Associated Faults....3157
Drive Cycle to Determine Fault Status....3157
DOCOT Sensor (Diesel Oxidation Catalyst Outlet Temperature)....3160
Overview....3161
Tools Required....3161
SPN 4766 FMI 2 - DOCOT signal does not agree with other exhaust sensors....3162
Fault Overview....3162
Malfunction Indicator Lamp (MIL) Reaction....3162
Associated Faults....3162
Drive Cycle to Determine Fault Status....3162
Possible Causes....3163
SPN 4766 FMI 3 - DOCOT signal Out of Range HIGH....3166
Fault Overview....3166
Malfunction Indicator Lamp (MIL) Reaction....3166
Drive Cycle to Determine Fault Status....3166
Possible Causes....3166
SPN 4766 FMI 4 - DOCOT signal Out of Range LOW....3169
Fault Overview....3169
Malfunction Indicator Lamp (MIL) Reaction....3169
Drive Cycle to Determine Fault Status....3169
Possible Causes....3169
DPFDP Sensor (Diesel Particulate Filter Differential Pressure)....3171
Overview....3172
Tools Required....3173
SPN 3251 FMI 2 - DPFDP signal erratic, intermittent, or incorrect....3174
Fault Overview....3174
Malfunction Indicator Lamp (MIL) Reaction....3174
Associated Faults....3174
Drive Cycle to Determine Fault Status....3174
Possible Causes....3175
SPN 3251 FMI 3 - DPFDP signal Out of Range HIGH....3178
Fault Overview....3178
Malfunction Indicator Lamp (MIL) Reaction....3178
Associated Fault....3178
Drive Cycle to Determine Fault Status....3178
Possible Causes....3178
SPN 3251 FMI 4- DPFDP signal Out of Range LOW....3180
Fault Overview....3180
Malfunction Indicator Lamp (MIL) Reaction....3180
Associated Faults....3180
Drive Cycle to Determine Fault Status....3180
Possible Causes....3181
DPFOT Sensor (Diesel Particulate Filter Outlet Temperature)....3183
Overview....3185
Tools Required....3185
SPN 3246 FMI 2 - DPFOT signal does not agree with other exhaust sensors....3187
Fault Overview....3187
Malfunction Indicator Lamp (MIL) Reaction....3187
Associated Faults....3187
Drive Cycle to Determine Fault Status....3187
Possible Causes....3188
SPN 3246 FMI 3 - DPFOT signal Out of Range HIGH....3190
Fault Overview....3190
Malfunction Indicator Lamp (MIL) Reaction....3190
Drive Cycle to Determine Fault Status....3190
Possible Causes....3190
SPN 3246 FMI 4 - DPFOT signal Out of Range LOW....3193
Fault Overview....3193
Malfunction Indicator Lamp (MIL) Reaction....3193
Drive Cycle to Determine Fault Status....3193
Possible Causes....3193
SPN 3246 FMI 20 - DPFOT signal drifted HIGH....3195
Fault Overview....3195
Malfunction Indicator Lamp (MIL) Reaction....3195
Associated Faults....3195
Drive Cycle to Determine Fault Status....3195
SPN 3246 FMI 21 - DPFOT signal drifted LOW....3201
Fault Overview....3201
Malfunction Indicator Lamp (MIL) Reaction....3201
Associated Faults....3201
Drive Cycle to Determine Fault Status....3201
DPF System (Diesel Particulate Filter)....3206
Overview....3208
Tools Required....3208
SPN 3719 FMI 0- DPF Soot Load - Highest (level 3/3)....3209
Fault Overview....3209
Malfunction Indicator Lamp (MIL) Reaction....3209
Associated Faults....3209
Drive Cycle to Determine Fault Status....3209
Fault Facts....3209
Possible Causes....3209
SPN 3719 FMI 15- DPF Soot Load - Lowest (level 1/3)....3213
Fault Overview....3213
Malfunction Indicator Lamp (MIL) Reaction....3213
Associated Faults....3213
Drive Cycle to Determine Fault Status....3213
Fault Facts....3213
Possible Causes....3213
SPN 3719 FMI 16- DPF Soot Load - Moderate (level 2/3)....3217
Fault Overview....3217
Malfunction Indicator Lamp (MIL) Reaction....3217
Associated Faults....3217
Drive Cycle to Determine Fault Status....3217
Fault Facts....3217
Possible Causes....3217
SPN 3720 FMI 0 - DPF Ash load at maximum limit....3221
Fault Overview....3221
Malfunction Indicator Lamp (MIL) Reaction....3221
Associated Faults....3221
Drive Cycle to Determine Fault Status....3221
SPN 3936 FMI 10 - DPF Thermal Management Mode Failed to Raise DOC-In Temp as Expected....3226
Fault Overview....3226
Malfunction Indicator Lamp (MIL) Reaction....3226
Associated Faults....3226
Drive Cycle to Determine Fault Status....3226
SPN 3936 FMI 20 - High Regen Frequency....3229
Fault Overview....3229
Malfunction Indicator Lamp (MIL) Reaction....3229
Associated Faults....3229
Drive Cycle to Determine Fault Status....3229
EBPV (Exhaust Back Pressure Valve)....3235
Tools Required....3235
ECB1 (Engine Compression Brake 1)....3238
Tools Required....3238
ECB2 (Engine Compression Brake 2)....3241
Tools Required....3241
ECL Switch (Engine Coolant Level)....3244
Tools Required....3244
Pinpoint Diagnostics With ServiceMaxx? Software....3244
ECM Power (Engine Control Module)....3246
Tools Required....3246
ECM Power Output (Engine Control Module)....3248
Tools Required....3248
SPN 3597 FMI 4 ? ECM Power Output 1....3249
SPN 3598 FMI 4 ? ECM Power Output 2....3250
SPN 3599 FMI 4 ? ECM Power Output 3....3252
ECM (Engine Control Module) Self-Diagnostics....3253
Tools Required....3253
Crank Sensor Relearn Procedure....3255
Tools Required....3255
Function....3255
ECS (Engine Coolant System)....3256
Tools Required....3256
Overview....3256
Tools Required....3256
SPN 110 FMI 17- Engine Coolant System below OBD monitoring temperature....3257
Fault Overview....3257
Malfunction Indicator Lamp (MIL) Reaction....3257
Associated Faults....3257
Fault Facts....3257
Drive Cycle to Determine Fault Status....3257
Possible Causes....3257
SPN 110 FMI 18- Engine Coolant System below closed loop minimum temperature....3259
Fault Overview....3259
Malfunction Indicator Lamp (MIL) Reaction....3259
Associated Faults....3259
Fault Facts....3259
Drive Cycle to Determine Fault Status....3259
Possible Causes....3259
Cold Soak Sensor Compare Check With ServiceMaxx? Software....3261
ECT1 Sensor (Engine Coolant Temperature 1)....3262
Tools Required....3262
Pinpoint Diagnostics With ServiceMaxx? Software....3262
ECT2 Sensor (Engine Coolant Temperature 2)....3264
Overview....3265
Tools Required....3265
SPN 4076 FMI 2 ECT2 signal erratic, intermittent, or incorrect....3266
Fault Overview....3266
Malfunction Indicator Lamp (MIL) Reaction....3266
Fault Facts....3266
Drive Cycle to Determine Fault Status....3266
Possible Causes....3267
Pinpoint Diagnostics With ServiceMaxx? Software....3269
EFC (Engine Fan Control) ? Two Speed and Variable....3272
Tools Required....3273
Function Two-Speed EFC....3273
Function Variable EFC....3273
EFC ? Two Speed Sensor Circuit Operation....3273
EFC ? Variable Sensor Circuit Operation....3273
EGRT Sensor (Exhaust Gas Recirculation Temperature)....3275
Tools Required....3275
Pinpoint Diagnostics With ServiceMaxx? Software....3276
EGR (Exhaust Gas Recirculation) Valve....3278
Tools Required....3279
Pinpoint Diagnostics With ServiceMaxx? Software....3279
Exhaust Gas Recirculation (EGR) System Monitor....3282
Tools Required....3282
SPN 3058 FMI 0 - Engine Did Not Go Into Open Loop EGR Control When Expected....3283
Fault Overview....3283
Malfunction Indicator Lamp (MIL) Reaction....3283
Associated Faults....3283
SPN 3058 FMI 10 - Engine Did Not Go Into Closed Loop EGR Control When Expected....3286
Fault Overview....3286
Malfunction Indicator Lamp (MIL) Reaction....3286
Associated Faults....3286
EOL Sensor (Engine Oil Level)....3289
Tools Required....3289
Pinpoint Diagnostics With ServiceMaxx? Software....3290
EOP Sensor (Engine Oil Pressure)....3292
Tools Required....3292
Pinpoint Diagnostics With ServiceMaxx? Software....3292
EOT Sensor (Engine Oil Temperature)....3295
Tools Required....3295
Pinpoint Diagnostics With ServiceMaxx? Software....3295
ETV (Engine Throttle Valve)....3297
Tools Required....3297
Pinpoint Diagnostics With ServiceMaxx? Software....3299
SPN 51 FMI 10 - ETP sensor feedback deviation during CSER....3302
Fault Overview....3302
Malfunction Indicator Lamp (MIL) Reaction....3302
Associated Faults....3302
Drive Cycle to Determine Fault Status....3302
EWPS (Engine Warning Protection System) ....3304
Function....3307
EWPS Programmable Parameters....3308
Tools Required....3308
SPN 110 FMI 0 - Engine Coolant System above Critical Temperature....3309
Fault Overview....3309
Malfunction Indicator Lamp (MIL) Reaction....3309
Associated Faults....3309
Fault Facts....3309
Drive Cycle to Determine Fault Status....3309
Possible Causes....3309
SPN 110 FMI 11 - Event Logger, Coolant Temp Hot, Extreme....3311
Fault Overview....3311
Malfunction Indicator Lamp (MIL) Reaction....3311
Associated Faults....3311
Fault Facts....3311
Drive Cycle to Determine Fault Status....3311
SPN 110 FMI 15 - Engine Coolant System above Warning Temperature....3313
Fault Overview....3313
Malfunction Indicator Lamp (MIL) Reaction....3313
Associated Faults....3313
Drive Cycle to Determine Fault Status....3313
Possible Causes....3313
SPN 188 FMI 0 - Engine speed unable to achieve desired idle speed (too high)....3315
Fault Overview....3315
Malfunction Indicator Lamp (MIL) Reaction....3315
Associated Faults....3315
Drive Cycle to Determine Fault Status....3315
Possible Cause....3315
SPN 188 FMI 1 - Engine speed unable to achieve desired idle speed (too low)....3317
Fault Overview....3317
Malfunction Indicator Lamp (MIL) Reaction....3317
Associated Faults....3317
Drive Cycle to Determine Fault Status....3317
Possible Causes....3317
SPN 190 - FMI 0 - Engine Overspeed Most Severe level....3320
Fault Overview....3320
Malfunction Indicator Lamp (MIL) Reaction....3320
Before beginning diagnosis:....3320
SPN 2588 FMI 0 - Vehicle overspeed 1, event log, extreme....3322
Fault Overview....3322
Malfunction Indicator Lamp (MIL) Reaction....3322
Associated Faults....3322
Fault Facts....3322
Drive Cycle to Determine Fault Status....3322
Possible Causes....3322
SPN 2588 FMI 15 - Vehicle overspeed 1, event log, non extreme....3323
Fault Overview....3323
Malfunction Indicator Lamp (MIL) Reaction....3323
Associated Faults....3323
Fault Facts....3323
Drive Cycle to Determine Fault Status....3323
Possible Causes....3323
SPN 2589 FMI 0 - Vehicle overspeed 2, event log, extreme....3324
Fault Overview....3324
Malfunction Indicator Lamp (MIL) Reaction....3324
Associated Faults....3324
Fault Facts....3324
Drive Cycle to Determine Fault Status....3324
Possible Causes....3324
SPN 2589 FMI 15 - Vehicle overspeed 2, event log, non extreme....3325
Fault Overview....3325
Malfunction Indicator Lamp (MIL) Reaction....3325
Associated Faults....3325
Fault Facts....3325
Drive Cycle to Determine Fault Status....3325
Possible Causes....3325
SPN 5395 FMI 0 - Engine Unable to Achieve Desired Idle Torque (Too High)....3326
Fault Overview....3326
Malfunction Indicator Lamp (MIL) Reaction....3326
Associated Faults....3326
Drive Cycle to Determine Fault Status....3326
Possible Causes....3326
SPN 5395 FMI 1 - Engine Unable to Achieve Desired Idle Torque (Too Low)....3328
Fault Overview....3328
Malfunction Indicator Lamp (MIL) Reaction....3328
Associated Faults....3328
Drive Cycle to Determine Fault Status....3328
FDP Sensor (Fuel Delivery Pressure)....3331
Tools Required....3331
SPN 94 FMI 0 - Fuel Delivery Pressure above Critical....3333
Fault Overview....3333
Malfunction Indicator Lamp (MIL) Reaction....3333
Drive Cycle to Determine Fault Status....3333
Possible Causes....3333
Pinpoint Diagnostics With ServiceMaxx? Software....3336
FPCV (Fuel Pressure Control Valve)....3338
Tools Required....3338
Pinpoint Diagnostics With ServiceMaxx? Software....3338
FRP Sensor (Fuel Rail Pressure)....3340
Overview....3341
Tools Required....3341
Pinpoint Diagnostics With ServiceMaxx? Software....3342
SPN 157 - FMI 20 FRP signal Drifted HIGH....3345
Fault Overview....3345
Malfunction Indicator Lamp (MIL) Reaction....3345
Associated Faults....3345
Drive Cycle....3345
SPN 157 - FMI 21 FRP signal Drifted LOW....3347
Fault Overview....3347
Malfunction Indicator Lamp (MIL) Reaction....3347
Associated Faults....3347
Drive Cycle....3347
FRP (Fuel Rail Pressure) System....3350
Overview....3352
Tools Required....3352
Pinpoint Diagnostics With ServiceMaxx? Software....3353
SPN 3055 FMI 0 - FRP Exceeded Maximum....3354
Fault Overview....3354
Malfunction Indicator Lamp (MIL) Reaction....3354
Associated Faults....3354
Drive Cycle to Determine Fault Status....3354
Possible Causes....3354
SPN 3055 FMI 1 - Low Fuel Pressure at Start....3356
Fault Overview....3356
Malfunction Indicator Lamp (MIL) Reaction....3356
Associated Faults....3356
Fault Facts....3356
Drive Cycle to Determine Fault Status....3356
Possible Causes....3356
SPN 3055 FMI 15 - FRP Below Minimum with Maximum Command....3360
Fault Overview....3360
Malfunction Indicator Lamp (MIL) Reaction....3360
Associated Faults....3360
Drive Cycle to Determine Fault Status....3360
Possible Causes....3360
SPN 3055 FMI 17 - FRP Above Maximum with Minimum Command....3364
Fault Overview....3364
Malfunction Indicator Lamp (MIL) Reaction....3364
Associated Faults....3364
Drive Cycle to Determine Fault Status....3364
Possible Causes....3364
Hard Brake Monitor....3366
Overview....3366
Tools Required....3366
Pinpoint Diagnostics With ServiceMaxx? Software....3366
HS (Humidity Sensor) / IAT (Inlet Air Temperature Sensor)....3367
Tools Required....3368
Pinpoint Diagnostics With ServiceMaxx? Software....3368
IMP (Intake Manifold Pressure)....3372
Overview....3373
Tools Required....3373
Pinpoint Diagnostics With ServiceMaxx? Software....3374
SPN 102 - FMI 10 IMP - Boost Slow Response....3377
Malfunction Indicator Lamp (MIL) Reaction....3377
Associated Faults....3377
Drive Cycle....3377
IMT Sensor (Intake Manifold Temperature)....3382
Tools Required....3382
Pinpoint Diagnostics With ServiceMaxx? Software....3382
INJ (Injector) Circuits....3385
Overview....3390
Tools Required....3390
SPN 651 FMI 4- Injector 1 short circuit....3391
Fault Overview....3391
Malfunction Indicator Lamp (MIL) Reaction....3391
Drive Cycle to Determine Fault Status....3391
Possible Causes....3391
SPN 651 FMI 5- Injector 1 Open load / circuit....3395
Fault Overview....3395
Malfunction Indicator Lamp (MIL) Reaction....3395
Drive Cycle to Determine Fault Status....3395
Possible Causes....3395
SPN 652 FMI 4- Injector 2 short circuit....3399
Fault Overview....3399
Malfunction Indicator Lamp (MIL) Reaction....3399
Drive Cycle to Determine Fault Status....3399
Possible Causes....3399
SPN 652 FMI 5- Injector 2 Open load / circuit....3403
Fault Overview....3403
Malfunction Indicator Lamp (MIL) Reaction....3403
Drive Cycle to Determine Fault Status....3403
Possible Causes....3403
SPN 653 FMI 4- Injector 3 short circuit....3407
Fault Overview....3407
Malfunction Indicator Lamp (MIL) Reaction....3407
Drive Cycle to Determine Fault Status....3407
Possible Causes....3407
SPN 653 FMI 5- Injector 3 Open load / circuit....3411
Fault Overview....3411
Malfunction Indicator Lamp (MIL) Reaction....3411
Drive Cycle to Determine Fault Status....3411
Possible Causes....3411
SPN 654 FMI 4- Injector 4 short circuit....3415
Fault Overview....3415
Malfunction Indicator Lamp (MIL) Reaction....3415
Drive Cycle to Determine Fault Status....3415
Possible Causes....3415
SPN 654 FMI 5- Injector 4 Open load / circuit....3419
Fault Overview....3419
Malfunction Indicator Lamp (MIL) Reaction....3419
Drive Cycle to Determine Fault Status....3419
Possible Causes....3419
SPN 655 FMI 4- Injector 5 short circuit....3423
Fault Overview....3423
Malfunction Indicator Lamp (MIL) Reaction....3423
Drive Cycle to Determine Fault Status....3423
Possible Causes....3423
SPN 655 FMI 5- Injector 5 Open load / circuit....3427
Fault Overview....3427
Malfunction Indicator Lamp (MIL) Reaction....3427
Drive Cycle to Determine Fault Status....3427
Possible Causes....3427
SPN 656 FMI 4- Injector 6 short circuit....3431
Fault Overview....3431
Malfunction Indicator Lamp (MIL) Reaction....3431
Drive Cycle to Determine Fault Status....3431
Possible Causes....3431
SPN 656 FMI 5- Injector 6 Open load / circuit....3435
Fault Overview....3435
Malfunction Indicator Lamp (MIL) Reaction....3435
Drive Cycle to Determine Fault Status....3435
Possible Causes....3435
SPN 2797 FMI 11 - Injector Control Group 1 short circuit (INJ 1, 3, 5)....3439
Fault Overview....3439
Malfunction Indicator Lamp (MIL) Reaction....3439
Associated Faults....3439
Drive Cycle to Determine Fault Status....3439
Possible Causes....3440
SPN 2798 FMI 11 - Injector Control Group 2 short circuit (INJ 2, 4, 6)....3449
Fault Overview....3449
Malfunction Indicator Lamp (MIL) Reaction....3449
Associated Faults....3449
Drive Cycle to Determine Fault Status....3449
Possible Causes....3450
IST (Idle Shutdown Timer) System (Clean Low Idle)....3459
IST (Clean Low Idle)....3459
IST (Idle Shutdown Timer) System (Federal - Optional)....3460
IST (Federal - Optional) Sensor Circuit Operation....3460
J1939 Data Link Communications....3461
Tools Required....3461
Pinpoint Diagnostics With ServiceMaxx? Software....3463
MAF Sensor (Mass Air Flow)....3464
Function....3464
MIL (Malfunction Indicator Lamp)....3465
Overview....3465
Tools Required....3465
O2S (Oxygen Sensor)....3467
Overview....3469
Tools Required....3470
Pinpoint Diagnostics With ServiceMaxx? Software....3471
SPN 724 FMI 20 ? O2S adaptation above maximum limit....3473
Fault Overview....3473
Malfunction Indicator Lamp (MIL) Reaction....3473
Drive Cycle to Determine Fault Status....3473
Possible Causes....3473
SPN 724 FMI 21 ? O2S adaptation below minimum limit....3476
SPN 3223 FMI 0 - O2S Heater Temperature Above Maximum....3477
Fault Overview....3477
Malfunction Indicator Lamp (MIL) Reaction....3477
Drive Cycle to Determine Fault Status....3477
SPN 3223 FMI 5 ? O2S heater open load / circuit....3479
Fault Overview....3479
Malfunction Indicator Lamp (MIL) Reaction....3479
Associated Faults....3479
Drive Cycle to Determine Fault Status....3479
Possible Causes....3479
Pinpoint O2S System Fault ....3482
RAPP (Remote Accelerator Pedal Position) ....3483
Overview....3483
Tools Required....3483
Service Interval Messages....3485
Service Interval Messages Operation....3485
SART (Stand Alone Real Time) Clock....3486
Tools Required....3486
TC1TOP Sensor (Turbocharger 1 Turbine Outlet Pressure)....3488
Tools Required....3488
Pinpoint Diagnostics With ServiceMaxx? Software....3489
TC1WC (Turbocharger 1 Wastegate Control)....3492
Tools Required....3492
TC2WC (Turbocharger 2 Wastegate Control)....3495
Tools Required....3495
TC2CIS (Turbocharger 2 Compressor Inlet Sensor)....3498
Overview....3499
Tools Required....3499
SPN 1173 FMI 2 - TC2CIT signal erratic, intermittent, or incorrect....3500
Fault Overview....3500
Malfunction Indicator Lamp (MIL) Reaction....3500
Associated Faults....3500
Drive Cycle to Determine Fault Status....3500
Possible Causes....3501
SPN 1173 FMI 3 - TC2CIT signal Out of Range HIGH....3503
Fault Overview....3503
Malfunction Indicator Lamp (MIL) Reaction....3503
Drive Cycle to Determine Fault Status....3503
Possible Causes....3503
SPN 1173 FMI 4 - TC2CIT signal Out of Range LOW....3506
Fault Overview....3506
Malfunction Indicator Lamp (MIL) Reaction....3506
Drive Cycle to Determine Fault Status....3506
Possible Causes....3506
SPN 1173 FMI 16 - TC2CIT signal above desired (Interstage CAC under cooling)....3508
Fault Overview....3508
Malfunction Indicator Lamp (MIL) Reaction....3508
Associated Faults....3508
Drive Cycle to Determine Fault Status....3508
Possible Causes....3508
SPN 1177 FMI 2 - TC2CIP signal erratic, intermittent, or incorrect....3511
Fault Overview....3511
Malfunction Indicator Lamp (MIL) Reaction....3511
Associated Faults....3511
Drive Cycle to Determine Fault Status....3511
Possible Causes....3511
SPN 1177 FMI 3 - TC2CIP signal Out of Range HIGH....3513
Fault Overview....3513
Malfunction Indicator Lamp (MIL) Reaction....3513
Drive Cycle to Determine Fault Status....3513
Possible Causes....3513
SPN 1177 FMI 4 - TC2CIP signal Out of Range LOW....3516
Fault Overview....3516
Malfunction Indicator Lamp (MIL) Reaction....3516
Drive Cycle to Determine Fault Status....3516
Possible Causes....3516
TOSS / VSS (Transmission Output Shaft Speed / Vehicle Speed Sensor) Sensor....3518
Overview....3520
Tools Required....3520
Pinpoint Diagnostics With ServiceMaxx? Software....3521
SPN 191 FMI 1 TOSS / VSS not detected while vehicle moving....3523
Malfunction Indicator Lamp (MIL) Reaction....3523
Drive Cycle to Determine Fault Status....3523
SPN 191 FMI 2 TOSS / VSS signal erratic, intermittent, or incorrect....3526
Malfunction Indicator Lamp (MIL) Reaction....3526
Drive Cycle to Determine Fault Status....3526
SPN 191 FMI 3 TOSS / VSS signal out of range HIGH....3529
Malfunction Indicator Lamp (MIL) Reaction....3529
Drive Cycle to Determine Fault Status....3529
SPN 191 FMI 4 TOSS / VSS signal out of range LOW....3532
Malfunction Indicator Lamp (MIL) Reaction....3532
Drive Cycle to Determine Fault Status....3532
SPN 191 FMI 16 TOSS / VSS reading higher then limit....3535
Malfunction Indicator Lamp (MIL) Reaction....3535
Drive Cycle to Determine Fault Status....3535
VREF (Voltage Reference)....3538
Tools Required....3539
WIF Sensor (Water In Fuel)....3545
Tools Required....3545
Pinpoint Diagnostics With ServiceMaxx? Software....3546
WIFL (Water In Fuel Lamp)....3548
Overview....3548
Tools Required....3548
SPN 97 - FMI 3 - WIFL short to PWR....3549
SPN 97 - FMI 4 - WIFL short to GND....3550
SPN 97 - FMI 5 - WIFL open / load circuit....3552
WTSL (Wait to Start Lamp)....3554
Overview....3554
Tools Required....3554
SPN 1081 - FMI 3 - WTSL circuit short to PWR....3555
Malfunction Indicator Lamp (MIL) Reaction....3555
SPN 1081 - FMI 4 - WTSL circuit short to GND....3557
Malfunction Indicator Lamp (MIL) Reaction....3557
SPN 1081 - FMI 5- WTSL open load / circuit....3559
Malfunction Indicator Lamp (MIL) Reaction....3559
Sensor and Actuator Locations....3561
Engine Mounted Components....3561
AFT System....3563
Engine Compression Brake Locations....3564
Vehicle Mounted Components....3564
Ambient Air Temperature Sensor....3564
Table of Contents....3566
Electrical Tools....3568
180-Pin Breakout Box....3568
3-Banana Plug Harness....3568
500 Ohm Resistor Harness....3569
Electronic Engine Terminal Test Kit....3569
Big Bore Terminal Test Probe Kit....3569
Digital Multimeter (DMM)....3570
EXP-1000 HD by Midtronics....3570
EZ-Tech? Electronic Service Tool (EST)....3571
ServiceMaxx? Software....3571
Interface cable (RP1210B compliant supporting J1939 and J1708)....3571
MaxxForce? 11 and 13 Engine Tool Kit....3571
Breakout Harness 4485A (APP)....3572
Breakout Harness 4602 (AFTFSV)....3572
Breakout Harness 4735A (O2S)....3572
Breakout Harness 4760A (DOCIT, DOCOT, DPFOT, and EGRT)....3572
Breakout Harness 4761A (DPFDP)....3573
Breakout Harness 4827 (IAHFS, ECT1, ECT2, EOL, and EOT)....3573
Breakout Harness 4828 (AFTFD and FPCV)....3573
Breakout Harness 4829 (FRP)....3573
Breakout Harness 4830 (AFTFIS, HS/IAT, and TC2CIS)....3574
Breakout Harness 4844 (EFAN)....3574
Breakout Harness 4850 (IMP)....3574
Breakout Harness 4870 (CMV)....3574
Breakout Harness 4871 (AAT and CFV)....3575
Breakout Harness 4881 (FDP)....3575
Breakout Harness 4882 (EOP)....3575
Breakout Harness 4883 (IMT)....3575
Breakout Harness 4885 (IAHR)....3576
Breakout Harness 4951 (CCOSS)....3576
Breakout Harness 4993 (CACOT)....3576
Breakout Harness 6002 (WIF)....3576
Breakout Harness 6003 (EBPV, TC1TOP, TC1WC, and TC2WC)....3577
Breakout Harness 6004 (ECB)....3577
Breakout Harness 6016 (ETV and EGR Valve)....3577
Breakout Harness 6021 (CKP and CMP)....3577
Breakout Harness 6027 (AFTFP2)....3578
Mechanical Tools....3579
Air Cap, Fuel Cap and Plug Kit....3579
Air Compressor Coolant Line Release Tool....3579
Air Intake Guard....3579
Blow-by Test Tool....3580
Clean Fuel Source Tool....3580
Inlet Air Heater Solenoid Test Adapter Kit....3581
Digital Manometer....3581
EGR Cooler Leak Detection Test Kit....3582
Lash Gauge (0.50mm)....3582
Lash Gauge (0.80mm)....3582
Fuel Block Off Tool....3582
Fuel Injector Cups....3583
Fuel Inlet Restriction and Aeration Tool....3583
Fuel Line Coupler....3583
Fuel Line Disconnect Tool 11.8 mm....3583
Fuel Line Disconnect Tool 16 mm....3584
Fuel Pressure Gauge....3584
High Pressure Rail Plugs....3585
High Pressure Return Line Tester....3585
Pressure Test Kit....3585
Radiator Pressure Test Kit....3586
Slack Tube? Manometer....3586
UV Leak Detection Kit....3587
Table of Contents....3588
Abbreviations and Acronyms....3590
Table of Contents....3596
Terms....3598
Table of Contents....3608
All Ratings....3610
MaxxForce? 11 (10.5 L)....3616
330 hp @ 1700 rpm....3616
370 hp @ 1700 rpm....3617
390 hp @ 1700 rpm....3618
MaxxForce? 13 (12.4 L)....3619
410 hp @ 1700 rpm....3619
430 hp @ 1700 rpm....3620
450 hp @ 1700 rpm (Allison Automatic Transmission)....3621
450 hp @ 1700 rpm (Manual Transmission)....3622
475 hp @ 1700 rpm....3623
Table of Contents....3624
Signal Values....3626
Table of Contents....3634
Description....3636
tables....2658
Technical Service Literature....2658
MaxxForce? 11 and 13 Diesel Engines....2665
Engine Brake Solenoid Specifications....2765
Engine Brake Oil Pressure Requirements....2767
Normal fuel return flow with number of connected injectors....2834
Example....2860
Example....2861
Example....2862
Example....2863
Entry Conditions for a Rolling Regen....2971
Entry Conditions for a Parked Regen....2972
Sensor Compare Checks....2974
Exhaust Restriction Test....2974
Check Rolling Regen Inhibitors....2976
Check Parked Regen Inhibitors....2977
Parked Regen Checks....2978
Connector Voltage Check ? AFTFD Disconnected....2988
Operational Voltage Check....2989
Actuator Resistance Check....2989
Harness Resistance Check....2989
Sensor Circuit Check....3001
Pinpoint Diagnostics Without ServiceMaxx? Software....3002
Harness Resistance Check....3002
Sensor Circuit Check....3005
Pinpoint Diagnostics Without ServiceMaxx? Software....3005
Harness Resistance Check....3005
SPN 102 FMI 16 ? Intake Manifold Pressure Overboost ....3015
SPN 102 FMI 18 ? Intake Manifold Pressure Underboost....3015
SPN 1173 FMI 16 ? TC2CIT signal above desired (Interstage CAC under cooling)....3015
SPN 2659 FMI 21 ? EGR Low Flow Rate detected....3016
Sensor Circuit Check....3023
Pinpoint Diagnostics Without ServiceMaxx? Software....3023
Harness Resistance Check....3024
Operational Voltage Check....3024
SPN 2630 FMI 2 ? CACOT signal does not agree with other sensors....3028
Sensor Circuit Check With ServiceMaxx? Software....3029
Connector Voltage Check Without ServiceMaxx? Software....3029
Harness Resistance Check....3029
Sensor Resistance Check....3034
Connector Voltage Check Without ServiceMaxx? software....3034
Harness Resistance Check....3034
Programmable Parameters....3035
Switch Checks....3036
Connector Voltage Check....3037
Operational Voltage Check....3038
Actuator Resistance Check....3038
Harness Resistance Check....3038
Connector Voltage Check....3067
Operational Voltage Check....3067
Actuator Resistance Check....3067
Harness Resistance Check....3067
SPN 626 FMI 18 ? Inlet Air Heater fault: Lack of heat in the Intake Manifold ....3073
Voltage Check on IAHFI - Actuator Test....3073
Amperage Draw Check - Actuator Test....3074
Voltage Checks on Relay Connector....3074
Voltage Checks on Relay - Actuator Test....3075
IAHFI Resistance Check....3077
Harness Resistance Check....3077
Connector Voltage Check ? IAHFS Disconnected....3079
Operational Voltage Check....3079
Actuator Resistance Check....3079
Harness Resistance Check....3080
Connector Voltage Check ? EBPV Disconnected....3236
Operational Voltage Check....3236
Actuator Resistance Check....3236
Harness Resistance Check....3237
Connector Voltage Check ? ECB1 Disconnected....3239
Operational Voltage Check....3239
Actuator Resistance Check....3239
Harness Resistance Check....3240
Connector Voltage Check ? ECB2 Disconnected....3242
Operational Voltage Check....3242
Actuator Resistance Check....3242
Harness Resistance Check....3243
SPN 111 FMI 1 ? Low Engine Coolant level....3245
Connector Voltage Check....3245
Harness Resistance Check....3245
SPN 158 FMI 15- ECM Switched voltage too HIGH....3247
SPN 158 FMI 17- ECM Switched voltage too LOW....3247
Voltage Checks at ECM....3247
Voltage Check....3249
Harness Resistance Check....3249
Voltage Check....3250
Harness Resistance Check....3250
Voltage Check....3252
Harness Resistance Check....3252
SPN 108 FMI 3- BARO signal Out of Range HIGH....3253
SPN 108 FMI 4 - BARO signal Out of Range LOW....3253
SPN 628 FMI 12 - ECM Memory Error....3254
SPN 629 FMI 2- ECM Error- Level 2 Monitoring....3254
SPN 629 FMI 8 - Engine Off timer fault....3254
SPN 629 FMI 12 - ECM Internal chip Error....3254
SPN 629 FMI 14 - ECM Internal component....3254
SPN 1110 FMI 31 ? ECM Detects Fueling Without Demand....3254
Sensor Circuit Check With ServiceMaxx? Software....3263
Connector Voltage Check Without ServiceMaxx? Software....3263
Harness Resistance Check....3263
SPN 4076 FMI 16 ? ECT2 signal does not agree with other sensors (Cold soak)....3270
Sensor Circuit Check With ServiceMaxx? Software....3270
Connector Voltage Check Without ServiceMaxx? Software....3270
Harness Resistance Check....3271
Voltage Check at Single or Two-Speed EFC Connector - Actuator Test....3274
Harness Resistance Check....3274
SPN 412 FMI 2 ? EGRT signal does not agree with other sensors....3276
Sensor Circuit Check With ServiceMaxx? Software....3277
Connector Voltage Check Without ServiceMaxx? Software....3277
Harness Resistance Check....3277
SPN 27 FMI 7 ? EGRP does not agree with commanded position....3280
Connector Voltage Check ? EGR Valve Disconnected....3280
Operational Voltage Check....3280
Harness Resistance Check....3281
Sensor Circuit Check With ServiceMaxx? Software....3290
Connector Voltage Check Without ServiceMaxx? Software....3291
Harness Resistance Check....3291
Sensor Circuit Check....3293
Connector Voltage Check....3293
Harness Resistance Check....3294
Sensor Circuit Check With ServiceMaxx? Software....3296
Pinpoint Diagnostics Without ServiceMaxx? Software....3296
Harness Resistance Check....3296
Connector Voltage Check ? ETV Disconnected....3300
Operational Voltage Check....3300
Harness Resistance Check....3301
Sensor Circuit Check With ServiceMaxx? Software....3336
Connector Voltage Check Without ServiceMaxx? Software....3337
Harness Resistance Check....3337
Connector Voltage Check ? FPCV Disconnected....3339
Operational Voltage Check....3339
Harness Resistance Check....3339
Sensor Circuit Check With ServiceMaxx? Software....3343
Connector Voltage Check Without ServiceMaxx? Software....3344
Harness Resistance Check....3344
SPN 157 FMI 0 - FRP relief valve opening fault....3353
SPN 157 FMI 14 - FRP Relief Valve failure....3353
SPN 1810 FMI 0 - Hard Brake monitor, event log, extreme....3366
SPN 1810 FMI 15- Hard Brake monitor, event log, non-extreme....3366
SPN 172 FMI 2 ? IAT signal does not agree with other sensors....3369
Sensor Circuit Check With ServiceMaxx? Software....3370
Connector Voltage Check Without ServiceMaxx? Software....3370
Harness Resistance Check....3371
Sensor Circuit Check With ServiceMaxx? Software....3375
Connector Voltage Check Without ServiceMaxx? Software....3375
Harness Resistance Check....3376
Cold Soak Sensor Compare Check With ServiceMaxx? Software....3383
SPN 105 FMI 2 ? IMT signal does not agree with other sensors....3383
SPN 105 FMI 18 ? IMT signal not responding as expected....3383
Sensor Circuit Check With ServiceMaxx? Software....3384
Connector Voltage Check Without ServiceMaxx? Software....3384
Harness Resistance Check....3384
Vehicle Diagnostic Connector Voltage Check....3462
EST Communication Check....3462
Harness Resistance Check....3462
SPN 1590 FMI 19 - Adaptive Cruise Control not detected on J1939....3463
MIL Connector Voltage Check Without ServiceMaxx? Software ....3466
Harness Resistance Check....3466
Connector Voltage Check Without ServiceMaxx? Software....3472
Harness Resistance Check....3472
SPN 3223 FMI 1? O2S heater temperature below minimum....3482
SPN 3223 FMI 17 ? O2S heater temperature below minimum at low battery PWR....3482
Sensor Circuit Check With ServiceMaxx? Software....3484
Harness Resistance Check....3484
Connector Voltage Check....3486
Harness Resistance Check....3487
SPN 5541 FMI 2 ? TC1TOP signal does not agree with BARO....3489
Sensor Circuit Check With ServiceMaxx? Software....3490
Connector Voltage Check Without ServiceMaxx? Software....3490
Harness Resistance Check....3491
Connector Voltage Check ? TC2WC Disconnected....3493
Operational Voltage Check....3493
Actuator Resistance Check....3493
Harness Resistance Check....3494
Connector Voltage Check ? TC2WC Disconnected....3496
Operational Voltage Check....3496
Actuator Resistance Check....3496
Harness Resistance Check....3497
SPN 84 FMI 2 - Vehicle speed anti-tampering fault....3521
TOSS / VSS Connector Voltage Check Without ServiceMaxx? Software....3521
TOSS / VSS Sensor Continuity Check Without ServiceMaxx? Software....3521
Harness Resistance Check....3522
TOSS / VSS Operational Check Without ServiceMaxx? Software....3522
Voltage Checks for SPN 3509 FMI 14 ? VREF1....3540
Harness Resistance Check for SPN 3509 FMI 14 ? VREF1....3540
Voltage Checks for SPN 3510 FMI 14 ? VREF2....3541
Harness Resistance Check for SPN 3510 FMI 14 ? VREF2....3541
Voltage Checks for SPN 3511 FMI 14 ? VREF3....3541
Harness Resistance Check for SPN 3511 FMI 14 ? VREF3....3542
Voltage Checks for SPN 3512 FMI 14 ? VREF4....3542
Harness Resistance Check for SPN 3512 FMI 14 ? VREF4....3542
Voltage Checks for SPN 3513 FMI 14 ? VREF5....3543
Harness Resistance Check for SPN 3513 FMI 14 ? VREF5....3543
Voltage Checks for SPN 3514 FMI 14 ? VREF6....3544
Harness Resistance Check for SPN 3514 FMI 14 ? VREF6....3544
Voltage Check....3546
Connector Resistance Check to GND....3547
Harness Resistance Check....3547
Key-On Engine-Off....3610
Engine Cranking....3610
Low Idle, no load, stabilized engine operating temperature....3611
High Idle, no load, stabilized engine operating temperature....3612
Full load, rated speed on dynamometer, stabilized engine operating temperature....3612
Component Specifications....3613
Actuator Output State....3614
Inlet Air Heater System....3615
Crankcase Pressure....3615
EBPV Rod Extension....3615
TC2WC Rod Extension....3615
0000001741 - MaxxForce 11 and 13 Engine Diagnostic Manual (2015-07)....3639
toc....3641
Table of Contents....3641
Safety Terminology....3645
Safety Instructions....3645
Work Area....3645
Safety Equipment....3645
Protective Measures....3645
Vehicle....3645
Engine....3646
Fire Prevention....3646
Batteries....3646
Compressed Air....3646
Tools....3646
Fluids Under Pressure....3647
Fuel....3647
Removal of Tools, Parts, and Equipment....3647
Table of Contents....3649
Diagnostic Trouble Code (DTC?s) List....3653
How To Use Symptom Based Diagnostics....3663
Operational Checkout Procedures....3664
1.0 - Preliminary Vehicle Operational Checkout Procedure....3664
2.0 - Engine Does Not Start Operational Checkout Procedure....3666
Overview....3666
3.0 - Engine Hard to Start Operational Checkout Procedure....3667
Overview....3667
4.0 - Engine Performance Problem Operational Checkout Procedure....3668
Overview....3668
5.0 - Cooling System Operational Checkout Procedure....3669
Overview....3669
6.0 - Engine Oil System Operational Checkout Procedure....3672
Overview....3672
7.0 - Fuel System Operational Checkout Procedure....3674
Overview....3674
8.0 - Engine Compression Brake Operational Checkout Procedure....3676
Overview....3676
Engine Does Not Start Symptoms....3678
2.1 - Engine Cranks Fast, Slow or Does Not Crank....3678
Overview....3678
Possible Causes....3678
Test Procedure....3678
2.2 - Engine Cranks But Does Not Start ....3682
Overview....3682
Possible Causes....3682
Test Procedure....3682
Engine Hard to Start Symptoms....3683
3.1 - Engine Hard to Start (Long Crank Time)....3683
Overview....3683
Possible Causes....3683
Test Procedure....3683
3.2 - Engine Starts, Then Stalls ....3684
Overview....3684
Possible Causes....3684
Test Procedure....3684
Engine Performance Problems Symptoms....3686
4.1 - Misfire / Rough Idle / Runs Rough....3686
Overview....3686
Possible Causes....3686
Test Procedure....3686
4.2 - Popping Noise from Intake....3689
Overview....3689
Possible Causes....3689
Test Procedure....3689
4.3 - Low Power (Slow Acceleration)....3691
Overview....3691
Possible Causes....3691
Test Procedure....3691
4.4 - Surge (Inconsistent Engine RPM During Steady State)....3694
Overview....3694
Possible Causes....3694
Test Procedure....3694
Engine Coolant Symptoms....3696
5.1 - Coolant Overflow....3696
Overview....3696
Possible Causes....3696
Test Procedure....3696
5.2 - Coolant Over Temperature....3699
Overview....3699
Possible Causes....3699
Test Procedure....3700
5.3 - Coolant Leak to Engine Oil....3702
Overview....3702
Possible Causes....3702
Test Procedure....3702
5.4 - Coolant Leak to Intake....3704
Overview....3704
Possible Causes....3704
Test Procedure....3704
5.5 - Coolant Leak to Exhaust....3706
Overview....3706
Possible Causes....3706
Test Procedure....3706
Engine Lubrication Symptoms....3707
6.1 - Low Engine Oil Pressure....3707
Overview....3707
Possible Causes....3707
Test Procedure....3707
6.2 - Oil Leak to Exhaust....3711
Overview....3711
Possible Causes....3711
Test Procedure....3711
Fuel System Symptoms....3713
7.1 - Metal in Fuel System / Noise from High-Pressure Fuel Pump....3713
Overview....3713
Possible Causes....3713
Test Procedure....3713
7.2 - Fuel Contamination....3715
Overview....3715
Possible Causes....3715
Test Procedure....3715
7.3 - Fuel Leak to Engine Oil....3717
Overview....3717
Possible Causes....3717
Test Procedure....3717
7.4 - Fuel Leak to Exhaust....3719
Overview....3719
Possible Causes....3719
Test Procedure....3719
Engine Brake Symptoms....3720
8.1 - Engine Compression Brake Inoperative....3720
Overview....3720
Possible Causes....3720
Test Procedure....3720
8.2 - Engine Compression Brake Engaged When Not Commanded....3722
Overview....3722
Possible Causes....3722
Test Procedure....3722
Parked Regeneration Symptom....3724
9.1 - Parked Regeneration Will Not Activate or Build Exhaust Temperature....3724
Overview....3724
Possible Causes....3724
Test Procedure....3724
Fault Code Diagnostics....3726
Section Information....3726
AAT (Ambient Air Temperature) Sensor ....3727
Overview of AAT Sensor Group....3727
Overview....3727
SPN 171 FMI 2 - AAT signal erratic, intermittent, or incorrect....3728
Fault Overview....3728
Lamp Reaction....3728
Associated Faults....3728
Fault Facts....3728
Drive Cycle to Determine Fault Status....3728
Possible Causes....3728
Pin-Point Test SPN 171 FMI 2....3731
Tools Required....3731
SPN 171 FMI 3 - AAT Signal Out of Range HIGH....3734
Fault Overview....3734
Lamp Reaction....3734
Associated Faults....3734
Drive Cycle to Determine Fault Status....3734
Fault Facts....3734
Possible Causes....3734
Pin-Point Test SPN 171 FMI 3....3737
Tools Required....3737
SPN 171 FMI 4 - AAT Signal Out of Range LOW....3740
Fault Overview....3740
Lamp Reaction....3740
Associated Faults....3740
Drive Cycle to Determine Fault Status....3740
Fault Facts....3740
Possible Causes....3740
AFT (Aftertreatment) System....3743
Overview of AFT Sensor Group....3743
Overview....3743
SPN 5298 FMI 2 - Reduced DOC Efficiency - De-Rate....3747
Fault Overview....3747
Lamp Reaction....3747
Associated Faults....3747
Fault Facts....3747
Drive Cycle to Determine Fault Status....3747
AFTFD (Aftertreatment Fuel Doser)....3753
Overview of AFTFD....3753
SPN 3471 FMI 7 - AFT Fuel Doser Valve not responding as expected....3756
Fault Overview....3756
Lamp Reaction....3756
Associated Faults....3756
Fault Facts....3756
Drive Cycle to Determine Fault Status....3756
SPN 3479 FMI 3 - AFT Fuel Doser Valve Short to PWR....3762
Tools Required....3762
SPN 3479 FMI 5 - AFT Fuel Doser Valve open load/circuit....3764
SPN 3479 FMI 6 - AFT Fuel Doser Valve High Side Short circuit....3765
AFTFP (Aftertreatment Fuel Pressure) Sensor ....3766
Overview of AFTFP Sensor....3766
Overview....3766
SPN 3471 FMI 1 - AFTFP1 below desired (Low system pressure)....3770
Fault Overview....3770
Lamp Reaction....3770
Associated Faults....3770
Fault Facts....3770
Drive Cycle to Determine Fault Status....3770
SPN 3480 FMI 2 - AFTFP1 signal erratic, intermittent, or incorrect....3775
Fault Overview....3775
Lamp Reaction....3775
Associated Faults....3775
Fault Facts....3775
Drive Cycle to Determine Fault Status....3775
Possible Causes....3775
SPN 3480 FMI 3 - AFTFP1 signal Out of Range HIGH....3777
Fault Overview....3777
Lamp Status....3777
Associated Faults....3777
Fault Facts....3777
Drive Cycle to Determine Fault Status....3777
Possible Causes....3777
SPN 3480 FMI 4 - AFTFP1 signal Out of Range LOW....3780
Fault Overview....3780
Lamp Reaction....3780
Associated Faults....3780
Fault Facts....3780
Drive Cycle to Determine Fault Status....3780
Possible Causes....3780
SPN 3556 FMI 0 - AFTFP2 below Warning Pressure....3783
Fault Overview....3783
Lamp Reaction....3783
Associated Faults....3783
Fault Facts....3783
Drive Cycle to Determine Fault Status....3783
SPN 3556 FMI 1 - AFTFP2 below desired (Possible system leak)....3787
Fault Overview....3787
Lamp Reaction....3787
Fault Facts....3787
Drive Cycle to Determine Fault Status....3787
SPN 4077 FMI 2 - AFTFP2 signal erratic, intermittent, or incorrect....3790
Fault Overview....3790
Lamp Reaction....3790
Fault Facts....3790
Drive Cycle to Determine Fault Status....3790
SPN 4077 FMI 3 - AFTFP2 signal Out of Range HIGH....3794
Tools Required....3794
Pinpoint Diagnostics With ServiceMaxx? Software....3794
SPN 4077 FMI 4 - AFTFP2 signal Out of Range LOW....3796
Tools Required....3796
Pinpoint Diagnostics With ServiceMaxx? Software....3796
SPN 5456 FMI 3 - AFTFT signal Out of Range HIGH....3798
Pinpoint Diagnostics With ServiceMaxx? software....3798
SPN 5456 FMI 4 - AFTFT signal Out of Range LOW....3800
Pinpoint Diagnostics With ServiceMaxx? software....3800
AFTFSO (Aftertreatment Fuel Shutoff) Valve Sensor ....3802
Overview of AFTFSO Sensor....3802
Overview....3802
SPN 3482 FMI 3 - AFT Fuel Shutoff Valve short to PWR....3804
Fault Overview....3804
Lamp Reaction....3804
Associated Faults....3804
Fault Facts....3804
Drive Cycle to Determine Fault Status....3804
Possible Causes....3805
SPN 3482 FM 4 - AFT Fuel Shutoff Valve Short to GND....3808
Fault Overview....3808
Lamp Reaction....3808
Associated Faults....3808
Fault Facts....3808
Drive Cycle to Determine Fault Status....3808
Possible Causes....3808
AMS (Air Management) System....3812
Overview of AMS Sensor....3812
Overview....3812
SPN 102 FMI 10 - Boost slow response fault....3813
Fault Overview....3813
Lamp Reaction....3813
Associated Faults....3813
Fault Facts....3813
Drive Cycle to Determine Fault Status....3813
Possible Causes....3813
SPN 102 FMI 16 - Overboost....3818
Fault Overview....3818
Lamp Reaction....3818
Associated Faults....3818
Fault Facts....3818
Drive Cycle to Determine Fault Status....3818
Possible Causes....3818
SPN 102 FMI 18 - Underboost....3820
Fault Overview....3820
Lamp Reaction....3820
Associated Faults....3820
Fault Facts....3820
Drive Cycle to Determine Fault Status....3820
Possible Causes....3820
SPN 2659 FMI 20 - EGR High Flow Rate detected....3822
Fault Overview....3822
Lamp Reaction....3822
Associated Faults....3822
Fault Facts....3822
Drive Cycle to Determine Fault Status....3822
Possible Causes....3822
SPN 2659 FMI 21 - EGR Low Flow Rate detected....3824
Fault Overview....3824
Lamp Reaction....3824
Associated Faults....3824
Fault Facts....3824
Drive Cycle to Determine Fault Status....3824
Possible Causes....3824
Special Tools....3824
APP (Accelerator Pedal Position) Sensor....3827
Overview of APP Sensor....3827
Overview....3827
SPN 91 FMI 2 - APP1 and APP2 signal conflict....3828
Fault Overview....3828
Lamp Reaction....3828
Associated Faults....3828
Fault Facts....3829
Drive Cycle to Determine Fault Status....3829
Possible Causes....3829
Pin-Point Test SPN 91 FMI 2....3833
Tools Required....3833
SPN 91 FMI 3 - APP1 signal Out of Range HIGH....3839
Fault Overview....3839
Lamp Reaction....3839
Associated Faults....3839
Fault Facts....3839
Drive Cycle to Determine Fault Status....3839
Possible Causes....3839
Pin-Point Test SPN 91 FMI 3....3841
Tools Required....3841
SPN 91 FMI 4 - APP1 signal Out of Range LOW....3843
Fault Overview....3843
Lamp Reaction....3843
Associated Faults....3843
Fault Facts....3843
Drive Cycle to Determine Fault Status....3843
Possible Causes....3843
Pin-Point Test SPN 91 FMI 4....3846
Tools Required....3846
SPN 2623 FMI 3 - APP2 signal Out of Range HIGH....3848
Fault Overview....3848
Lamp Reaction....3848
Associated Faults....3848
Fault Facts....3848
Drive Cycle to Determine Fault Status....3848
Possible Causes....3848
Pin-Point Test SPN 2623 FMI 3....3850
Tools Required....3850
SPN 2623 FMI 4 - APP2 signal Out of Range LOW....3852
Fault Overview....3852
Lamp Reaction....3852
Associated Faults....3852
Fault Facts....3852
Drive Cycle to Determine Fault Status....3852
Possible Causes....3852
Pin-Point Test SPN 2623 FMI 4....3855
Tools Required....3855
BARO (Barometric Pressure) Sensor....3857
Overview of BARO Sensor....3857
Overview....3857
SPN 108 FMI 3 - BARO signal Out of Range HIGH....3858
Fault Overview....3858
Lamp Reaction....3858
Associated Faults....3858
Fault Facts....3858
Drive Cycle to Determine Fault Status....3858
Possible Causes....3858
SPN 108 FMI 4 - BARO signal Out of Range LOW....3860
Fault Overview....3860
Lamp Reaction....3860
Associated Faults....3860
Fault Facts....3860
Drive Cycle to Determine Fault Status....3860
Possible Causes....3860
Body Sensor....3862
Overview of Body Sensor....3862
SPN 837 FMI 14 - Speedometer Drive Output Error....3863
Fault Overview....3863
Lamp Reaction....3863
Associated Faults....3863
Fault Facts....3863
Drive Cycle to Determine Fault Status....3863
Possible Causes....3863
Pin-Point Test SPN 837 FMI 14....3865
Tools Required....3865
SPN 1590 FMI 19 - Adaptive Cruise Control not detected on J1939....3866
Fault Overview....3866
Lamp Reaction....3866
Associated Faults....3866
Fault Facts....3866
Drive Cycle to Determine Fault Status....3866
Possible Causes....3866
CACOT (Charge Air Cooler Outlet Temperature) Sensor ....3868
Overview of CACOT Sensor Group....3868
Overview....3868
SPN 2630 FMI 2 - CACOT signal erratic, intermittent, or incorrect....3870
Fault Overview....3870
Lamp Reaction....3870
Associated Faults....3870
Fault Facts....3870
Drive Cycle to Determine Fault Status....3870
Possible Causes....3870
Pin-Point Test SPN 2630 FMI 2....3873
Tools Required....3873
SPN 2630 FMI 3 - CACOT Signal Out of Range HIGH....3875
Fault Overview....3875
Lamp Reaction....3875
Associated Faults....3875
Fault Facts....3875
Drive Cycle to Determine Fault Status....3875
Possible Causes....3875
Pin-Point Tests (SPN 2630 FMI 3)....3878
Tools Required....3878
SPN 2630 FMI 4 - CACOT Signal Out of Range LOW....3881
Fault Overview....3881
Lamp Reaction....3881
Associated Faults....3881
Fault Facts....3881
Drive Cycle to Determine Fault Status....3881
Possible Causes....3881
SPN 2630 FMI 16 - CACOT Undercooling....3883
Fault Overview....3883
Lamp Reaction....3883
Fault Facts....3883
Drive Cycle to Determine Fault Status....3883
Possible Causes....3883
CCOSS (Crankcase Oil Separator Speed) Sensor ....3886
Overview of CCOSS Sensor....3886
Overview....3886
SPN 4227 FMI 7 - CC Oil Separator: Not spinning....3887
Fault Overview....3887
Lamp Reaction....3887
Associated Faults....3887
Fault Facts....3887
Drive Cycle to Determine Fault Status....3887
Possible Causes....3887
Pin-Point Test SPN 4227 FMI 7....3891
CFV (Coolant Flow) Valve....3895
CKP (Crankshaft Position) Sensor ....3899
Overview of CKP Sensor Group....3899
Overview....3899
SPN 637 FMI 8 - CKP signal noise....3900
Fault Overview....3900
Lamp Reaction....3900
Associated Faults....3900
Fault Facts....3900
Drive Cycle to Determine Fault Status....3900
Possible Causes....3900
Pin-Point Test SPN 637 FMI 8....3903
Tools Required....3903
SPN 637 FMI 10 - CKP signal inactive....3906
Fault Overview....3906
Lamp Reaction....3906
Associated Faults....3906
Fault Facts....3906
Drive Cycle to Determine Fault Status....3906
Possible Causes....3906
Pin-Point Test SPN 637 FMI 10....3909
Tools Required....3909
CMP (Camshaft Position) Sensor ....3912
Overview of CMP Sensor Group....3912
Overview....3912
SPN 636 FMI 2 - CMP and CKP Synchronization Error....3913
Fault Overview....3913
Lamp Reaction....3913
Associated Faults....3913
Fault Facts....3913
Drive Cycle to Determine Fault Status....3913
Possible Causes....3913
Pin-Point Test SPN 636 FMI 2....3917
Tools Required....3917
SPN 636 FMI 8 - CMP signal noise....3920
Fault Overview....3920
Lamp Reaction....3920
Associated Faults....3920
Fault Fact....3920
Drive Cycle to Determine Fault Status....3920
Possible Causes....3920
Pin-Point Test SPN 636 FMI 8....3924
Tools Required....3924
SPN 636 FMI 10 - CMP signal inactive....3927
Fault Overview....3927
Lamp Reaction....3927
Associated Faults....3927
Fault Fact....3927
Drive Cycle to Determine Fault Status....3927
Possible Causes....3927
Pin-Point Test SPN 636 FMI 10....3931
Tools Required....3931
CMV (Coolant Mixer) Valve....3934
Tools Required....3935
Tools Required....3937
Tools Required....3939
Cylinder Balance....3941
Overview of Cylinder Balance Sensor Group....3941
Overview....3941
SPN 651 FMI 13 - Injector 1 programmable parameter error....3943
Fault Overview....3943
Lamp Reaction....3943
Associated Faults....3943
Fault Facts....3943
Drive Cycle to Determine Fault Status....3943
Possible Causes....3943
SPN 651 FMI 16 - Injector 1 Fuel Quantity / Timing High Error....3945
Fault Overview....3945
Lamp Reaction....3945
Associated Faults....3945
Fault Facts....3945
Drive Cycle to Determine Fault Status....3945
Possible Causes....3945
SPN 651 FMI 18 - Injector 1 Fuel Quantity / Timing Low Error....3948
Fault Overview....3948
Lamp Reaction....3948
Associated Faults....3948
Fault Facts....3948
Drive Cycle to Determine Fault Status....3948
Possible Causes....3948
SPN 652 FMI 13 - Injector 2 programmable parameter error....3951
Fault Overview....3951
Lamp Reaction....3951
Associated Faults....3951
Fault Facts....3951
Drive Cycle to Determine Fault Status....3951
Possible Causes....3951
SPN 652 FMI 16 - Injector 2 Fuel Quantity / Timing High Error....3953
Fault Overview....3953
Lamp Reaction....3953
Associated Faults....3953
Fault Facts....3953
Drive Cycle to Determine Fault Status....3953
Possible Causes....3953
SPN 652 FMI 18 - Injector 2 Fuel Quantity / Timing Low Error....3956
Fault Overview....3956
Lamp Reaction....3956
Associated Faults....3956
Fault Facts....3956
Drive Cycle to Determine Fault Status....3956
Possible Causes....3956
SPN 653 FMI 13 - Injector 3 programmable parameter error....3959
Fault Overview....3959
Lamp Reaction....3959
Associated Faults....3959
Fault Facts....3959
Drive Cycle to Determine Fault Status....3959
Possible Causes....3959
SPN 653 FMI 16 - Injector 3 Fuel Quantity / Timing High Error....3961
Fault Overview....3961
Lamp Reaction....3961
Associated Faults....3961
Fault Facts....3961
Drive Cycle to Determine Fault Status....3961
Possible Causes....3961
SPN 653 FMI 18 - Injector 3 Fuel Quantity / Timing Low Error....3964
Fault Overview....3964
Lamp Reaction....3964
Associated Faults....3964
Fault Facts....3964
Drive Cycle to Determine Fault Status....3964
Possible Causes....3964
SPN 654 FMI 13 - Injector 4 programmable parameter error....3967
Fault Overview....3967
Lamp Reaction....3967
Associated Faults....3967
Fault Facts....3967
Drive Cycle to Determine Fault Status....3967
Possible Causes....3967
SPN 654 FMI 16 - Injector 4 Fuel Quantity / Timing High Error....3969
Fault Overview....3969
Lamp Reaction....3969
Associated Faults....3969
Fault Facts....3969
Drive Cycle to Determine Fault Status....3969
Possible Causes....3969
SPN 654 FMI 18 - Injector 4 Fuel Quantity / Timing Low Error....3972
Fault Overview....3972
Lamp Reaction....3972
Associated Faults....3972
Fault Facts....3972
Drive Cycle to Determine Fault Status....3972
Possible Causes....3972
SPN 655 FMI 13 - Injector 5 programmable parameter error....3975
Fault Overview....3975
Lamp Reaction....3975
Associated Faults....3975
Fault Facts....3975
Drive Cycle to Determine Fault Status....3975
Possible Causes....3975
SPN 655 FMI 16 - Injector 5 Fuel Quantity / Timing High Error....3977
Fault Overview....3977
Lamp Reaction....3977
Associated Faults....3977
Fault Facts....3977
Drive Cycle to Determine Fault Status....3977
Possible Causes....3977
SPN 655 FMI 18 - Injector 5 Fuel Quantity / Timing Low Error....3980
Fault Overview....3980
Lamp Reaction....3980
Associated Faults....3980
Fault Facts....3980
Drive Cycle to Determine Fault Status....3980
Possible Causes....3980
SPN 656 FMI 13 - Injector 6 programmable parameter error....3983
Fault Overview....3983
Lamp Reaction....3983
Associated Faults....3983
Fault Facts....3983
Drive Cycle to Determine Fault Status....3983
Possible Causes....3983
SPN 656 FMI 16 - Injector 6 Fuel Quantity / Timing High Error....3985
Fault Overview....3985
Lamp Reaction....3985
Associated Faults....3985
Fault Facts....3985
Drive Cycle to Determine Fault Status....3985
Possible Causes....3985
SPN 656 FMI 18 - Injector 6 Fuel Quantity / Timing Low Error....3988
Fault Overview....3988
Lamp Reaction....3988
Associated Faults....3988
Fault Facts....3988
Drive Cycle to Determine Fault Status....3988
Possible Causes....3988
SPN 1322 FMI 31- Misfire - Multiple Cylinders....3991
Fault Overview....3991
Lamp Reaction....3991
Associated Faults....3991
Fault Facts....3991
Drive Cycle to Determine Fault Status....3991
Possible Causes....3991
SPN 1323 FMI 31- Misfire - Cylinder 1....3995
Fault Overview....3995
Lamp Reaction....3995
Associated Faults....3995
Fault Facts....3995
Drive Cycle to Determine Fault Status....3995
Possible Causes....3995
SPN 1324 FMI 31- Misfire - Cylinder 2....3999
Fault Overview....3999
Lamp Reaction....3999
Associated Faults....3999
Fault Facts....3999
Drive Cycle to Determine Fault Status....3999
Possible Causes....3999
SPN 1325 FMI 31- Misfire - Cylinder 3....4003
Fault Overview....4003
Lamp Reaction....4003
Associated Faults....4003
Fault Facts....4003
Drive Cycle to Determine Fault Status....4003
Possible Causes....4003
SPN 1326 FMI 31- Misfire - Cylinder 4....4007
Fault Overview....4007
Lamp Reaction....4007
Associated Faults....4007
Fault Facts....4007
Drive Cycle to Determine Fault Status....4007
Possible Causes....4007
SPN 1327 FMI 31- Misfire - Cylinder 5....4011
Fault Overview....4011
Lamp Reaction....4011
Associated Faults....4011
Fault Facts....4011
Drive Cycle to Determine Fault Status....4011
Possible Causes....4011
SPN 1328 FMI 31- Misfire - Cylinder 6....4015
Fault Overview....4015
Lamp Reaction....4015
Associated Faults....4015
Fault Facts....4015
Drive Cycle to Determine Fault Status....4015
Possible Causes....4015
DOCIT (Diesel Oxidation Catalyst Inlet Temperature) Sensor ....4019
Overview of DOCIT Sensor Group....4019
Overview....4019
SPN 4765 FMI 2 - DOCIT signal erratic, intermittent, or incorrect....4020
Fault Overview....4020
Lamp Reaction....4020
Associated Faults....4020
Drive Cycle to Determine Fault Status....4020
Possible Causes....4020
SPN 4765 FMI 3 - DOCIT signal Out of Range HIGH....4023
Fault Overview....4023
Lamp Reaction....4023
Associated Faults....4023
Fault Facts....4023
Drive Cycle to Determine Fault Status....4023
Possible Causes....4023
SPN 4765 FMI 4 - DOCIT signal Out of Range LOW....4026
Fault Overview....4026
Lamp Reaction....4026
Associated Faults....4026
Fault Facts....4026
Possible Causes....4026
SPN 4765 FMI 20 - DOCIT DOCIT signal drifted HIGH....4028
Fault Overview....4028
Lamp Reaction....4028
Associated Faults....4028
Drive Cycle to Determine Fault Status....4028
SPN 4765 FMI 21 - DOCIT signal drifted LOW....4030
Fault Overview....4030
Lamp Reaction....4030
Associated Faults....4030
Drive Cycle to Determine Fault Status....4030
DOCOT Sensor (Diesel Oxidation Catalyst Outlet Temperature)....4033
Overview of DOCOT Sensor....4033
Overview....4033
SPN 4766 FMI 2 - DOCOT signal erratic, intermittent, or incorrect....4036
Fault Overview....4036
Lamp Reaction....4036
Fault Facts....4036
Drive Cycle to Determine Fault Status....4036
Possible Causes....4036
SPN 4766 FMI 3 - DOCOT signal Out of Range HIGH....4039
Fault Overview....4039
Lamp Reaction....4039
Associated Faults....4039
Fault Facts....4039
Drive Cycle to Determine Fault Status....4039
Possible Causes....4039
SPN 4766 FMI 4 - DOCOT signal Out of Range LOW....4042
Fault Overview....4042
Lamp Reaction....4042
Associated Faults....4042
Fault Facts....4042
Drive Cycle to Determine Fault Status....4042
Possible Causes....4042
SPN 4766 FMI 10 - Catalyst System Efficiency Below Threshold....4044
Fault Overview....4044
Lamp Reaction....4044
Associated Faults....4044
Fault Facts....4044
Drive Cycle to Determine Fault Status....4044
SPN 4766 FMI 20 - DOCOT signal drifted HIGH....4049
Fault Overview....4049
Lamp Reaction....4049
Associated Faults....4049
Fault Facts....4049
Drive Cycle to Determine Fault Status....4049
SPN 4766 FMI 21 - DOCOT signal drifted LOW....4054
Fault Overview....4054
Lamp Reaction....4054
Associated Faults....4054
Fault Facts....4054
Drive Cycle to Determine Fault Status....4054
DPF (Diesel Particulate Filter) System ....4060
Overview of DPF Sensor....4060
Overview....4060
SPN 3719 FMI 0 - DPF Soot Load - Highest (level 3/3)....4063
Fault Overview....4063
Lamp Reaction....4063
Associated Faults....4063
Drive Cycle to Determine Fault Status....4063
Fault Facts....4063
Possible Causes....4063
SPN 3719 FMI 15 - DPF Soot Load - Lowest (level 1/3)....4065
Fault Overview....4065
Lamp Reaction....4065
Associated Faults....4065
Drive Cycle to Determine Fault Status....4065
Fault Facts....4065
Possible Causes....4065
SPN 3719 FMI 16 - DPF Soot Load - Moderate (level 2/3)....4067
Fault Overview....4067
Lamp Reaction....4067
Associated Faults....4067
Drive Cycle to Determine Fault Status....4067
Fault Facts....4067
Possible Causes....4067
SPN 3720 FMI 0 - DPF Ash load at maximum limit (Remove DPF for cleaning)....4069
Fault Overview....4069
Lamp Reaction....4069
Associated Faults....4069
Fault Facts....4069
Drive Cycle to Determine Fault Status....4069
SPN 3936 FMI 8 - DPF Regenerations are Occurring too Frequently....4074
Fault Overview....4074
Lamp Reaction....4074
Associated Faults....4074
Fault Facts....4074
Drive Cycle to Determine Fault Status....4074
Possible Causes....4074
SPN 3936 FMI 10 - DPF System above Warning Temperature....4077
Fault Overview....4077
Lamp Reaction....4077
Associated Faults....4077
Fault Facts....4077
Drive Cycle to Determine Fault Status....4077
SPN 5319 FMI 31 - DPF incomplete Regeneration....4080
Fault Overview....4080
Lamp Reaction....4080
Associated Faults....4080
Fault Facts....4080
Drive Cycle to Determine Fault Status....4080
Possible Causes....4080
DPFDP (Diesel Particulate Filter Differential Pressure) Sensor ....4083
Overview of DPFDP Sensor....4083
Overview....4083
SPN 3251 FMI 0 - DPFDP excessively HIGH (Plugged filter)....4085
Fault Overview....4085
Lamp Reaction....4085
Associated Faults....4085
Fault Facts....4085
Drive Cycle to Determine Fault Status....4085
SPN 3251 FMI 2 - DPFDP signal erratic, intermittent, or incorrect....4090
Fault Overview....4090
Lamp Reaction....4090
Associated Faults....4090
Fault Facts....4090
Drive Cycle to Determine Fault Status....4090
Possible Causes....4090
SPN 3251 FMI 3 - DPFDP signal Out of Range HIGH....4093
Fault Overview....4093
Lamp Reaction....4093
Associated Fault....4093
Fault Facts....4093
Drive Cycle to Determine Fault Status....4093
Possible Causes....4093
SPN 3251 FMI 4 - DPFDP signal Out of Range LOW....4096
Fault Overview....4096
Lamp Reaction....4096
Associated Faults....4096
Fault Facts....4096
Drive Cycle to Determine Fault Status....4096
Possible Causes....4096
SPN 3251 FMI 21 - DPFDP excessively LOW (Sensor/circuit fault or missing DPF)....4100
Fault Overview....4100
Lamp Reaction....4100
Associated Faults....4100
Fault Facts....4100
Drive Cycle to Determine Fault Status....4100
DPFOT (Diesel Particulate Filter Outlet Temperature) Sensor ....4102
Overview of DPFOT Sensor Group....4102
Overview....4102
SPN 3246 FMI 2 - DPFOT signal erratic, intermittent or incorrect....4104
Fault Overview....4104
Lamp Reaction....4104
Associated Faults....4104
Fault Facts....4104
Drive Cycle to Determine Fault Status....4104
Possible Causes....4104
SPN 3246 FMI 3 - DPFOT Signal Out of Range HIGH....4107
Fault Overview....4107
Lamp Reaction....4107
Associated Faults....4107
Fault Facts....4107
Drive Cycle to Determine Fault Status....4107
Possible Causes....4107
SPN 3246 FMI 4 - DPFOT Signal Out of Range LOW....4110
Fault Overview....4110
Lamp Reaction....4110
Associated Faults....4110
Fault Facts....4110
Drive Cycle to Determine Fault Status....4110
Possible Causes....4110
SPN 3246 FMI 20 - DPFOT signal drifted HIGH....4112
Fault Overview....4112
Lamp Reaction....4112
Associated Faults....4112
Fault Facts....4112
Drive Cycle to Determine Fault Status....4112
SPN 3246 FMI 21 - DPFOT signal drifted LOW....4117
Fault Overview....4117
Lamp Reaction....4117
Associated Faults....4117
Fault Facts....4117
Drive Cycle to Determine Fault Status....4117
EBP (Exhaust Back Pressure) Sensor....4121
Overview of EBP Sensor Group....4121
Overview....4121
SPN 5543 FMI 3 - EBPC short to PWR....4122
Fault Overview....4122
Lamp Reaction....4122
Associated Faults....4122
Fault Facts....4122
Drive Cycle to Determine Fault Status....4122
Possible Causes....4122
Pin-Point Test SPN 5543 FMI 3....4125
Tools Required....4125
SPN 5543 FMI 4 - EBPC short to GND....4126
Fault Overview....4126
Lamp Reaction....4126
Associated Faults....4126
Fault Facts....4126
Drive Cycle to Determine Fault Status....4126
Possible Causes....4126
Pin-Point Test SPN 5543 FMI 4....4129
Tools Required....4129
SPN 5543 FMI 5 - EBPC open load/circuit....4130
Fault Overview....4130
Lamp Reaction....4130
Associated Faults....4130
Fault Facts....4130
Drive Cycle to Determine Fault Status....4130
Possible Causes....4130
Pin-Point Test SPN 5543 FMI 5....4133
Tools Required....4133
ECB1 (Engine Compression Brake 1) Sensor....4134
Overview of ECB1 Sensor Group....4134
Overview....4134
SPN 1072 FMI 3 - ECB1 Control short to PWR....4135
Fault Overview....4135
Lamp Reaction....4135
Associated Faults....4135
Fault Facts....4135
Drive Cycle to Determine Fault Status....4135
Possible Causes....4135
Pin-Point Test SPN 1073 FMI 3....4137
Tools Required....4137
SPN 1072 FMI 4 - ECB1 Control short to GND....4139
Fault Overview....4139
Lamp Reaction....4139
Associated Faults....4139
Fault Facts....4139
Drive Cycle to Determine Fault Status....4139
Possible Causes....4139
Pin-Point Test SPN 1072 FMI 4....4141
Tools Required....4141
SPN 1072 FMI 5 - ECB1 Control open load/circuit....4143
Fault Overview....4143
Lamp Reaction....4143
Associated Faults....4143
Fault Facts....4143
Drive Cycle to Determine Fault Status....4143
Possible Causes....4143
Pin-Point Test SPN 1072 FMI 5....4146
Tools Required....4146
ECB2 (Engine Compression Brake 2) Sensor....4148
Overview of ECB2 Sensor....4148
Overview....4148
SPN 1073 FMI 3 - ECB2 Control short to PWR....4149
Fault Overview....4149
Lamp Reaction....4149
Associated Faults....4149
Fault Facts....4149
Drive Cycle to Determine Fault Status....4149
Possible Causes....4149
Pin-Point Test SPN 1073 FMI 3....4151
Tools Required....4151
SPN 1073 FMI 4 - ECB2 Control short to GND....4153
Fault Overview....4153
Lamp Reaction....4153
Associated Faults....4153
Fault Facts....4153
Drive Cycle to Determine Fault Status....4153
Possible Causes....4153
Pin-Point Test SPN 1073 FMI 4....4155
Tools Required....4155
SPN 1073 FMI 5 - ECB2 Control open load/circuit....4157
Fault Overview....4157
Lamp Reaction....4157
Associated Faults....4157
Fault Facts....4157
Drive Cycle to Determine Fault Status....4157
Possible Causes....4157
Pin-Point Test SPN 1073 FMI 5....4160
Tools Required....4160
ECL (Engine Coolant Level) Switch Sensor....4162
Overview of ECL Switch Sensor ....4162
Overview....4162
SPN 111 FMI 1 - ECL below Warning/Critical Level....4163
Fault Overview....4163
Lamp Reaction....4163
Associated Faults....4163
Fault Facts....4163
Drive Cycle to Determine Fault Status....4163
Possible Causes....4163
ECM Power (Engine Control Module)....4166
Overview of ECM Power Sensor ....4166
Overview....4166
SPN 158 FMI 15 - ECM Switched voltage too HIGH....4168
Fault Overview....4168
Lamp Reaction....4168
Associated Faults....4168
Fault Facts....4168
Drive Cycle to Determine Fault Status....4168
Possible Causes....4168
SPN 158 FMI 17 - ECM Switched voltage too LOW....4170
Fault Overview....4170
Lamp Reaction....4170
Associated Faults....4170
Fault Facts....4170
Drive Cycle to Determine Fault Status....4170
Possible Causes....4170
Pin-Point Test SPN 158 FMI 17....4174
Tools Required....4174
SPN 628 FMI 12 - ECM Memory Error....4182
Fault Overview....4182
Lamp Reaction....4182
Associated Faults....4182
Fault Facts....4182
Drive Cycle to Determine Fault Status....4182
Possible Causes....4182
SPN 629 FMI 2 - ECM Error - Level 2 monitoring....4184
Fault Overview....4184
Lamp Reaction....4184
Associated Faults....4184
Fault Facts....4184
Drive Cycle to Determine Fault Status....4184
Possible Causes....4184
SPN 629 FMI 8 - ECM Error - Engine Off Timer Fault....4186
Fault Overview....4186
Lamp Reaction....4186
Associated Faults....4186
Fault Facts....4186
Drive Cycle to Determine Fault Status....4186
Possible Causes....4186
SPN 629 FMI 12 - ECM Internal chip Error....4188
Fault Overview....4188
Lamp Reaction....4188
Associated Faults....4188
Fault Facts....4188
Drive Cycle to Determine Fault Status....4188
Possible Causes....4188
SPN 629 FMI 14 - ECM Internal component overtemperature....4190
Fault Overview....4190
Lamp Reaction....4190
Associated Faults....4190
Fault Facts....4190
Drive Cycle to Determine Fault Status....4190
Possible Causes....4190
SPN 629 FMI 31 - Accelerator Pedal fault causing ECM Internal chip Error....4192
Fault Overview....4192
Lamp Reaction....4192
Associated Faults....4192
Fault Facts....4192
Drive Cycle to Determine Fault Status....4192
Possible Causes....4192
SPN 1110 FMI 31 - ECM Detect Fueling Without Driver Demand....4194
Fault Overview....4194
Lamp Reaction....4194
Associated Faults....4194
Fault Facts....4194
Drive Cycle to Determine Fault Status....4194
Possible Causes....4194
SPN 3597 FMI 4 - ECM Power Output 1 below normal....4196
Fault Overview....4196
Lamp Reaction....4196
Associated Faults....4196
Fault Facts....4196
Drive Cycle to Determine Fault Status....4196
Possible Causes....4196
Pin-Point Test SPN 3597 FMI 4....4199
Tools Required....4199
SPN 3598 FMI 4 - ECM Power Output 2 below normal....4200
Fault Overview....4200
Lamp Reaction....4200
Associated Faults....4200
Fault Facts....4200
Drive Cycle to Determine Fault Status....4200
Possible Causes....4200
Pin-Point Test SPN 3598 FMI 4....4203
Tools Required....4203
SPN 3599 FMI 4 - ECM Power Output 3 below normal....4205
Fault Overview....4205
Lamp Reaction....4205
Associated Faults....4205
Fault Facts....4205
Drive Cycle to Determine Fault Status....4205
Possible Causes....4205
Pin-Point Test SPN 3599 FMI 4See latest version of Navistar? MaxxForce? 11 and 13 Engine and Aftertreatment Wiring Schematic F....4208
ECT1 (Engine Coolant Temperature 1) Sensor ....4210
Overview of ECT1 Sensor Group....4210
Overview....4210
SPN 110 FMI 3 - ECT1 signal Out of Range HIGH....4211
Fault Overview....4211
Lamp Reaction....4211
Associated Faults....4211
Fault Facts....4211
Drive Cycle to Determine Fault Status....4211
Possible Causes....4211
Pin-Point Tests (SPN 110 FMI 3)....4214
Tools Required....4214
SPN 110 FMI 4 - ECT1 signal Out of Range LOW....4216
Fault Overview....4216
Lamp Reaction....4216
Associated Faults....4216
Fault Facts....4216
Drive Cycle to Determine Fault Status....4216
Possible Causes....4216
SPN 1659 FMI 20 - ECT1 below expected: Check Thermostat....4218
Fault Overview....4218
Lamp Reaction....4218
Associated Faults....4218
Fault Facts....4218
Drive Cycle to Determine Fault Status....4218
Possible Causes....4218
ECT2 Sensor (Engine Coolant Temperature 2)....4220
Overview of ECT2 Sensor Group....4220
Overview....4220
SPN 4076 FMI 2 - ECT2 signal erratic, intermittent, or incorrect....4221
Fault Overview....4221
Lamp Reaction....4221
Associated Faults....4221
Fault Facts....4221
Drive Cycle to Determine Fault Status....4221
Possible Causes....4221
Pin-Point Test SPN 4076 FMI 2....4224
Tools Required....4224
SPN 4076 FMI 3 - ECT2 signal Out of Range HIGH....4225
Fault Overview....4225
Lamp Reaction....4225
Associated Faults....4225
Fault Facts....4225
Drive Cycle to Determine Fault Status....4225
Possible Causes....4225
Pin-Point Tests (SPN 4076 FMI 3)....4228
Tools Required....4228
SPN 4076 FMI 4 - ECT2 signal Out of Range LOW....4230
Fault Overview....4230
Lamp Reaction....4230
Associated Faults....4230
Fault Facts....4230
Drive Cycle to Determine Fault Status....4230
Possible Causes....4230
SPN 4076 FMI 17 - ECT2 signal stuck low, not warming up....4232
Fault Overview....4232
Lamp Reaction....4232
Associated Faults....4232
Fault Facts....4232
Drive Cycle to Determine Fault Status....4232
Possible Causes....4232
EFC (Engine Fan Control) ? Two Speed and Variable....4234
Overview of EFC Sensor Group....4234
Overview....4234
SPN 647 FMI 3 - EFC short to PWR....4235
Fault Overview....4235
Lamp Reaction....4235
Associated Faults....4235
Fault Facts....4235
Drive Cycle to Determine Fault Status....4235
Possible Causes....4235
Pin-Point Test SPN 647 FMI 3....4238
Tools Required....4238
SPN 647 FMI 4 - EFC short to GND....4240
Fault Overview....4240
Lamp Reaction....4240
Associated Faults....4240
Fault Facts....4240
Drive Cycle to Determine Fault Status....4240
Possible Causes....4240
Pin-Point Test SPN 647 FMI 4....4243
Tools Required....4243
SPN 647 FMI 5 - EFC open load/circuit....4245
Fault Overview....4245
Lamp Reaction....4245
Associated Faults....4245
Fault Facts....4245
Drive Cycle to Determine Fault Status....4245
Possible Causes....4245
Pin-Point Test SPN 647 FMI 5....4248
Tools Required....4248
EGR (Exhaust Gas Recirculation) Valve Sensor....4250
Overview of EGR Valve Sensor Group....4250
Overview....4250
SPN 27 FMI 0 - EGRP fault: over temperature....4254
Fault Overview....4254
Lamp Reaction....4254
Associated Faults....4254
Drive Cycle to Determine Fault Status....4254
SPN 27 FMI 3 - EGRP signal Out of Range HIGH....4256
Pinpoint Diagnostics With ServiceMaxx? Software....4256
SPN 27 FMI 4 - EGRP signal Out of Range LOW....4258
Fault Overview....4258
Lamp Reaction....4258
Associated Faults....4258
Drive Cycle to Determine Fault Status....4258
SPN 27 FMI 7 - EGRP does not agree with commanded position....4260
Fault Overview....4260
Lamp Reaction....4260
Associated Faults....4260
Fault Facts....4260
Drive Cycle to Determine Fault Status....4260
Possible Causes....4260
SPN 2791 FMI 3 - EGRC short to PWR....4263
Pinpoint Diagnostics With ServiceMaxx? Software....4263
SPN 2791 FMI 5 - EGRC open load/circuit....4265
Fault Overview....4265
Lamp Reaction....4265
Associated Faults....4265
Fault Facts....4265
Drive Cycle to Determine Fault Status....4265
Possible Causes....4265
SPN 2791 FMI 8 - EGR valve not receiving ECM PWM signal....4267
Pinpoint Diagnostics With ServiceMaxx? Software....4267
SPN 3058 FMI 10 - Engine did not go into close loop EGR control when expected....4269
Fault Overview....4269
Lamp Reaction....4269
Associated Faults....4269
Fault Facts....4269
Drive Cycle to Determine Fault Status....4269
Possible Causes....4269
SPN 4752 FMI 4 - EGR Cooler Efficiency: EGR Outlet Temperature above expected....4272
Fault Overview....4272
Lamp Reaction....4272
Associated Faults....4272
Fault Facts....4272
Drive Cycle to Determine Fault Status....4272
Possible Causes....4272
EGRGT (Exhaust Gas Recirculation Cooler Gas Temperature) Sensor ....4274
Overview of EGRGT Sensor Group....4274
Overview....4274
SPN 412 FMI 1 - EGRGT signal stuck low, not warming up....4275
Tools Required....4275
Pinpoint Diagnostics With ServiceMaxx? Software....4275
SPN 412 FMI 2 - EGRGT signal erratic, intermittent, or incorrect....4277
Fault Overview....4277
Lamp Reaction....4277
Associated Faults....4277
Fault Facts....4277
Drive Cycle to Determine Fault Status....4277
Possible Causes....4277
Pin-Point Test SPN 412 FMI 2....4280
Tools Required....4280
SPN 412 FMI 3 - EGRGT signal Out of Range HIGH....4282
Tools Required....4282
Pinpoint Diagnostics With ServiceMaxx? Software....4282
SPN 412 FMI 4 - EGRGT signal Out of Range LOW....4284
Tools Required....4284
Pinpoint Diagnostics With ServiceMaxx? Software....4284
Engine Brake....4286
Overview of Engine Brake Sensor Group....4286
Overview....4286
SPN 1810 FMI 0 - Hard Brake monitor, event log, extreme....4287
Fault Overview....4287
Lamp Reaction....4287
Associated Faults....4287
Fault Facts....4287
Drive Cycle to Determine Fault Status....4287
Possible Causes....4287
SPN 1810 FMI 15 - Hard Brake monitor, event log non-extreme....4289
Fault Overview....4289
Lamp Reaction....4289
Associated Faults....4289
Fault Facts....4289
Drive Cycle to Determine Fault Status....4289
Possible Causes....4289
EOL (Engine Oil Level) Sensor ....4291
Overview of EOL Sensor Group....4291
Overview....4291
SPN 98 FMI 3 - EOL signal Out of Range HIGH....4292
Fault Overview....4292
Lamp Reaction....4292
Associated Faults....4292
Fault Facts....4292
Drive Cycle to Determine Fault Status....4292
Possible Causes....4292
Pin-Point Test SPN 98 FMI 3....4294
Tools Required....4294
SPN 98 FMI 4 - EOL signal Out of Range LOW....4296
Fault Overview....4296
Lamp Reaction....4296
Associated Faults....4296
Fault Facts....4296
Drive Cycle to Determine Fault Status....4296
Possible Causes....4296
Pin-Point Test SPN 98 FMI 4....4298
Tools Required....4298
SPN 1135 FMI 3 - EOT2 signal Out of Range HIGH....4299
Fault Overview....4299
Lamp Reaction....4299
Associated Faults....4299
Fault Facts....4299
Drive Cycle to Determine Fault Status....4299
Possible Causes....4299
Pin-Point Test SPN 1135 FMI 3....4301
Tools Required....4301
SPN 1135 FMI 4 - EOT2 signal Out of Range LOW....4303
Fault Overview....4303
Lamp Reaction....4303
Associated Faults....4303
Fault Facts....4303
Drive Cycle to Determine Fault Status....4303
Possible Causes....4303
Pin-Point Test SPN 1135 FMI 4....4305
Tools Required....4305
EOP (Engine Oil Pressure) Sensor ....4306
Overview of EOP Sensor....4306
Overview....4306
SPN 100 FMI 3 - EOP signal Out of Range HIGH....4307
Fault Overview....4307
Lamp Reaction....4307
Associated Faults....4307
Fault Facts....4307
Drive Cycle to Determine Fault Status....4307
Possible Causes....4307
Pin-Point Test SPN 100 FMI 3....4310
Tools Required....4310
SPN 100 FMI 4 - EOP signal Out of Range LOW....4311
Fault Overview....4311
Lamp Reaction....4311
Associated Faults....4311
Fault Facts....4311
Drive Cycle to Determine Fault Status....4311
Possible Causes....4311
Pin-Point Test SPN 100 FMI 4....4314
Tools Required....4314
EOT (Engine Oil Temperature) Sensor ....4315
Overview of EOT Sensor....4315
Overview....4315
SPN 175 FMI 3 - EOT signal Out of Range HIGH....4316
Fault Overview....4316
Lamp Reaction....4316
Drive Cycle to Determine Fault Status....4316
Possible Causes....4316
Pin-Point Test SPN 175 FMI 3....4319
Tools Required....4319
SPN 175 FMI 4 - EOT signal Out of Range LOW....4321
Fault Overview....4321
Lamp Reaction....4321
Drive Cycle to Determine Fault Status....4321
Possible Causes....4321
ETV (Engine Throttle Valve) Sensor ....4323
Overview of ETV Sensor Group....4323
Overview....4323
SPN 51 FMI 0 - ETP fault: over temperature....4325
Fault Overview....4325
Lamp Reaction....4325
Associated Faults....4325
Fault Facts....4325
Drive Cycle to Determine Fault Status....4325
Possible Causes....4325
SPN 51 FMI 3 - ETP signal Out of Range HIGH....4327
Pinpoint Diagnostics With ServiceMaxx? Software....4327
SPN 51 FMI 4 - ETP signal Out of Range LOW....4330
Fault Overview....4330
Lamp Reaction....4330
Associated Faults....4330
Fault Facts....4330
Drive Cycle to Determine Fault Status....4330
Possible Causes....4330
Pin-Point Test SPN 51 FMI 4....4333
Tools Required....4333
SPN 51 FMI 7 - ETP does not agree with commanded position....4335
Fault Overview....4335
Lamp Reaction....4335
Associated Faults....4335
Fault Facts....4335
Drive Cycle to Determine Fault Status....4335
Possible Causes....4335
Pin-Point Test SPN 51 FMI 7....4338
Tools Required....4338
SPN 3464 FMI 3 - ETV short to PWR....4339
Pinpoint Diagnostics With ServiceMaxx? Software....4339
SPN 3464 FMI 5 - ETV open load/circuit....4342
Pinpoint Diagnostics With ServiceMaxx? Software....4342
SPN 3464 FMI 8 - ETC not receiving command from ECM....4345
Pinpoint Diagnostics With ServiceMaxx? Software....4345
EWPS (Engine Warning Protection System) Sensor ....4348
Overview of EWPS Sensor Group....4348
Overview....4349
SPN 84 FMI 2 - Vehicle speed anti-tampering fault....4350
Fault Overview....4350
Lamp Reaction....4350
Associated Faults....4350
Fault Facts....4350
Drive Cycle to Determine Fault Status....4350
Possible Causes....4350
SPN 100 FMI 1 - Engine Oil System below Critical Pressure....4352
Fault Overview....4352
Lamp Reaction....4352
Associated Faults....4352
Fault Facts....4352
Drive Cycle to Determine Fault Status....4352
Possible Causes....4352
SPN 100 FMI 11 - Low oil pressure vehicle event....4354
Fault Overview....4354
Lamp Reaction....4354
Associated Faults....4354
Fault Facts....4354
Drive Cycle to Determine Fault Status....4354
Possible Causes....4354
SPN 100 FMI 17 - Low Engine Oil Pressure, event log....4356
Fault Overview....4356
Lamp Reaction....4356
Associated Faults....4356
Fault Facts....4356
Drive Cycle to Determine Fault Status....4356
Possible Causes....4356
SPN 100 FMI 18 - Engine Oil System below Warning Pressure....4358
Fault Overview....4358
Lamp Reaction....4358
Associated Faults....4358
Fault Facts....4358
Drive Cycle to Determine Fault Status....4358
Possible Causes....4358
SPN 110 FMI 0 - Engine Cooling System above Critical Temperature....4360
Fault Overview....4360
Lamp Reaction....4360
Associated Faults....4360
Fault Facts....4360
Drive Cycle to Determine Fault Status....4360
Possible Causes....4360
SPN 110 FMI 11 - Event logger, coolant temperature hot, extreme....4362
Fault Overview....4362
Lamp Reaction....4362
Associated Faults....4362
Fault Facts....4362
Drive Cycle to Determine Fault Status....4362
Possible Causes....4362
SPN 110 FMI 15 - Engine Cooling System above Warning Temperature....4364
Fault Overview....4364
Lamp Reaction....4364
Associated Faults....4364
Fault Facts....4364
Drive Cycle to Determine Fault Status....4364
Possible Causes....4364
SPN 110 FMI 16 - Engine Cooling System Above OBD Maximum Temperature....4366
Fault Overview....4366
Lamp Reaction....4366
Associated Faults....4366
Fault Facts....4366
Drive Cycle to Determine Fault Status....4366
Possible Causes....4366
SPN 110 FMI 17 - Engine Coolant Temperature stuck in range low....4368
Fault Overview....4368
Lamp Reaction....4368
Associated Faults....4368
Fault Facts....4368
Drive Cycle to Determine Fault Status....4368
Possible Causes....4368
SPN 110 FMI 18 - Engine Cooling System below closed loop minimum Temperature....4370
Fault Overview....4370
Lamp Reaction....4370
Associated Faults....4370
Fault Facts....4370
Drive Cycle to Determine Fault Status....4370
Possible Causes....4370
SPN 175 FMI 0 - Engine Oil System above Critical Temperature....4372
Fault Overview....4372
Lamp Reaction....4372
Associated Faults....4372
Fault Facts....4372
Drive Cycle to Determine Fault Status....4372
Possible Causes....4372
SPN 175 FMI 11 - Oil Temperature Exceeds limit by large amount....4374
Fault Overview....4374
Lamp Reaction....4374
Associated Faults....4374
Fault Facts....4374
Drive Cycle to Determine Fault Status....4374
Possible Causes....4374
SPN 175 FMI 15 - Engine Oil System above Warning Temperature....4376
Fault Overview....4376
Lamp Reaction....4376
Associated Faults....4376
Fault Facts....4376
Drive Cycle to Determine Fault Status....4376
Possible Causes....4376
SPN 188 FMI 0 - Engine unable to achieve desired idle speed (Too High)....4378
Fault Overview....4378
Lamp Reaction....4378
Associated Faults....4378
Fault Facts....4378
Drive Cycle to Determine Fault Status....4378
Possible Cause....4378
SPN 188 FMI 1 - Engine unable to achieve desired idle speed (Too Low)....4381
Fault Overview....4381
Lamp Reaction....4381
Associated Faults....4381
Fault Facts....4381
Drive Cycle to Determine Fault Status....4381
Possible Causes....4381
SPN 188 FMI 16 - Engine Overspeed at idle - engine shut down....4384
Fault Overview....4384
Lamp Reaction....4384
Associated Faults....4384
Fault Facts....4384
Drive Cycle to Determine Fault Status....4384
Possible Causes....4384
SPN 190 FMI 0 - Engine overspeed - Most Severe Level....4386
Fault Overview....4386
Lamp Reaction....4386
Associated Faults....4386
Fault Facts....4386
Drive Cycle to Determine Fault Status....4386
Possible Causes....4386
SPN 190 FMI 11 - Engine Overspeed, event log....4390
Fault Overview....4390
Lamp Reaction....4390
Associated Faults....4390
Fault Facts....4390
Drive Cycle to Determine Fault Status....4390
Possible Causes....4390
SPN 190 FMI 15 - Engine overspeed - Least Severe Level....4392
Fault Overview....4392
Lamp Reaction....4392
Associated Faults....4392
Fault Facts....4392
Drive Cycle to Determine Fault Status....4392
Possible Causes....4392
EWPS Programmable Parameters....4396
SPN 731 FMI 16 - Knock Detected: Cylinder Acceleration Above Normal....4397
Fault Overview....4397
Lamp Reaction....4397
Associated Faults....4397
Fault Facts....4397
Drive Cycle to Determine Fault Status....4397
Possible Causes....4397
SPN 731 FMI 18 - Knock Detected: Unexpected Fueling without Demand....4400
Fault Overview....4400
Lamp Reaction....4400
Associated Faults....4400
Fault Facts....4400
Drive Cycle to Determine Fault Status....4400
Possible Causes....4400
SPN 2588 FMI 0 - Vehicle overspeed 1, event log, extreme....4403
Fault Overview....4403
Lamp Reaction....4403
Associated Faults....4403
Fault Facts....4403
Drive Cycle to Determine Fault Status....4403
Possible Causes....4403
SPN 2588 FMI 15 - Vehicle overspeed 1, event log, non extreme....4405
Fault Overview....4405
Lamp Reaction....4405
Associated Faults....4405
Fault Facts....4405
Drive Cycle to Determine Fault Status....4405
Possible Causes....4405
SPN 2589 FMI 0 - Vehicle overspeed 2, event log, extreme....4407
Fault Overview....4407
Lamp Reaction....4407
Associated Faults....4407
Fault Facts....4407
Drive Cycle to Determine Fault Status....4407
Possible Causes....4407
SPN 2589 FMI 15 - Vehicle overspeed 2, event log, non extreme....4409
Fault Overview....4409
Lamp Reaction....4409
Associated Faults....4409
Fault Facts....4409
Drive Cycle to Determine Fault Status....4409
Possible Causes....4409
SPN 4076 FMI 0 - ECT2 above Critical (EWPS programmable limit)....4411
Fault Overview....4411
Lamp Reaction....4411
Associated Faults....4411
Fault Facts....4411
Drive Cycle to Determine Fault Status....4411
Possible Causes....4411
SPN 4076 FMI 15 - ECT2 above Warning (EWPS programmable limit)....4413
Fault Overview....4413
Lamp Reaction....4413
Associated Faults....4413
Fault Facts....4413
Drive Cycle to Determine Fault Status....4413
Possible Causes....4413
SPN 5395 FMI 0 - Engine unable to achieve desired idle torque (too high)....4415
Fault Overview....4415
Lamp Reaction....4415
Associated Faults....4415
Drive Cycle to Determine Fault Status....4415
Possible Causes....4415
SPN 5395 FMI 1 - Engine unable to achieve desired idle torque (too low)....4417
Fault Overview....4417
Lamp Reaction....4417
Associated Faults....4417
Drive Cycle to Determine Fault Status....4417
FDP (Fuel Delivery Pressure) Sensor ....4420
Overview of FDP Sensor Group....4420
Overview....4420
SPN 94 FMI 0 - Fuel Delivery Pressure above Critical....4421
Fault Overview....4421
Lamp Reaction....4421
Associated Faults....4421
Drive Cycle to Determine Fault Status....4421
Fault Facts....4421
Possible Causes....4421
SPN 94 FMI 3 - FDP signal Out of Range HIGH....4423
Fault Overview....4423
Lamp Reaction....4423
Associated Faults....4423
Fault Facts....4423
Drive Cycle to Determine Fault Status....4423
Possible Causes....4423
Pin-Point Test SPN 94 FMI 3....4426
Tools Required....4426
SPN 94 FMI 4 - FDP signal Out of Range LOW....4427
Fault Overview....4427
Lamp Reaction....4427
Associated Faults....4427
Fault Facts....4427
Drive Cycle to Determine Fault Status....4427
Possible Causes....4427
Pin-Point Test SPN 94 FMI 4....4430
Tools Required....4430
FPCV (Fuel Pressure Control Valve) Sensor....4431
Overview of FPCV Sensor Group....4431
Overview....4431
SPN 633 FMI 3 - FPCV short to PWR....4432
Fault Overview....4432
Lamp Reaction....4432
Associated Faults....4432
Fault Facts....4432
Drive Cycle to Determine Fault Status....4432
Possible Causes....4432
Pin-Point Test SPN 633 FMI 3....4434
Tools Required....4434
SPN 633 FMI 4 - FPCV short to GND....4436
Fault Overview....4436
Lamp Reaction....4436
Associated Faults....4436
Fault Facts....4436
Drive Cycle to Determine Fault Status....4436
Possible Causes....4436
Pin-Point Test SPN 633 FMI 4....4438
Tools Required....4438
SPN 633 FMI 5 - FPCV open load/circuit....4440
Fault Overview....4440
Lamp Reaction....4440
Associated Faults....4440
Fault Facts....4440
Drive Cycle to Determine Fault Status....4440
Possible Causes....4440
Pin-Point Test SPN 633 FMI 5....4442
Tools Required....4442
FRP (Fuel Rail Pressure) Sensor ....4444
Overview of FRP Sensor Group....4444
Overview....4444
SPN 157 FMI 3 - FRP signal Out of Range HIGH....4446
Fault Overview....4446
Lamp Reaction....4446
Associated Faults....4446
Fault Facts....4446
Drive Cycle to Determine Fault Status....4446
Possible Causes....4446
Pin-Point Test SPN 157 FMI 3....4449
Tools Required....4449
SPN 157 FMI 4 - FRP signal Out of Range LOW....4453
Fault Overview....4453
Lamp Reaction....4453
Associated Faults....4453
Fault Facts....4453
Drive Cycle to Determine Fault Status....4453
Possible Causes....4453
Pin-Point Test SPN 157 FMI 4....4455
Tools Required....4455
SPN 157 FMI 20 - FRP Rationality Offset High....4456
Fault Overview....4456
Lamp Reaction....4456
Associated Faults....4456
Fault Facts....4456
Drive Cycle to Determine Fault Status....4456
Possible Causes....4456
Pin-Point Test SPN 157 FMI 20....4459
Tools Required....4459
SPN 157 FMI 21 - FRP Rationality Offset Low....4460
Fault Overview....4460
Lamp Reaction....4460
Associated Faults....4460
Fault Facts....4460
Drive Cycle to Determine Fault Status....4460
Possible Causes....4460
Pin-Point Test SPN 157 FMI 21....4463
Tools Required....4463
FRP (Fuel Rail Pressure) System....4466
Overview of FRP Group....4466
Overview....4466
SPN 3055 FMI 0 - FRP exceeded maximum....4468
Fault Overview....4468
Lamp Reaction....4468
Associated Faults....4468
Fault Facts....4468
Drive Cycle to Determine Fault Status....4468
Possible Causes....4468
SPN 3055 FMI 1 - Low Fuel Pressure at start....4470
Fault Overview....4470
Lamp Reaction....4470
Associated Faults....4470
Fault Facts....4470
Drive Cycle to Determine Fault Status....4470
Possible Causes....4470
SPN 3055 FMI 15 - FRP below minimum with maximum command....4474
Fault Overview....4474
Lamp Reaction....4474
Associated Faults....4474
Fault Facts....4474
Drive Cycle to Determine Fault Status....4474
Possible Causes....4474
SPN 3055 FMI 17 - FRP above maximum with minimum command....4478
Fault Overview....4478
Lamp Reaction....4478
Associated Faults....4478
Fault Facts....4478
Drive Cycle to Determine Fault Status....4478
Possible Causes....4478
IAH (Intake Air Heater Control) Sensor....4481
Overview of IAH Sensor....4481
Overview....4481
SPN 626 FMI 18 - IAH fault: Lack of heat in the Intake Manifold....4482
Fault Overview....4482
Lamp Reaction....4482
Associated Faults....4482
Fault Facts....4482
Drive Cycle to Determine Fault Status....4482
Possible Causes....4482
SPN 5548 FMI 3 - IAHFI short to PWR....4485
Fault Overview....4485
Lamp Reaction....4485
Associated Faults....4485
Fault Facts....4485
Drive Cycle to Determine Fault Status....4485
Possible Causes....4485
Pin-Point Test SPN 5548 FMI 3....4489
Tools Required....4489
SPN 5548 FMI 4 - IAHFI short to GND....4494
Fault Overview....4494
Lamp Reaction....4494
Associated Faults....4494
Fault Facts....4494
Drive Cycle to Determine Fault Status....4494
Possible Causes....4494
Pin-Point Test SPN 5548 FMI 4....4498
Tools Required....4498
SPN 5548 FMI 5 - IAHFI open/load circuit....4502
Fault Overview....4502
Lamp Reaction....4502
Associated Faults....4502
Fault Facts....4502
Drive Cycle to Determine Fault Status....4502
Possible Causes....4502
Pin-Point Test SPN 5548 FMI 5....4506
Tools Required....4506
SPN 5548 FMI 7 - IAH Relay return (Relay, or igniter, or circuit failure)....4511
Fault Overview....4511
Lamp Reaction....4511
Associated Faults....4511
Fault Facts....4511
Drive Cycle to Determine Fault Status....4511
Possible Causes....4511
Pin-Point Test SPN 5548 FMI 7....4514
Tools Required....4514
IAHFS Sensor....4518
Overview of IAHFS Sensor....4518
Fault Overview....4518
SPN 626 FMI 3 - IAHFS short to PWR....4519
Fault Overview....4519
Lamp Reaction....4519
Associated Faults....4519
Fault Facts....4519
Drive Cycle to Determine Fault Status....4519
Possible Causes....4519
Pin-Point Test SPN 626 FMI 3....4522
Tools Required....4522
SPN 626 FMI 4 - IAHFS short to GND....4524
Fault Overview....4524
Lamp Reaction....4524
Associated Faults....4524
Fault Facts....4524
Drive Cycle to Determine Fault Status....4524
Possible Causes....4524
Pin-Point Test SPN 626 FMI 4....4527
Tools Required....4527
SPN 626 FMI 5 - IAHFS open load/circuit....4529
Fault Overview....4529
Lamp Reaction....4529
Associated Faults....4529
Fault Facts....4529
Drive Cycle to Determine Fault Status....4529
Possible Causes....4529
Pin-Point Test SPN 626 FMI 5....4532
Tools Required....4532
IMP (Intake Manifold Pressure) Sensor....4534
Overview of IMP Sensor Group....4534
Overview....4534
SPN 102 FMI 2 - IMP signal erratic, intermittent, or incorrect....4536
Fault Overview....4536
Lamp Reaction....4536
Associated Faults....4536
Fault Facts....4536
Drive Cycle to Determine Fault Status....4536
Possible Causes....4536
Pin-Point Test SPN 102 FMI 2....4539
Tools Required....4539
SPN 102 FMI 3 - IMP signal Out of Range HIGH....4542
Fault Overview....4542
Lamp Reaction....4542
Associated Faults....4542
Fault Facts....4542
Drive Cycle to Determine Fault Status....4542
Possible Causes....4542
Pin-Point Test SPN 102 FMI 3....4544
Tools Required....4544
SPN 102 FMI 4 - IMP signal Out of Range LOW....4546
Fault Overview....4546
Lamp Reaction....4546
Associated Faults....4546
Fault Facts....4546
Drive Cycle to Determine Fault Status....4546
Possible Causes....4546
Pin-Point Test SPN 102 FMI 4....4548
Tools Required....4548
IMT (Intake Manifold Temperature) Sensor ....4550
Overview of IMT Sensor Group....4550
Overview....4550
SPN 105 FMI 2 - IMT Signal Erratic, Intermittent, or Incorrect....4551
Fault Overview....4551
Lamp Reaction....4551
Associated Faults....4551
Fault Facts....4551
Drive Cycle to Determine Fault Status....4551
Possible Causes....4551
Pin-Point Test SPN 105 FMI 2....4554
Tools Required....4554
SPN 105 FMI 3 - IMT Signal Out of Range HIGH....4557
Fault Overview....4557
Lamp Reaction....4557
Associated Faults....4557
Fault Facts....4557
Drive Cycle to Determine Fault Status....4557
Possible Causes....4557
Pin-Point Test SPN 105 FMI 3....4560
Tools Required....4560
SPN 105 FMI 4 - IMT Signal Out of Range LOW....4561
Fault Overview....4561
Lamp Reaction....4561
Associated Faults....4561
Fault Facts....4561
Drive Cycle to Determine Fault Status....4561
Possible Causes....4561
INJ (Injector) Circuits....4563
Overview of INJ Circuit Group....4563
Overview....4563
SPN 651 FMI 4 - Injector 1 Short Circuit....4566
Fault Overview....4566
Lamp Reaction....4566
Associated Faults....4566
Fault Facts....4566
Drive Cycle to Determine Fault Status....4566
Possible Causes....4566
Pin-Point Test SPN 651 FMI 4....4571
Tools Required....4571
SPN 651 FMI 5 - Injector 1 Open Load / Circuit....4577
Fault Overview....4577
Lamp Reaction....4577
Associated Faults....4577
Fault Facts....4577
Drive Cycle to Determine Fault Status....4577
Possible Causes....4577
Pin-Point Test SPN 651 FMI 5....4580
Tools Required....4580
SPN 652 FMI 4 - Injector 2 Short Circuit....4584
Fault Overview....4584
Lamp Reaction....4584
Associated Faults....4584
Fault Facts....4584
Drive Cycle to Determine Fault Status....4584
Possible Causes....4584
Pin-Point Test SPN 652 FMI 4....4589
Tools Required....4589
SPN 652 FMI 5 - Injector 2 Open Load / Circuit....4595
Fault Overview....4595
Lamp Reaction....4595
Associated Faults....4595
Fault Facts....4595
Drive Cycle to Determine Fault Status....4595
Possible Causes....4595
Pin-Point Test SPN 652 FMI 5....4598
Tools Required....4598
SPN 653 FMI 4 - Injector 3 Short Circuit....4602
Fault Overview....4602
Lamp Reaction....4602
Associated Faults....4602
Fault Facts....4602
Drive Cycle to Determine Fault Status....4602
Possible Causes....4602
Pin-Point Test SPN 653 FMI 4....4607
Tools Required....4607
SPN 653 FMI 5 - Injector 3 Open Load / Circuit....4613
Fault Overview....4613
Lamp Reaction....4613
Associated Faults....4613
Fault Facts....4613
Drive Cycle to Determine Fault Status....4613
Possible Causes....4613
Pin-Point Test SPN 653 FMI 5....4616
Tools Required....4616
SPN 654 FMI 4 - Injector 4 Short Circuit....4620
Fault Overview....4620
Lamp Reaction....4620
Associated Faults....4620
Fault Facts....4620
Drive Cycle to Determine Fault Status....4620
Possible Causes....4620
Pin-Point Test SPN 654 FMI 4....4625
Tools Required....4625
SPN 654 FMI 5 - Injector 4 Open Load / Circuit....4631
Fault Overview....4631
Lamp Reaction....4631
Associated Faults....4631
Fault Facts....4631
Drive Cycle to Determine Fault Status....4631
Possible Causes....4631
Pin-Point Test SPN 654 FMI 5....4634
Tools Required....4634
SPN 655 FMI 4 - Injector 5 Short Circuit....4638
Fault Overview....4638
Lamp Reaction....4638
Associated Faults....4638
Fault Facts....4638
Drive Cycle to Determine Fault Status....4638
Possible Causes....4638
Pin-Point Test SPN 655 FMI 4....4643
Tools Required....4643
SPN 655 FMI 5 - Injector 5 Open Load / Circuit....4649
Fault Overview....4649
Lamp Reaction....4649
Associated Faults....4649
Fault Facts....4649
Drive Cycle to Determine Fault Status....4649
Possible Causes....4649
Pin-Point Test SPN 655 FMI 5....4652
Tools Required....4652
SPN 656 FMI 4 - Injector 6 Short Circuit....4656
Fault Overview....4656
Lamp Reaction....4656
Associated Faults....4656
Fault Facts....4656
Drive Cycle to Determine Fault Status....4656
Possible Causes....4656
Pin-Point Test SPN 656 FMI 4....4661
Tools Required....4661
SPN 656 FMI 5 - Injector 6 Open Load / Circuit....4667
Fault Overview....4667
Lamp Reaction....4667
Associated Faults....4667
Fault Facts....4667
Drive Cycle to Determine Fault Status....4667
Possible Causes....4667
Pin-Point Test SPN 656 FMI 5....4670
Tools Required....4670
SPN 2797 FMI 11 - Injector Control Group 1 Short Circuit (INJ 1, 2, 3)....4674
Fault Overview....4674
Lamp Reaction....4674
Associated Faults....4674
Drive Cycle to Determine Fault Status....4674
Fault Facts....4674
Possible Causes....4674
Pin-Point Test....4683
Tools Required....4683
SPN 2798 FMI 11 - Injector Control Group 2 Short Circuit (INJ 4, 5, 6)....4698
Fault Overview....4698
Lamp Reaction....4698
Associated Faults....4698
Fault Facts....4698
Drive Cycle to Determine Fault Status....4698
Possible Causes....4698
Pin-Point Test SPN 2798 FMI 11....4707
Tools Required....4707
J1939 Data Link Communications....4722
Overview of J1939 Sensor Group....4722
Overview....4722
SPN 560 FMI 19 - Transmission Driveline Engaged Not Detected on J1939....4723
Fault Overview....4723
Lamp Reaction....4723
Associated Faults....4723
Fault Facts....4723
Drive Cycle to Determine Fault Status....4723
Possible Causes....4723
SPN 639 FMI 14 - J1939 Data Link Error (ECM Unable to Transmit)....4726
Fault Overview....4726
Lamp Reaction....4726
Associated Faults....4726
Fault Facts....4726
Drive Cycle to Determine Fault Status....4726
Possible Causes....4726
Pin-Point Test SPN 639 FMI 14....4729
Tools Required....4729
SPN 639 FMI 19 - J1939 Data Link Error (ECM unable to transmit or receive)....4731
Fault Overview....4731
Lamp Reaction....4731
Associated Faults....4731
Fault Facts....4731
Drive Cycle to Determine Fault Status....4731
Possible Causes....4731
Pin-Point Test SPN 639 FMI 19....4734
Tools Required....4734
MIL (Malfunction Indicator Lamp) Sensor....4736
Overview of MIL Sensor....4736
Overview....4736
Tools Required....4736
SPN 1213 FMI 3 - MIL Circuit Short to PWR....4737
Fault Overview....4737
Lamp Reaction....4737
Associated Faults....4737
Fault Facts....4737
Drive Cycle to Determine Fault Status....4737
Possible Causes....4737
Pin-Point Test SPN 1213 FMI 3....4739
Tools Required....4739
SPN 1213 FMI 4 - MIL Circuit Short to GND....4740
Fault Overview....4740
Lamp Reaction....4740
Associated Faults....4740
Fault Facts....4740
Drive Cycle to Determine Fault Status....4740
Possible Causes....4740
Pin-Point Test SPN 1213 FMI 4....4742
Tools Required....4742
SPN 1213 FMI 5 - MIL Open Load / Circuit....4743
Fault Overview....4743
Lamp Reaction....4743
Associated Faults....4743
Fault Facts....4743
Drive Cycle to Determine Fault Status....4743
Possible Causes....4743
Pin-Point Test SPN 1213 FMI 5....4745
Tools Required....4745
O2S (Oxygen Sensor)....4746
Overview of O2S Sensor Group....4746
Overview....4746
SPN 724 FMI 2 - O2S Slow response detected fueling to non-fueling....4748
Fault Overview....4748
Lamp Reaction....4748
Associated Faults....4748
Fault Facts....4748
Drive Cycle to Determine Fault Status....4748
Possible Causes....4748
SPN 724 FMI 3 - O2S Circuit Fault: Open or short to PWR....4750
Fault Overview....4750
Lamp Reaction....4750
Associated Faults....4750
Fault Facts....4750
Drive Cycle to Determine Fault Status....4750
Possible Causes....4750
Pin-Point Test SPN 724 FMI 3....4753
Tools Required....4753
SPN 724 FMI 4 - O2S Circuit Fault: Short to GND....4756
Fault Overview....4756
Lamp Reaction....4756
Associated Faults....4756
Fault Facts....4756
Drive Cycle to Determine Fault Status....4756
Possible Causes....4756
Pin-Point Test SPN 724 FMI 4....4759
Tools Required....4759
SPN 724 FMI 5 - O2S Circuit Fault: Open circuit....4764
Fault Overview....4764
Lamp Reaction....4764
Associated Faults....4764
Fault Facts....4764
Drive Cycle to Determine Fault Status....4765
Possible Causes....4765
Pin-Point Test SPN 724 FMI 5....4768
Tools Required....4768
SPN 724 FMI 20 - O2S adaptation above maximum limit....4771
Fault Overview....4771
Lamp Reaction....4771
Associated Faults....4771
Fault Facts....4771
Drive Cycle to Determine Fault Status....4771
Possible Causes....4771
SPN 724 FMI 21 - O2S adaptation below minimum limit....4774
Fault Overview....4774
Lamp Reaction....4774
Associated Faults....4774
Fault Facts....4774
Drive Cycle to Determine Fault Status....4774
Possible Causes....4774
SPN 3223 FMI 0 - O2S Heater Temperature Above Maximum....4777
Fault Overview....4777
Lamp Reaction....4777
Associated Faults....4777
Fault Facts....4777
Drive Cycle to Determine Fault Status....4777
Possible Causes....4777
Pin-Point Test SPN 3223 FMI 0....4779
Tools Required....4779
SPN 3223 FMI 1 - O2S Heater Temperature Below Minimum....4781
Fault Overview....4781
Lamp Reaction....4781
Associated Faults....4781
Fault Facts....4781
Drive Cycle to Determine Fault Status....4782
Possible Causes....4782
Pin-Point Test SPN 3223 FMI 1....4785
Tools Required....4785
SPN 3223 FMI 3 - O2S Heater Short to PWR....4788
Fault Overview....4788
Lamp Reaction....4788
Associated Faults....4788
Fault Facts....4788
Drive Cycle to Determine Fault Status....4788
Possible Causes....4788
Pin-Point Test SPN 3223 FMI 3....4791
Tools Required....4791
SPN 3223 FMI 4 - O2S Heater Short to GND....4794
Fault Overview....4794
Lamp Reaction....4794
Associated Faults....4794
Fault Facts....4794
Drive Cycle to Determine Fault Status....4794
Possible Causes....4794
Pin-Point Test SPN 3223 FMI 4....4797
Tools Required....4797
SPN 3223 FMI 5 - O2S Heater Open Load / Circuit....4800
Fault Overview....4800
Lamp Reaction....4800
Associated Faults....4800
Fault Facts....4800
Drive Cycle to Determine Fault Status....4800
Possible Causes....4800
Pin-Point Test SPN 3223 FMI 5....4803
Tools Required....4803
SPN 3223 FMI 17 - O2S heater temperature below minimum at low battery PWR....4807
Fault Overview....4807
Lamp Reaction....4807
Associated Faults....4807
Fault Facts....4807
Drive Cycle to Determine Fault Status....4807
Possible Causes....4807
Pin-Point Test SPN 3223 FMI 17....4810
Tools Required....4810
RAPP (Remote Accelerator Pedal Position) Sensor....4811
Overview of RAPP Sensor Group....4811
Overview....4811
SPN 974 FMI 3 - Remote APP Signal Out of Range HIGH....4812
Fault Overview....4812
Lamp Reaction....4812
Associated Faults....4812
Fault Facts....4812
Drive Cycle to Determine Fault Status....4812
Possible Causes....4812
Pin-Point Test SPN 974 FMI 3....4815
Tools Required....4815
SPN 974 FMI 4 - Remote APP Signal Out of Range LOW....4818
Fault Overview....4818
Lamp Reaction....4818
Associated Faults....4818
Fault Facts....4818
Drive Cycle to Determine Fault Status....4818
Possible Causes....4818
Pin-Point Test SPN 974 FMI 4....4821
Tools Required....4821
Service....4825
Overview of Service Group....4825
SPN 1378 FMI 31 - Change Engine Oil Service Interval....4826
Service Interval Messages Operation....4826
Lamp Reaction....4826
Possible Causes....4826
TC1TOP (Turbocharger 1 Turbine Outlet Pressure) Sensor ....4827
Overview of TC1TOP Sensor....4827
Overview....4827
SPN 5541 FMI 2 - TC1TOP signal erratic, intermittent, or incorrect....4828
Fault Overview....4828
Lamp Reaction....4828
Associated Faults....4828
Fault Facts....4828
Drive Cycle to Determine Fault Status....4828
Possible Causes....4828
Pin-Point Test SPN 5541 FMI 2....4831
Tools Required....4831
SPN 5541 FMI 3 - TC1TOP signal Out of Range HIGH....4834
Fault Overview....4834
Lamp Reaction....4834
Associated Faults....4834
Fault Facts....4834
Drive Cycle to Determine Fault Status....4834
Possible Causes....4834
Pin-Point Test SPN 5541 FMI 3....4837
Tools Required....4837
SPN 5541 FMI 4 - TC1TOP signal Out of Range LOW....4838
Fault Overview....4838
Lamp Reaction....4838
Associated Faults....4838
Possible Causes....4838
Pin-Point Test SPN 5541 FMI 4....4841
Tools Required....4841
SPN 5542 FMI 15 - TC1TOP Above Desired....4842
Fault Overview....4842
Lamp Reaction....4842
Associated Faults....4842
Fault Facts....4842
Drive Cycle to Determine Fault Status....4842
Possible Causes....4842
SPN 5542 FMI 17 - TC1TOP below desired....4844
Fault Overview....4844
Lamp Reaction....4844
Associated Faults....4844
Fault Facts....4844
Drive Cycle to Determine Fault Status....4844
Possible Causes....4844
TC2CIS (Turbocharger 2 Compressor Inlet) Sensor....4846
Overview of TC2CIS Sensor....4846
Overview....4846
SPN 1173 FMI 2 - TC2CIT signal erratic, intermittent, or incorrect....4847
Fault Overview....4847
Lamp Reaction....4847
Associated Faults....4847
Fault Facts....4847
Drive Cycle to Determine Fault Status....4847
Possible Causes....4847
Pin-Point Test SPN 1173 FMI 2....4850
Tools Required....4850
SPN 1173 FMI 3 - TC2CIT signal Out of Range HIGH....4853
Fault Overview....4853
Lamp Reaction....4853
Associated Faults....4853
Fault Facts....4853
Drive Cycle to Determine Fault Status....4853
Possible Causes....4853
Pin-Point Test SPN 1173 FMI 3....4856
Tools Required....4856
SPN 1173 FMI 4 - TC2CIT signal Out of Range LOW....4858
Fault Overview....4858
Lamp Reaction....4858
Associated Faults....4858
Fault Facts....4858
Drive Cycle to Determine Fault Status....4858
Possible Causes....4858
SPN 1173 FMI 16 - TC2CIT signal above desired (Interstage CAC under cooling)....4860
Fault Overview....4860
Lamp Reaction....4860
Associated Faults....4860
Fault Facts....4860
Drive Cycle to Determine Fault Status....4860
Possible Causes....4860
SPN 1177 FMI 2 - TC2CIP signal erratic, intermittent, or incorrect....4863
Fault Overview....4863
Lamp Reaction....4863
Associated Faults....4863
Fault Facts....4863
Drive Cycle to Determine Fault Status....4863
Possible Causes....4863
Pin-Point Test SPN 1177 FMI 2....4866
Tools Required....4866
SPN 1177 FMI 3 - TC2CIP signal Out of Range HIGH....4869
Fault Overview....4869
Lamp Reaction....4869
Associated Faults....4869
Fault Facts....4869
Drive Cycle to Determine Fault Status....4869
Possible Causes....4869
Pin-Point Test SPN 1177 FMI 3....4872
Tools Required....4872
SPN 1177 FMI 4 - TC2CIP Signal Out of Range LOW....4875
Fault Overview....4875
Lamp Reaction....4875
Associated Faults....4875
Fault Facts....4875
Drive Cycle to Determine Fault Status....4875
Possible Causes....4875
Pin-Point Test SPN 1177 FMI 4....4878
Tools Required....4878
TC1WC (Turbocharger 1 Wastegate Control)....4880
Tools Required....4881
Tools Required....4883
TC2WC (Turbocharger 2 Wastegate Control) Sensor....4885
Overview of TC2WC Sensor....4885
Overview....4885
SPN 1189 FMI 3 - TC2WC short to PWR....4886
Fault Overview....4886
Lamp Reaction....4886
Associated Faults....4886
Fault Facts....4886
Drive Cycle to Determine Fault Status....4886
Possible Causes....4886
Pin-Point Test SPN 1189 FMI 3....4889
Tools Required....4889
SPN 1189 FMI 4 - TC2WC Open or short to GND....4890
Fault Overview....4890
Lamp Reaction....4890
Associated Faults....4890
Fault Facts....4890
Drive Cycle to Determine Fault Status....4890
Possible Causes....4890
Pin-Point Test SPN 1189 FMI 4....4893
Tools Required....4893
SPN 1189 FMI 5 - TC2WC open load/circuit....4894
Fault Overview....4894
Lamp Reaction....4894
Associated Faults....4894
Fault Facts....4894
Drive Cycle to Determine Fault Status....4894
Possible Causes....4894
Pin-Point SPN 1189 FMI 5....4897
Tools Required....4897
TOSS (Transmission Output Shaft Speed) / VSS (Vehicle Speed) Sensor....4898
Overview of TOSS Sensor Group....4898
Overview....4898
SPN 191 FMI 1 - TOSS/VSS not detected with vehicle moving....4900
Fault Overview....4900
Lamp Reaction....4900
Associated Faults....4900
Fault Facts....4900
Drive Cycle to Determine Fault Status....4900
Possible Causes....4900
Pin-Point Test SPN 191 FMI 1....4904
Tools Required....4904
SPN 191 FMI 2 - TOSS/VSS signal erratic, intermittent, or incorrect....4910
Fault Overview....4910
Lamp Reaction....4910
Associated Faults....4910
Fault Facts....4910
Drive Cycle to Determine Fault Status....4910
Possible Causes....4910
Pin-Point Test SPN 191 FMI 2....4914
Tools Required....4914
SPN 191 FMI 3 - TOSS/VSS signal out of range HIGH....4920
Fault Overview....4920
Lamp Reaction....4920
Associated Faults....4920
Fault Facts....4920
Drive Cycle to Determine Fault Status....4920
Possible Causes....4920
Pin-Point Test SPN 191 FMI 3....4923
Tools Required....4923
SPN 191 FMI 4 - TOSS/VSS signal out of range LOW....4927
Fault Overview....4927
Lamp Reaction....4927
Associated Faults....4927
Fault Facts....4927
Drive Cycle to Determine Fault Status....4927
Possible Causes....4927
Pin-Point Test SPN 191 FMI 4....4930
Tools Required....4930
SPN 191 FMI 16 - TOSS/VSS reading higher than limit (Hardwired)....4936
Overview....4936
Lamp Reaction....4936
Associated Faults....4936
Fault Facts....4936
Drive Cycle to Determine Fault Status....4936
VREF (Voltage Reference) Sensor....4937
Overview of VREF Sensor Group....4937
Overview....4937
SPN 3509 FMI 14 - VREF 1 voltage above or below normal....4938
Fault Overview....4938
Lamp Reaction....4938
Associated Faults....4938
Fault Facts....4938
Drive Cycle to Determine Fault Status....4938
Possible Causes....4938
Pin-Point Test SPN 3509 FMI 14 ....4940
Tools Required....4940
SPN 3510 FMI 14 - VREF 2 voltage above or below normal....4942
Fault Overview....4942
Lamp Reaction....4942
Associated Faults....4942
Fault Facts....4942
Drive Cycle to Determine Fault Status....4942
Possible Causes....4942
Pin-Point Test SPN 3510 FMI 14 ....4945
Tools Required....4945
SPN 3511 FMI 14 - VREF 3 voltage above or below normal....4949
Fault Overview....4949
Lamp Reaction....4949
Associated Faults....4949
Fault Facts....4949
Drive Cycle to Determine Fault Status....4949
Possible Causes....4949
Pin-Point Test SPN 3511 FMI 14 ....4951
Tools Required....4951
SPN 3512 FMI 14 - VREF 4 voltage above or below normal....4953
Fault Overview....4953
Lamp Reaction....4953
Associated Faults....4953
Fault Facts....4953
Drive Cycle to Determine Fault Status....4953
Possible Causes....4953
Pin-Point Test SPN 3512 FMI 14 ....4957
Tools Required....4957
SPN 3513 FMI 14 - VREF 5 voltage above or below normal....4963
Fault Overview....4963
Lamp Reaction....4963
Associated Faults....4963
Fault Facts....4963
Drive Cycle to Determine Fault Status....4963
Possible Causes....4963
Pin-Point Test SPN 3513 FMI 14 ....4967
Tools Required....4967
SPN 3514 FMI 14 - VREF 6 voltage above or below normal....4973
Fault Overview....4973
Lamp Reaction....4973
Associated Faults....4973
Fault Facts....4973
Drive Cycle to Determine Fault Status....4973
Possible Causes....4973
Pin-Point Test SPN 3514 FMI 14 ....4975
Tools Required....4975
WIF Sensor (Water In Fuel)....4977
Overview of WIF Sensor Group....4977
Overview....4977
SPN 4192 FMI 3 - WIF signal Out of Range HIGH....4978
Fault Overview....4978
Lamp Reaction....4978
Associated Faults....4978
Fault Facts....4978
Drive Cycle to Determine Fault Status....4978
Possible Causes....4978
Pin-Point Test SPN 4192 FMI 3....4981
Tools Required....4981
SPN 4192 FMI 4 - WIF signal Out of Range LOW....4983
Fault Overview....4983
Lamp Reaction....4983
Associated Faults....4983
Fault Facts....4983
Drive Cycle to Determine Fault Status....4983
Possible Causes....4983
Pin-Point Test SPN 4192 FMI 4....4986
Tools Required....4986
WTSL (Wait to Start Lamp)....4988
Overview of WTSL Sensor Group....4988
Overview....4988
SPN 1081 FMI 3 - WTSL circuit short to PWR....4989
Fault Overview....4989
Lamp Reaction....4989
Associated Faults....4989
Fault Facts....4989
Drive Cycle to Determine Fault Status....4989
Possible Causes....4989
Pin-Point Test SPN 1081 FMI 3....4991
Tools Required....4991
SPN 1081 FMI 4 - WTSL circuit short to GRD....4993
Fault Overview....4993
Lamp Reaction....4993
Associated Faults....4993
Fault Facts....4993
Drive Cycle to Determine Fault Status....4993
Possible Causes....4993
Pin-Point Test SPN 1081 FMI 4....4996
Tools Required....4996
SPN 1081 FMI 5 - WTSL open load/circuit....4998
Fault Overview....4998
Lamp Reaction....4998
Associated Faults....4998
Fault Facts....4998
Drive Cycle to Determine Fault Status....4998
Possible Causes....4998
Pin-Point Test SPN 1081 FMI 5....5001
Tools Required....5001
Table of Contents....5005
ServiceMaxx? Software Procedures....5009
Connection and Data Recording....5009
Overview....5009
Engine Auto-Detection....5009
Connection (Sniffer)....5009
Tools Required....5009
Equipment Condition....5009
Test Setup....5009
Test Procedure....5010
Snapshot Recording Procedure:....5010
Snapshot Playback Procedure....5011
Diagnostic Trouble Code Overview....5013
DTC Type:....5013
Pending DTC....5013
Active DTC....5013
Healing DTC....5013
Previously Active DTC....5013
DTC Count....5013
Freeze Frame....5013
Check for DTCs....5014
Procedure:....5014
Session Files....5015
Overview....5015
Obtain Vehicle Health Report....5017
Overview....5017
Tools Required....5017
Equipment Condition....5017
Test Setup....5017
Test Procedure....5017
Expected Outcome....5017
Follow-On Procedure....5017
Programmable Features....5018
Overview....5018
Tool Required....5018
Equipment Condition....5018
Test Setup....5018
Test Procedure....5019
Expected Outcome....5021
Follow-On Procedure....5021
Record Snapshot of KOEO Data....5022
Overview....5022
Tools Required....5022
Equipment Condition....5022
Test Setup....5022
Test Procedure....5022
Expected Outcome....5023
Follow-On Procedure....5023
DPF Service Procedure....5024
Overview....5024
Tools Required....5024
Equipment Condition....5024
Test Setup....5024
Test Procedure....5025
Onboard Filter Cleanliness Test....5027
Overview....5027
Tools Required....5027
Equipment Condition....5027
Test Setup....5027
Test Procedure....5027
Expected Outcome....5029
Follow-On Procedure....5030
Viewing graphs of recorded data....5031
Overview....5031
Tools Required....5031
Equipment Condition....5031
Test Setup....5031
Test Procedure....5031
Expected Outcome....5033
Follow-On Procedure....5033
IQA Adjustment....5034
Overview....5034
Tools Required....5034
Equipment Condition....5034
Test Setup....5034
Test Procedure....5034
Expected Outcome....5036
Follow-On Procedure....5037
Crankshaft Position Sensor Relearn Procedure....5038
Overview....5038
Tools Required....5038
Equipment Condition....5038
Test Setup....5038
Test Procedure....5038
Expected Outcome....5040
Follow-On Procedure....5040
Oxygen (O2) Sensor Calibration....5041
Overview....5041
Tools Required....5041
Equipment Condition....5041
Test Setup....5041
Test Procedure....5041
Expected Outcome....5041
Follow-On Procedure....5042
Intermittent or Inactive Fault Diagnostic Procedure....5043
Overview....5043
Tools Required....5043
Equipment Condition....5043
Test Setup....5043
Test Procedure....5043
Expected Outcome....5043
Follow-On Procedure....5043
Connecting EST with ServiceMaxx? Software to Engine....5044
Interface Device Selection....5044
?J1939....5046
Connecting ServiceMaxx? Software....5047
Pinpoint Diagnostic Graphic Legend....5048
Service Bay Tests....5055
Engine Off Tests....5055
Actuator Test....5055
Overview....5055
Tools Required....5055
Test Setup....5055
Test Procedure....5055
Expected Outcome....5056
Follow-On Procedure....5056
ETV Position Test....5057
Overview....5057
Tools Required....5057
Equipment Condition....5057
Test Setup....5057
Test Procedure....5057
Expected Outcome....5058
Follow-On Procedure....5058
EGR Valve Position Test....5059
Overview....5059
Tools Required....5059
Equipment Condition....5059
Test Setup....5059
Test Procedure....5059
Expected Outcome....5060
Follow-On Procedure....5060
Continuous Monitor Test....5061
Overview....5061
Position Sensor Voltages are Monitored:....5061
Pressure Sensor Voltages are Monitored:....5061
Temperature Sensor Voltages are Monitored:....5062
Other Voltage Signals Monitored:....5062
Tools Required....5062
Equipment Condition....5062
Test Setup....5062
Test Procedure....5063
Expected Outcome....5064
Follow-On Procedure....5064
Relative Compression Test....5065
Overview....5065
Tools Required....5065
Equipment Condition....5065
Test Setup....5065
Test Procedure....5065
Expected Outcome....5067
Follow-On Procedure....5067
Inlet Air Heater Test....5068
Overview....5068
Tools Required....5068
Equipment Condition....5068
Test Setup....5068
Test Procedure....5069
Expected Outcome....5069
Follow-On Procedure....5069
Low Coolant Level Reset Request....5070
Overview....5070
Tools Required....5070
Equipment Condition....5070
Test Setup....5070
Test Procedure....5070
Expected Outcome....5072
Follow-On Procedure....5072
FRP Relief Valve Reset Procedure....5073
Overview....5073
Tools Required....5073
Equipment Condition....5073
Test Setup....5073
Test Procedure....5073
Expected Outcome....5075
Follow-On Procedure....5075
Engine Running Tests....5076
Air Management Test....5076
Overview....5076
Tools Required....5076
Equipment Conditions....5076
Test Setup....5076
Test Procedure....5077
Expected Outcome....5078
Follow-On Procedure....5078
High Pressure Pump Test....5079
Overview....5079
Tools Required....5079
Equipment Condition....5079
Test Setup....5079
Test Procedure....5080
Expected Outcome....5081
Follow-On Procedure....5081
Engine Fan Test....5082
Overview....5082
Tools Required....5082
Equipment Conditions....5082
Test Setup....5082
Test Procedure....5083
On/Off Two Speed Fan....5084
Variable Speed Fan....5085
Expected Outcome....5086
Follow-On Procedure....5086
Multiple Cylinder Cutout Test....5087
Overview....5087
Tools Required....5087
Equipment Conditions....5087
Test Setup....5087
Test Procedure....5088
Expected Outcome....5090
Follow-On Procedure....5090
Cylinder Balance....5091
Overview....5091
Tools Required....5091
Equipment Condition....5091
Test Setup....5091
Test Procedure....5091
Expected Outcome....5092
Follow-On Procedure....5093
DSI Deaeration Procedure....5094
Overview....5094
Tools Required....5094
Equipment Condition....5094
Test Setup....5095
Test Procedure....5096
Expected Outcome....5096
Follow-On Procedure....5096
Low Idle to High Idle Test....5097
Overview....5097
Tools Required....5097
Equipment Condition....5097
Test Setup....5097
Test Procedure....5097
Expected Outcome....5099
Follow-On Procedure....5099
Road Tests....5100
Lug Down Test....5100
Overview....5100
Tools Required....5100
Equipment Condition....5100
Test Setup....5100
Test Procedure....5101
Expected Outcome....5102
Follow-On Procedure....5102
Lug Down Test (RPM, FRP, and FRP Desired) Graph....5103
Overview....5103
Graph Analysis:....5103
Actions:....5103
Lug Down Test (RPM, APP1, Vehicle Speed, and IMP) Graph....5104
Overview....5104
Graph Analysis:....5104
Action:....5104
Lug Down Test (Engine Load and TC1TOP) Graph....5105
Overview....5105
Graph Analysis:....5105
Actions:....5105
Normal Exhaust Gas Temp Graph....5106
Overview....5106
Tools Required....5106
Equipment Condition....5106
Test Setup....5106
Test Procedure....5107
Expected Outcome....5107
Follow-On Procedure....5107
Inverted Exhaust Gas Temp Graph....5108
Overview....5108
Tools Required....5108
Equipment Condition....5108
Test Setup....5108
Test Procedure....5109
Expected Outcome....5109
Follow-On Procedure....5109
Low Exhaust Gas Temp Graph....5110
Overview....5110
Tools Required....5110
Equipment Condition....5110
Test Setup....5110
Test Procedure....5111
Expected Outcome....5111
Follow-On Procedure....5111
Air Control Valve (ACV) Test....5112
Turbocharger 2 Wastegate (TC2WC) Functional Test....5112
Overview....5112
Tools Required....5112
Equipment Condition....5112
Test Setup....5112
Test Procedure....5112
Expected Outcome ....5114
Follow-On Procedure....5114
Exhaust Back Pressure Valve Functional Test....5115
Overview....5115
Tools Required....5115
Equipment Condition....5115
Test Setup....5115
Test Procedure....5115
Expected Outcome....5117
Follow-On Procedure....5117
Low-Pressure Fuel System Tests....5118
Fuel System Priming....5118
Overview....5118
Tools Required....5118
Equipment Condition....5118
Test Setup....5118
Test Procedure....5119
Expected Outcome....5121
Follow-On Procedure....5121
Fuel Delivery Pressure (FDP) Test....5122
Overview....5122
Tools Required....5122
Equipment Conditions....5122
Test Set-up....5122
Test Procedure....5123
Expected Outcome....5123
Follow-on Procedure....5123
Start From Clean Fuel Source Test....5124
Overview....5124
Tools Required....5124
Equipment Condition....5124
Test Setup....5124
Test Procedure....5125
Expected Outcome....5125
Follow-on Procedure....5125
Fuel Aeration Test....5126
Overview....5126
Tools Required....5126
Equipment Condition....5126
Test Setup 1....5126
Test Procedure 1....5127
Test Setup 2....5127
Test Procedure 2....5127
Expected Outcome....5128
Follow-On Condition....5128
Fuel Restriction Test....5129
Overview....5129
Tools Required....5129
Equipment Condition....5129
Test Setup 1....5129
Test Procedure 1....5130
Test Setup 2....5130
Test Procedure 2....5131
Test Setup 3....5131
Test Procedure 3....5132
Expected Outcome....5132
Follow-On Procedure....5132
High-Pressure Fuel System Tests....5133
HP Pump Inlet Pressure Test....5133
Overview....5133
Tools Required....5133
Equipment Condition....5133
Test Setup....5133
Test Procedure....5134
Expected Outcome....5134
Follow-On Procedure....5134
Fuel Rail Pressure (FRP) Return Flow Test....5135
Overview....5135
Tools Required....5135
Equipment Condition....5135
Test Setup 1....5135
Test Procedure 1....5135
Test Setup 2....5136
Test Procedure 2....5136
Expected Outcome Test Procedure 1....5136
Expected Outcome Test Procedure 2....5136
Follow-On Procedure....5137
Fuel Rail Pressure (FRP) Leak Isolation ....5138
Overview....5138
Tools Required....5138
Equipment Condition....5138
Test Setup....5138
Test Procedure....5139
Expected Outcome....5139
Follow-On Procedure....5139
HP Pump Fuel Return Pressure Test....5140
Overview....5140
Tools Required....5140
Equipment Condition....5140
Test Setup....5140
Test Procedure....5141
Expected Outcome....5141
Follow-On Procedure....5141
HP Pump Fuel Return Flow Test....5142
Overview....5142
Tools Required....5142
Equipment Condition....5142
Test Setup....5142
Test Procedure....5143
Expected Outcome....5143
Follow-On Procedure....5143
HPFP CPA Test....5144
Overview....5144
Tools Required....5144
Equipment Condition....5144
Test Setup....5145
Test Procedure....5155
Expected Outcome....5159
Follow-On Procedure....5159
HPFP Test Entry Conditions....5160
Overview....5160
Tools Required....5160
Equipment Condition....5160
Test Procedure....5160
Expected Outcome....5161
Follow-On Procedure....5161
Inlet Air Heater Tests....5162
Inlet Air Heater Fuel Igniter (IAHFI) Test....5162
Overview....5162
Tools Required....5162
Equipment Condition....5162
Test Setup....5162
Test Procedure....5162
Expected Outcome....5163
Equipment Condition....5163
Fuel Supply at Intake Air Heater Fuel Solenoid (IAHFS) Test....5164
Overview....5164
Tools Required....5164
Equipment Condition....5164
Test Setup....5164
Test Procedure....5164
Expected Outcome....5165
Follow-On Procedure....5165
Fuel Supply at Intake Air Heater Fuel Igniter (IAHFI) Test....5166
Overview....5166
Tools Required....5166
Equipment Condition....5166
Test Setup....5166
Test Procedure....5166
Expected Outcome....5167
Follow-On Procedure....5167
General Test Procedures....5168
Batteries and Electrical System Inspection....5168
Overview....5168
Tools Required....5168
Equipment Condition....5168
Inspection Procedure....5168
Expected Outcome....5168
Engine Cranking Test....5169
Overview....5169
Tools Required....5169
Equipment Condition....5169
Test Setup....5169
Test Procedure....5169
Expected Outcome....5169
Follow-On Procedure....5169
Crankcase Oil Breather Separator Test....5170
Overview....5170
Tools Required....5170
Equipment Condition....5170
Test Setup....5170
Test Procedure....5170
Expected Outcome....5171
Follow-On Condition....5171
Charge Air Cooler (CAC) Pressure Test....5172
Overview....5172
Tools Required....5172
Equipment Condition....5172
Test Setup....5173
Test Procedure....5173
Expected Outcome....5177
Follow-On Procedure....5177
Interstage Cooler (ISC) Pressure Test....5180
Overview....5180
Tools Required....5180
Equipment Condition....5180
Test Setup....5180
Test Procedure....5181
Expected Outcome....5182
Follow-On Procedure....5182
Crankcase Pressure Test....5183
Overview....5183
Tools....5183
Test Setup....5183
Test procedure....5184
Expected Outcome....5185
Follow-On Procedure....5185
Smoke Test (Air Intake System)....5186
Overview....5186
Tools Required....5186
Equipment Condition....5186
Test Setup ....5186
Test Procedure....5187
Expected Outcome....5189
Follow-On Procedure....5189
Smoke Test (Exhaust System)....5190
Overview....5190
Tools Required....5190
Equipment Condition....5190
Test Setup 1 (Upstream Of DPF)....5191
Test Procedure 1 (Upstream Of DPF)....5193
Relay Diagnostics....5195
Overview....5195
Relay Diagnostics Applicability Table....5195
Relay Test 1 - Switched-86 GND....5196
Overview....5196
Tools Required....5196
Equipment Conditions....5196
Test Setup....5196
Test Procedure....5196
Expected Outcome....5197
Follow-On Procedure....5198
Relay Test 2 - Switched-86 PWR....5199
Overview....5199
Tools Required....5199
Equipment Conditions....5199
Test Setup....5199
Test Procedure....5199
Expected Outcome....5200
Follow-On Procedure....5201
Relay Test 3 - Switched-85 GND....5202
Overview....5202
Tools Required....5202
Equipment Conditions....5202
Test setup....5202
Test Procedure....5202
Expected Outcome....5204
Follow-On Procedure....5204
Relay Test 4 ? Switched-85 Shared 30....5205
Overview....5205
Tools Required....5205
Equipment Conditions....5205
Test setup....5205
Test Procedure....5205
Expected Outcome....5207
Follow-On Procedure....5207
Relay Test 5 - Switched-85 GND, FMI 4....5208
Overview....5208
Tools Required....5208
Equipment Conditions....5208
Test setup....5208
Test Procedure....5208
Expected Outcome....5209
Follow-On Procedure....5209
Relay Test 6 - Switched-86 PWR, No Code....5210
Overview....5210
Tools Required....5210
Equipment Conditions....5210
Test setup....5210
Test Procedure....5210
Expected Outcome....5211
Follow-On Procedure....5212
Relay Test 7 - Switched-85 GND, No Code....5213
Overview....5213
Tools Required....5213
Equipment Conditions....5213
Test setup....5213
Test Procedure....5213
Expected Outcome....5214
Follow-On Procedure....5214
J1939 Diagnostics....5215
Overview....5215
Tools Required....5215
Equipment Condition....5215
Test Setup....5215
Test Procedure....5215
Expected Outcome....5216
Follow-On Procedure....5216
Induction System Cleaning Procedure....5217
Overview....5217
Tools Required....5217
Equipment Condition....5217
Test Setup....5217
Test Procedure....5229
Expected Outcome....5230
Follow-On Procedure....5230
Exhaust Restriction Isolation Test....5231
Overview....5231
Tools Required....5231
Equipment Condition....5231
Test Setup....5231
Test Procedure....5231
Expected Outcome....5232
Follow-On Procedure....5232
Fuel System Flushing Procedure....5233
Overview....5233
Coolant Test Procedures....5234
Deaeration Tank Cap Test....5234
Overview....5234
Tools Required....5235
Equipment Condition....5235
Test Setup....5236
Test Procedure....5236
Expected Outcome....5236
Follow-On Procedure....5236
Cooling System Pressure Test....5237
Overview....5237
Tools Required....5237
Equipment Condition....5237
Test Setup....5238
Test Procedure....5239
Expected Outcome....5239
Follow-On Procedure....5239
Air Compressor Leaking Coolant to Oil Test....5240
Overview....5240
Tools Required....5240
Equipment Condition....5240
Test Setup....5240
Test Procedure....5240
Expected Outcome....5240
Follow-On Procedure....5240
Air Compressor Leaking Air to Coolant Test....5241
Overview....5241
Tools Required....5241
Equipment Condition....5241
Test Setup....5241
Test Procedure....5241
Expected Outcome....5241
Follow-On Procedure....5241
Aftertreatment Fuel Injector (AFTFI) Coolant Leak Test....5242
Overview....5242
Tools Required....5242
Equipment Condition....5242
Test Setup....5242
Test Procedure....5242
Expected Outcome....5243
Follow-On Procedure....5243
EGR Cooler Leak Test....5244
Overview....5244
Tools Required....5244
Equipment condition....5244
Test Setup....5244
Test Procedure....5257
Expected Outcome....5260
Follow-On Procedure....5261
Thermostat Operational Test....5262
Overview....5262
Tools Required....5262
Equipment Condition....5262
Test Setup....5262
Test Procedure....5262
Expected Outcome....5263
Follow-On Procedure....5263
Coolant Control Valve (CCV) Assembly and Coolant Mixer Valve (CMV) Operation....5264
Coolant Control Valve (CCV) Test....5265
Engine Oil Tests....5269
Oil Pressure Verification Test ....5269
Overview....5269
Tools Required....5269
Equipment Condition....5269
Test Setup....5269
Test Procedure....5269
Expected Outcome....5271
Follow-On Procedure....5271
Power Steering Fluid Leak to Engine Oil Test....5272
Overview....5272
Tools Required....5272
Equipment Condition....5272
Test Setup....5272
Test Procedure....5272
Expected Outcome....5272
Follow-On Procedure....5272
Instrument Panel Engine Oil Pressure Gauge Validation Test....5273
Overview....5273
Tools Required....5273
Equipment Condition....5273
Test Setup....5273
Test Procedure....5273
Expected Outcome....5274
Follow-On Procedure....5274
Engine Brake....5275
Engine Compression Brake ECM Inputs and Programmable Parameter Checks....5275
Overview....5275
Tools Required....5275
Equipment Condition....5275
Test Setup....5275
Test Procedure....5275
Expected Outcome....5278
Follow-On Procedure....5279
Engine Compression Brake Operational Test....5279
Overview....5279
Tools Required....5279
Equipment Condition....5279
Test Setup....5279
Test Procedure....5279
Expected Outcome....5280
Follow-On Procedure....5280
Engine System Inspections....5281
Initial Key On Check....5281
Tools Required....5281
Equipment Condition....5281
Test Setup....5281
Test Procedure....5281
Expected Outcome....5281
Follow-On Procedure....5281
Fuel Level and System Inspection....5282
Overview....5282
Tools Required....5282
Equipment Condition....5282
Preliminary Inspection Procedure....5282
Inspection Procedure Canister Style Filter....5283
Inspection Procedure Cartridge Style Filter....5284
Expected Outcome....5286
Fuel Quality Inspection....5287
Overview....5287
Tools Required....5287
Equipment Condition....5287
Inspection Procedure....5287
Expected Outcome....5288
Engine Oil Level and Quality Inspection....5289
Overview....5289
Tools Required....5289
Equipment Condition....5289
Inspection Procedure....5290
Expected Outcome....5290
Coolant Level Inspection....5291
Overview....5291
Tools Required....5291
Equipment Condition....5291
Inspection Procedure....5291
Expected Outcome....5291
Coolant Quality Inspection....5292
Overview....5292
Tools Required....5292
Equipment Condition....5292
Inspection Procedure....5292
Expected Outcome....5292
Coolant Leak - Visual....5293
Overview....5293
Tools Required....5293
Equipment Condition....5293
Inspection Procedure....5293
Expected Outcome....5293
Coolant in Exhaust Inspection....5294
Overview....5294
Tools Required....5294
Equipment Condition....5294
Inspection Procedure....5294
Expected Outcome....5294
Coolant to Oil Inspection....5295
Overview....5295
Tools Required....5295
Inspection Procedure....5295
Expected Outcome....5295
Cylinder Sleeve Cavitation and Crack Inspection....5296
Overview....5296
Tools Required....5296
Equipment Condition....5296
Inspection Procedure....5296
Expected Outcome....5296
Interstage Cooler Inspection....5297
Overview....5297
Tools Required....5297
Equipment Condition....5297
Inspection Procedure....5297
Expected Outcome....5297
Charge Air Cooler Inspection....5298
Overview....5298
Tools Required....5298
Equipment Condition....5298
Inspection Procedure....5298
Expected Outcome....5299
Intake Air Inspection....5300
Overview....5300
Tools Required....5300
Equipment Condition....5300
Inspection Procedure....5300
Expected Outcome....5300
Exhaust and Aftertreatment System Inspection ....5301
Overview....5301
Tools Required....5301
Equipment Condition....5301
Inspection Procedure....5301
Expected Outcome....5303
Oil and Crankcase Inspection....5304
Overview....5304
Tools Required....5304
Equipment Condition....5304
Inspection Procedure....5304
Expected Outcome....5305
Oil pump and Fan Drive Oil Leak Inspection....5306
Overview....5306
Tools Required....5306
Equipment Condition....5306
Inspection Procedure....5306
Expected Outcome....5308
Cylinder Head, Valve train, and Engine Brake Housing Oil Leak Inspection....5309
Overview....5309
Tools Required....5309
Equipment Condition....5309
Inspection Procedure....5309
Expected Outcome....5314
Engine Brake Inspection....5315
Overview....5315
Tools Required....5315
Equipment Condition....5315
Inspection Procedure....5315
Expected Outcome....5317
HP-Turbocharger Radial Play Inspection....5318
Overview....5318
Tools Required....5318
Equipment Condition....5318
Inspection Procedure....5318
Expected Outcome....5318
Internal Engine Damage Inspection....5319
Overview....5319
Tools Required....5319
Equipment Condition....5319
Inspection Procedure....5319
Expected Outcome....5322
Connecting Rod, Main Bearing, and Journal Inspection....5323
Overview....5323
Tools Required....5323
Equipment Condition....5323
Inspection Procedure....5323
Expected Outcome....5326
Aftertreatment....5327
Snap Acceleration Test....5327
Overview....5327
Tools Required....5327
Equipment Condition....5327
Test Setup....5327
Test Procedure....5327
Expected Outcome....5327
Follow-On Procedure....5327
Hot Run Sensor Comparison Test....5328
Overview....5328
Tools Required....5328
Equipment Condition....5328
Test Setup....5328
Test Procedure....5328
Expected Outcome....5329
Follow-On Procedure....5329
Aftertreatment Fuel Injector (AFTFI) Inspection....5330
Overview....5330
Tools Required....5330
Equipment Condition....5330
Inspection Procedure....5330
Expected Outcome....5330
Table of Contents....5331
All Ratings....5333
Key On Engine Off Specifications....5333
Engine Cranking Specifications....5334
Low Idle No Load....5335
High Idle No Load....5336
Full Load....5337
Component Specifications....5338
Actuator Output State....5339
Inlet Air Heater System....5340
Crankcase Pressure....5341
EBPV Rod Extension....5342
TC2WC Rod Extension....5342
MaxxForce? 11 (10.5 L)....5343
330 hp @ 1700 rpm....5343
370 hp @ 1700 rpm....5343
390 hp @ 1700 rpm....5344
MaxxForce? 13 (12.4 L)....5345
410 hp @ 1700 rpm....5345
430 hp @ 1700 rpm....5345
450 hp @ 1700 rpm (Allison Automatic Transmission)....5346
450 hp @ 1700 rpm (Manual Transmission)....5346
475 hp @ 1700 rpm....5347
Fluids....5347
Fluid Specifications and Info....5347
Fuel....5347
Ultra Low Sulfur Diesel (ULSD)....5347
Acceptable Fuel Blends....5347
Use of Higher Biodiesel Fuel Blends (B6 to B20)....5348
Engine Lubrication Oil....5348
SAE Oil Viscosity Grades and Temperature Ranges....5349
Coolant....5349
Cooling System Capacity....5349
Coolant Mixtures....5350
Table of Contents....5351
Electrical Tools....5353
180-pin Breakout Box....5353
2010 MaxxForce 11 & 13 Harness Kit ....5354
3-Banana Plug Harness....5354
500 Ohm Resistor Harness....5354
Electronic Engine Terminal Test Kit....5355
Big Bore Terminal Test Probe Kit....5355
Digital Multimeter (DMM)....5356
EXP-1000 HD by Midtronics....5357
EZ-Tech? Electronic Service Tool (EST)....5358
ServiceMaxx? Software....5358
Interface cable (RP1210B compliant supporting J1939 and J1708)....5358
MaxxForce? 11 and 13 Engine Tool Kit....5359
Breakout Harness 4485A (APP)....5360
Breakout Harness 4602 (AFTFSV)....5360
Breakout Harness 4735A (O2S)....5361
Breakout Harness 4760A (DOCIT, DOCOT, DPFOT, and EGRT)....5361
Breakout Harness 4761A (DPFDP)....5362
Breakout Harness 4827 (IAHFS, ECT1, ECT2, EOL, and EOT)....5362
Breakout Harness 4828 (AFTFD and FPCV)....5363
Breakout Harness 4829 (FRP)....5363
Breakout Harness 4830 (AFTFIS, HS/IAT, and TC2CIS)....5364
Breakout Harness 4850 (IMP)....5364
Breakout Harness 4870 (CMV)....5365
Breakout Harness 4871 (AAT and CFV)....5365
Breakout Harness 4881 (FDP)....5366
Breakout Harness 4882 (EOP)....5366
Breakout Harness 4883 (IMT)....5367
Breakout Harness 4885 (IAHR)....5367
Breakout Harness 4951 (CCOSS)....5368
Breakout Harness 4993 (CACOT)....5368
Breakout Harness 6002 (WIF)....5369
Breakout Harness 6003 (EBPV, TC1TOP, TC1WC, and TC2WC)....5369
Breakout Harness 6004 (ECB)....5369
Breakout Harness 6016 (ETV and EGR Valve)....5370
Breakout Harness 6021 (CKP and CMP)....5370
Breakout Harness 6027 (AFTFP2)....5371
Mechanical Tools....5372
Air Cap, Fuel Cap and Plug Kit....5372
Air Compressor Coolant Line Release Tool....5372
Air Intake Guard....5373
Blow-by Test Tool....5374
Clean Fuel Source Tool....5374
Inlet Air Heater Solenoid Test Adapter Kit....5375
Digital Manometer....5376
EGR Cooler Leak Detection Test Kit....5377
Charge Air Cooler Test Kit....5377
Digital IR Thermometer....5378
Lash Gauge (0.50mm)....5378
Lash Gauge (0.80mm)....5379
Fuel Block Off Tool....5379
Fuel Injector Cups....5380
Fuel Inlet Restriction and Aeration Tool....5380
Fuel Line Coupler....5381
Fuel Line Disconnect Tool 11.8 mm....5381
Fuel Line Disconnect Tool 16 mm....5382
Fuel Pressure Gauge....5382
High Pressure Rail Plugs....5383
High Pressure Return Line Tester....5383
Pressure Test Kit....5384
Radiator Pressure Test Kit....5384
Slack Tube? Manometer....5386
UV Leak Detection Kit....5387
Vacuum Analyzer and Fuel Pump Tester....5388
Table of Contents....5389
Engine Component Locator....5391
Table of Contents....5395
Engine Identification....5397
Engine Serial Number....5397
Engine Serial Number Examples....5397
Engine Serial Number Codes....5397
Engine Emission Label ....5398
Engine Accessory Labels....5399
Engine Specifications....5400
Heavy Duty On Board Diagnostics (HD-OBD)....5402
Engine Description....5402
Optional Equipment....5403
Chassis Mounted Equipment....5403
Air Management System....5405
Airflow....5406
Turbochargers....5407
Air Control Valve (ACV)....5408
Boost Control....5409
Low Pressure Charge Air Cooler (LPCAC)....5409
High Pressure Charge Air Cooler (HPCAC)....5409
High Pressure Boost Pressure (HPBP) Sensor ....5409
High Pressure Boost Temperature (HPBT) Sensor ....5410
Low Pressure Boost Pressure (LPBP) and Low Pressure Boost Temperature (LPBT) Sensors ....5410
Exhaust Gas Recirculation (EGR) System....5411
EGR System Overview....5412
EGR Flow....5412
EGR System Control....5412
EGRV Control....5413
EGR ? Open Loop....5414
EGR ? Closed Loop ....5414
EGR Flow Cooling....5414
Aftertreatment (AFT) System....5415
Diesel Particulate Filter (DPF)....5416
Diesel Oxidation Catalyst (DOC)....5416
Aftertreatment (AFT) System Conditions and Responses....5416
Downstream Fuel Injection....5417
Downstream Injection (DSI) Unit....5418
Aftertreatment Fuel Injector (AFI)....5418
Crankcase Oil Separator....5419
Aftertreatment System....5421
Diesel Particulate Filter (DPF)....5422
Diesel Oxidation Catalyst (DOC)....5423
Aftertreatment (AFT) System Conditions and Responses....5424
Aftertreatment Fuel Injection....5425
AFT Fuel Doser Module Injection....5426
Aftertreatment Fuel Injector (AFTFI)....5426
Fuel Management System....5427
Fuel System Components....5427
Fuel Flow....5428
Low Pressure Fuel System....5429
Chassis Mounted Filter/Water Separator....5429
Fuel Primer Pump Assembly....5429
Low Pressure (LP) Fuel Pump....5430
Fuel Filter Assembly....5430
High Pressure Fuel System....5431
High Pressure (HP) Pump....5432
Fuel Pressure Control Valve (FPCV)....5432
Fuel Rail....5432
Fuel Rail Pressure (FRP) Sensor....5432
Rail Pressure Limiting Valve....5432
Injectors....5432
Inlet Air Heater System....5433
Inlet Air Heater System Components....5433
Inlet Air Heater Fuel Igniter (IAHFI)....5433
Inlet Air Heater Relay (IAHR)....5434
Inlet Air Heater Fuel Solenoid (IAHFS) Valve....5434
Inlet Air Heater System Operation....5435
Oil Flow and Components....5436
Crankcase Oil Separator....5438
Remote Mounted Centrifugal Oil Filter (Optional)....5439
Engine Cooling System....5440
Cooling System Flow....5440
Thermostat Operation....5442
Coolant Control Valve (CCV) assembly operation....5443
Coolant Flow Valve (CFV)....5443
Coolant Mixer Valve (CMV)....5443
Engine Brake System....5444
Engine Brake Control System Components....5444
Engine Brake System Description....5445
Engine Brake System Operation....5446
Electronic Control System....5447
Electronic Control System Components....5447
Operation and Function....5447
Reference Voltage (VREF)....5447
Signal Conditioner....5447
Microprocessor....5447
Diagnostic Trouble Codes....5447
Microprocessor Memory....5447
ROM....5448
RAM....5448
Actuator Control....5449
Actuators....5450
Coolant Control Valve (CCV)....5450
Exhaust Back Pressure Valve (EBPV) Control....5450
Exhaust Gas Recirculation (EGR) Valve ....5450
Air Control Valve (ACV)....5450
Inlet Air Heater Relay (IAHR)....5451
Inlet Air Heater Fuel Solenoid (IAHFS) Valve....5452
Engine Throttle Valve (ETV)....5452
Fuel Pressure Control Valve (FPCV)....5452
Aftertreatment Fuel Doser (AFTFD)....5453
Aftertreatment Fuel Shutoff Valve (AFTFSV)....5453
Engine and Vehicle Sensors....5454
Thermistor Sensors....5454
Aftertreatment Temperature Sensors....5454
Engine Coolant Temperature (ECT) Sensors....5455
Engine Oil Temperature (EOT) Sensor....5455
Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....5455
Charge Air Cooler Outlet Temp (CACOT) Sensor....5455
Intake Manifold Temperature (IMT) Sensor....5455
Exhaust Gas Recirculation Temperature (EGRT) Sensor....5455
Ambient Air Temperature (AAT) Sensor....5456
Variable Capacitance Sensors....5456
DPF Differential Pressure (DPFDP) Sensor....5457
Fuel Delivery Pressure (FDP) Sensor....5457
Engine Oil Pressure (EOP) Sensor....5457
Fuel Rail Pressure (FRP) Sensor....5457
Intake Manifold Pressure (IMP) Sensor....5457
Aftertreatment Fuel Inlet Sensor (AFTFIS) ....5457
Aftertreatment Fuel Pressure 2 (AFTFP2) sensor....5457
Turbocharger 1 Turbine Outlet Pressure (TC1TOP)....5458
Magnetic Pickup Sensors....5459
Crankshaft Position (CKP) Sensor....5460
Camshaft Position (CMP) Sensor....5460
Vehicle Speed Sensor (VSS)....5460
Crankcase Oil Separator Speed (CCOSS) sensor....5460
Potentiometer Sensors....5461
Accelerator Pedal Position (APP)....5461
Switches....5462
Driveline Disengagement Switch (DDS)....5462
Engine Coolant Level (ECL) Switch....5462
Oil Level Sensor (OLS)....5462
Additional Sensors....5463
Engine Oil Level (EOL) Sensor....5463
Oxygen Sensor (O2S)....5464
Heavy Duty On Board Diagnostics (HD-OBD)....5465
Overview....5465
Table of Contents....5467
Standard Electronic Control Features....5469
Aftertreatment (AFT) System....5469
Cold Ambient Protection (CAP)....5469
Coolant Temperature Compensation (CTC)....5469
Data Plate....5469
Electronic Speedometer and Tachometer....5470
Engine Crank Inhibit (ECI)....5470
Engine Electronic Governor Control....5470
Engine Fan Control (EFC)....5470
Event Logging System ....5470
Fast Idle Advance....5470
Intake Air Heater Assist....5471
IST (Idle Shutdown Timer) System (Clean Low Idle)....5471
IST (Clean Low Idle)....5471
IST (Idle Shutdown Timer) System (Federal - Optional)....5471
IST (Federal - Optional) Sensor Circuit Operation....5471
J1939 Datalink ....5472
Password Protection....5473
Service Diagnostics....5473
Trip Reporting....5473
Vehicle Setup....5473
Optional Electronic Control Features....5473
Cruise Control....5473
Driver Reward....5473
Navistar? Engine Brake....5474
Engine Warning Protection System (EWPS)....5474
Gear Down Protection (GDP)....5474
Idle Shutdown Timer (IST)....5474
Progressive Shift....5475
Power Take Off (PTO) - In Cab....5475
Power Take Off (PTO) - Remote....5475
Service Interval....5476
Traction Control....5476
Up-Shift Indicator....5476
Road Speed Limiter....5476
Table of Contents....5477
Abbreviations and Acronyms....5479
Table of Contents....5487
Terminology....5489
tables....3643
Technical Service Literature....3643
On Board Filter Cleanliness Test (OBFCT) Parked Regen Checks...3751
Parked Regen Checks....3751
Specifications....3751
Pass / Fail....3751
Decision....3751
On Board Filter Cleanliness Test (OBFCT) Parked Regen Checks...3760
Parked Regen Checks....3760
Specifications....3760
Pass / Fail....3760
Decision....3760
Connector Voltage Check ? AFTFD Disconnected....3762
Operational Voltage Check....3763
Actuator Resistance Check....3763
Harness Resistance Check....3763
Connector Voltage Check ? AFTFD Disconnected....3764
Operational Voltage Check....3764
Actuator Resistance Check....3764
Harness Resistance Check....3764
Connector Voltage Check ? AFTFD Disconnected....3765
Operational Voltage Check....3765
Actuator Resistance Check....3765
Harness Resistance Check....3765
On Board Filter Cleanliness Test (OBFCT) Parked Regen Checks...3773
Parked Regen Checks....3773
Specifications....3773
Pass / Fail....3773
Decision....3773
Associated Faults....3787
Associated Faults....3790
Sensor Circuit Check....3795
Pinpoint Diagnostics Without ServiceMaxx? Software....3795
Harness Resistance Check....3795
Sensor Circuit Check....3797
Pinpoint Diagnostics Without ServiceMaxx? Software....3797
Harness Resistance Check....3797
Sensor Circuit Check....3798
Pinpoint Diagnostics Without ServiceMaxx? Software....3799
Harness Resistance Check....3799
Sensor Circuit Check....3800
Pinpoint Diagnostics Without ServiceMaxx? Software....3801
Harness Resistance Check....3801
Parked Regen Checks....3816
Associated Faults....3883
Connector Voltage Check....3896
Operational Voltage Check....3896
Actuator Resistance Check....3896
Harness Resistance Check....3896
Connector Voltage Check....3897
Operational Voltage Check....3897
Actuator Resistance Check....3897
Harness Resistance Check....3897
Connector Voltage Check....3898
Operational Voltage Check....3898
Actuator Resistance Check....3898
Harness Resistance Check....3898
Connector Voltage Check....3935
Operational Voltage Check....3935
Actuator Resistance Check....3935
Harness Resistance Check....3936
Connector Voltage Check....3937
Operational Voltage Check....3937
Actuator Resistance Check....3937
Harness Resistance Check....3938
Connector Voltage Check....3939
Operational Voltage Check....3939
Actuator Resistance Check....3939
Harness Resistance Check....3940
Associated Faults....4036
Parked Regen Checks....4047
Parked Regen Checks....4087
Parked Regen Checks....4116
Parked Regen Checks....4116
Specifications....4116
Pass/Fail....4116
Decision....4116
Parked Regen Checks....4120
Connector Voltage Check ? EGR Valve Disconnected....4256
Operational Voltage Check....4257
Harness Resistance Check....4257
Connector Voltage Check ? EGR Valve Disconnected....4263
Operational Voltage Check....4264
Harness Resistance Check....4264
Connector Voltage Check ? EGR Valve Disconnected....4267
Operational Voltage Check....4268
Harness Resistance Check....4268
Sensor Circuit Check With ServiceMaxx? Software....4275
Connector Voltage Check Without ServiceMaxx? Software....4276
Harness Resistance Check....4276
Sensor Circuit Check With ServiceMaxx? Software....4282
Connector Voltage Check Without ServiceMaxx? Software....4283
Harness Resistance Check....4283
Sensor Circuit Check With ServiceMaxx? Software....4284
Connector Voltage Check Without ServiceMaxx? Software....4285
Harness Resistance Check....4285
Connector Voltage Check ? ETV Disconnected....4327
Operational Voltage Check....4328
Harness Resistance Check....4329
Connector Voltage Check ? ETV Disconnected....4339
Operational Voltage Check....4340
Harness Resistance Check....4341
Connector Voltage Check ? ETV Disconnected....4342
Operational Voltage Check....4343
Harness Resistance Check....4344
Connector Voltage Check ? ETV Disconnected....4345
Operational Voltage Check....4346
Harness Resistance Check....4347
Connector Voltage Check ? TC2WC Disconnected....4881
Operational Voltage Check....4881
Actuator Resistance Check....4882
Harness Resistance Check....4882
Connector Voltage Check ? TC2WC Disconnected....4883
Operational Voltage Check....4883
Actuator Resistance Check....4884
Harness Resistance Check....4884
Check Regen Inhibitors....5029
High Pressure Pump Test Entry Conditions and Corrective Actions....5161
Primary Fuel Filter (Cartridge Style) Inspection....5285
MaxxForce? 11 and 13 Diesel Engines....5400
0000001742 - Manuel de Diagnostique Les moteurs MaxxForce 11 et 13 2010 (2013-02)....5500
toc....5502
Table des Mati?res....5502
Terminologie de s?curit?....5506
Instructions de s?curit?....5506
Zone de travail....5506
?quipement de s?curit?....5506
Mesures protectrices....5506
V?hicule....5506
Moteur....5506
Pr?vention des incendies....5507
Batteries....5507
Air comprim?....5507
Outils....5507
Liquides sous pression....5507
Carburant....5507
Enl?vement d'outils, de pi?ces, et d'?quipement....5507
Table des Mati?res....5508
Identification du moteur....5510
Num?ro de s?rie du moteur....5510
Exemples de num?ro de s?rie moteur....5510
Codes du num?ro de s?rie du moteur....5510
?tiquette d'?missions du moteur ....5510
?tiquettes et plaquessignal?tiques des accessoires du moteur....5511
Sp?cifications du moteur....5511
Diagnostics embarqu?s ?Heavy Duty On Board Diagnostics? (HD-OBD)....5513
Description du moteur....5513
?quipement en option....5514
?quipement mont? sur le ch?ssis....5514
Emplacement des composants du moteur....5516
Syst?me de gestion d'air....5520
D?bit d'air....5521
Turbocompresseurs....5522
Soupape de r?gulation d'air (ACV)....5523
Contr?le de la suralimentation....5524
Refroidisseur d'air de suralimentation basse pression (LPCAC)....5524
Refroidisseur d'air de suralimentation haute pression (HPCAC)....5524
Capteur de pression de suralimentation haute pression (HPBP) ....5524
Sonde de temp?rature de suralimentation haute pression (HPBT) ....5525
Capteurs de pression de suralimentation basse pression (LPBP) et de temp?rature de suralimentation basse pression (LPBT) ....5525
Syst?me de recirculation des gaz d'?chappement (RGE)....5526
Aper?u du syst?me EGR....5527
D?bit RGE....5527
Commande du syst?me RGE....5527
Commande de la SRGE....5527
RGE ? Boucle ouverte....5528
RGE ? Boucle ferm?e ....5528
Refroidissement du d?bit de RGE....5528
Traitement postcombustion (AFT)....5529
Filtre ? particules diesel (DPF)....5530
Convertisseur catalytique d'oxydation diesel (DOC)....5530
?tats et r?ponses du syst?me postcombustion (AFT)....5530
Injection de carburant en aval....5531
Doseur d'injection en aval (DSI)....5532
Injecteur de carburant postcombustion (AFI)....5532
S?parateur d'huile du carter....5533
Syst?me de gestion du carburant....5535
Composants du circuit d'alimentation....5535
D?bit de carburant....5536
Circuit d'alimentation ? basse pression....5537
Filtre/s?parateur d'eau mont? sur le ch?ssis....5537
Ensemble de pompe d'amor?age du carburant....5538
Pompe ? carburant basse pression (LP)....5538
Ensemble de filtre de carburant....5538
Circuit d'alimentation haute pression....5539
Pompe haute pression (HP)....5541
Soupape de r?glage de pression carburant (FPCV)....5541
Rampe d'alimentation en carburant....5541
Capteur de pression de rampe de carburant (FRP)....5541
Soupape de d?charge de la rampe de carburant....5541
Injecteurs....5541
Dispositif de d?marrage ? froid....5541
Composants du dispositif de d?marrage ? froid....5541
Allumeur de carburant de d?marrage ? froid (CSFI)....5541
Relais de d?marrage ? froid (CSR)....5542
?lectrovalve d'alimentation de d?marrage ? froid (CSFS)....5542
Fonctionnement du dispositif de d?marrage ? froid....5542
Circulation d'huile et composants....5543
S?parateur d'huile du carter....5545
Filtre ? huile centrifuge distant (en option)....5546
Circuit de refroidissement du moteur....5547
D?bit de syst?me de refroidissement....5547
Fonctionnement du thermostat....5548
Fonctionnement de la soupape r?gulatrice de liquide de refroidissement (CCV)....5550
Soupape de d?bit de liquide de refroidissement (CFV)....5550
Soupape de m?langeur de refroidissement (CMV)....5550
Syst?me de freinage du moteur....5551
Composants du syst?me de commande de freinage du moteur....5551
Description du syst?me de freinage du moteur....5552
Fonctionnement du syst?me de frein moteur....5552
Syst?me de commande ?lectronique....5553
Composants du syst?me de commande ?lectronique....5553
Fonctionnement et fonction....5553
Tension de r?f?rence (Vref)....5553
Conditionneur de signaux....5553
Microprocesseur....5553
Codes d?anomalie....5553
M?moire du microprocesseur....5553
M?moire morte (ROM)....5553
RAM....5553
Commande d'actionneur....5555
Actionneurs....5555
Soupape r?gulatrice de liquide de refroidissement (CCV)....5555
Commande de la soupape de contre-pression ? l'?chappement (EBPV)....5555
Soupape de recirculation des gaz d'?chappement (RGE) ....5555
Soupape de r?gulation d'air (ACV)....5555
Relais de d?marrage ? froid (CSR)....5556
?lectrovalve d'alimentation de d?marrage ? froid (CSFS)....5557
Papillon des gaz (ETV)....5557
Soupape de r?glage de pression carburant (FPCV)....5557
Doseur de carburant postcombustion (AFTFD)....5558
Soupape d'arr?t de carburant postcombustion (AFTFSV)....5558
Capteurs du moteur et du v?hicule....5558
Capteurs ? thermistance....5558
Sondes de temp?rature post-traitement....5558
Capteurs de temp?rature du liquide de refroidissement du moteur (ECT)....5559
Capteur de temp?rature de l'huile du moteur (EOT)....5559
Capteur d'entr?e du compresseur de turbocompresseur 2 (TC2CIS)....5559
Capteur de temp?rature de sortie du refroidisseur d'air de suralimentation (CACOT)....5559
Sonde de temp?rature de la tubulure d'admission....5559
Capteur de temp?rature de recirculation des gaz d'?chappement (EGRT)....5559
Capteur de temp?rature de l'air ambiant (AAT)....5559
Capteurs ? capacit? variable....5560
Capteur de pression diff?rentielle DPF (DPFDP)....5560
Capteur de pression d'alimentation en carburant (FDP)....5560
Capteur de pression d'huile moteur (EOP)....5560
Capteur de pression de rampe de carburant (FRP)....5560
Capteur de pression du collecteur d'admission (IMP)....5560
Capteur d'admission de carburant postcombustion (AFTFIS) ....5561
Capteur de pression de carburant postcombustion 2 (AFTFP2)....5561
Pression de sortie de la turbine du turbocompresseur 1 (TC1TOP)....5561
Capteurs magn?tiques....5561
Capteur de position du vilebrequin (CKP)....5561
Capteur de position de l'arbre ? cames (CMP)....5562
Capteur de vitesse du v?hicule (VSS)....5562
Capteur de vitesse du s?parateur d'huile du carter (CCOSS)....5562
Capteurs ? potentiom?tre....5562
Position de p?dale d'acc?l?rateur (APP)....5562
Commutateurs....5563
Commutateur de d?sengagement de la transmission (DDS)....5563
Commutateur de niveau de liquide de refroidissement du moteur (ECL)....5563
Capteur de niveau d'huile (OLS)....5563
Capteurs suppl?mentaires....5563
Connecteur de sonde d'oxyg?ne (O2S)....5563
Capteur d'humidit? (HS)....5564
Table des Mati?res....5566
Fonctions de la commande ?lectronique standard....5568
Traitement postcombustion (AFT)....5568
Protection temps froid (CAP)....5568
Assistance de d?marrage ? froid....5568
Temp?rature de compensation du liquide de refroidissement (CTC)....5568
Plaque d'identification....5568
Compteur de vitesse et compte-tours ?lectroniques....5569
Neutralisation du d?marrage du moteur (ECI)....5569
Commande ?lectronique des r?gulateurs du moteur....5569
Commande du ventilateur (EFC)....5569
Syst?me de journalisation des ?v?nements ....5569
Avance au ralenti acc?l?r?....5569
Liaison de donn?es J1939 ....5570
Protection par mot de passe....5570
Diagnostics d'entretien....5570
Compte-rendu de voyage....5570
Configuration v?hicule....5570
Fonctions de la commande ?lectronique en option....5571
R?gulateur de vitesse....5571
R?compense du conducteur....5571
MaxxForce? Frein sur ?chappement....5571
Syst?me d'avertissement et de protection du moteur (EWPS)....5571
Protection de r?trogradation (GDP)....5572
Minuteur d'arr?t du ralenti (IST)....5572
Changement de vitesses progressif....5572
Prise de force (PTO) - De bord....5572
Prise de force (PTO) - ? distance....5572
Intervalle d'entretien....5574
Traction asservie....5574
T?moin de passage au rapport sup?rieur....5574
Limiteur de vitesse....5574
Table des Mati?res....5576
Fichiers de session....5578
Codes d?anomalie (DTC)....5578
Num?ro de param?tre suspect (SPN) ....5578
Voyant d'anomalie (FMI)....5578
En attente....5578
Activ?e....5578
Activ? pr?c?demment....5578
Donn?es d'image fig?e....5578
Fonctions programmables dans le module ECM ....5580
Connexion de l'EST avec le logiciel ServiceMaxx? au moteur....5580
Tests du poste de travail....5580
Essais Arr?t moteur....5580
Test d'actionneur....5580
Essai de surveillance continue....5580
Entretien du filtre ? particules diesel....5580
Test de compression relative....5581
Essais moteur EN MARCHE....5581
Essai d'injection d'air....5581
Essai de pompe haute pression....5582
Essai de coupure de cylindre....5583
Essai de propret? du filtre ? bord....5583
Proc?dures de l'appareil de diagnostic des pannes....5584
Proc?dures avec moteur coup?....5584
Assistance de d?marrage ? froid ....5584
?talonnage de la sonde d'oxyg?ne....5584
R?glage du d?bit d'injection....5584
Proc?dures de moteur en marche....5584
Ventilateur....5584
Table des Mati?res....5586
Circuit de refroidissement....5588
Perte de liquide de refroidissement....5588
Sympt?me....5588
Causes possibles....5588
Outils....5588
Proc?dure....5588
Trop-plein de liquide de refroidissement....5590
Sympt?me....5590
Causes possibles....5590
Outils....5590
Proc?dure....5590
Fuite de liquide de refroidissement dans l'?chappement....5592
SYMPT?MES....5592
Causes possibles....5592
Outils....5592
Inspection de fuite de liquide de refroidissement de l'injecteur de carburant postcombustion (AFI)....5593
Inspection de fuite au refroidisseur RGE....5593
Fuite de liquide de refroidissement dans le carburant ....5594
Sympt?me....5594
Causes possibles....5594
Outils....5594
Proc?dure....5594
Fuite de liquide de refroidissement dans le collecteur d'admission....5595
Sympt?me....5595
Causes possibles....5595
Outils....5595
Proc?dure....5595
Fuite de liquide de refroidissement dans l'huile de lubrification....5596
Sympt?me....5596
Causes possibles....5596
Outils....5596
Inspection de contamination de l'huile de lubrification....5596
Test d'?tanch?it? de la culasse....5597
Proc?dure....5597
Surchauffe du liquide de refroidissement....5598
Sympt?me....5598
Causes possibles....5598
Outils....5598
Inspection des conditions de surchauffe du liquide de refroidissement....5598
Surchauffe du liquide de refroidissement ? refroidissement du moteur....5600
Proc?dure....5600
Composants du circuit de refroidissement....5602
D?bit de syst?me de refroidissement....5603
Fonctionnement du thermostat....5603
Fonctionnement de la soupape r?gulatrice de liquide de refroidissement (CCV) et de la soupape de m?lange du liquide de refroidissement (CMV)....5604
Fonctionnement de la soupape de m?lange du liquide de refroidissement (CMV)....5605
Proc?dure....5605
Circuit de graissage....5608
Inspection visuelle du niveau d'huile....5608
Entretien incorrect ....5608
Dilution du liquide de refroidissement....5608
Fuite de liquide de direction assist?e dans l'huile de lubrification....5608
Sympt?me....5608
Causes possibles....5608
Proc?dure....5608
Pr?sence d'huile de lubrification dans le liquide de refroidissement....5609
Sympt?me....5609
Causes possibles....5609
Outils....5609
Proc?dure....5609
Pr?sence d'huile de lubrification dans l'admission....5609
Sympt?me....5609
Causes possibles....5609
Proc?dure....5609
Pr?sence d'huile de lubrification dans l'?chappement....5610
Sympt?me....5610
Causes possibles....5610
Proc?dure....5610
Basse pression d?huile....5611
Sympt?me....5611
Causes possibles....5611
Outils....5611
Proc?dure....5612
Circuit d'alimentation....5615
Consommation de carburant excessive....5615
Sympt?me....5615
Causes possibles....5615
Cons?quences de l'action de l'op?rateur....5615
Effets de l'application....5615
Effets du ch?ssis....5615
Effets du moteur....5615
Proc?dure....5615
Pr?sence de carburant dans le liquide de refroidissement....5616
Sympt?me....5616
Causes possibles....5616
Outils....5616
Proc?dure....5616
Pr?sence de carburant dans l'huile de lubrification....5617
Sympt?me....5617
Causes possibles....5617
Outils....5617
Proc?dure....5617
Carburant dans l'admission....5618
Sympt?me....5618
Causes possibles....5618
Proc?dure....5618
Carburant dans l'?chappement....5618
Sympt?me....5618
Causes possibles....5618
Outils....5618
Proc?dure....5618
Pression du carburant et a?ration....5619
Sympt?me....5619
CAUSES POSSIBLES....5619
Proc?dure....5619
Eau dans le carburant....5619
SYMPT?MES....5619
Causes possibles....5619
Outils....5619
Proc?dure....5619
Amor?age du circuit d'alimentation en carburant....5621
Proc?dure....5621
Syst?me de freinage du moteur....5623
Inspection du frein moteur....5623
Sympt?me....5623
Causes possibles....5623
Outils....5623
?tapes pr?liminaires....5623
Le frein moteur ne s'active pas/met longtemps ? s'activer....5624
Le frein moteur ne s'?teint pas/met longtemps ? s'?teindre....5625
?chec du d?marrage du moteur....5625
Frein moteur peu efficace/peu puissant....5625
Frein moteur lent ? fonctionner ou tr?s faible....5625
Chute de la pression d'huile en dessous du minimum requis pour le fonctionnement du frein moteur....5627
Un ou plusieurs cylindres ne parviennent pas ? arr?ter de freiner, ou calage du moteur....5627
Rat?s ou perte de puissance du moteur....5627
Table des Mati?res....5628
Formulaire de diagnostic EGED-475....5630
Renseignements sur le v?hicule et page de plainte du formulaire de diagnostic....5631
Instructions sur les essais obligatoires....5632
1. V?rification initiale, cl? de contact en position de marche....5633
Fonction....5633
Outils....5633
Proc?dure....5633
2. Inspection visuelle....5633
Fonction....5633
Outils....5633
Huile-moteur....5633
Niveau du liquide de refroidissement....5634
Syst?me ?lectrique....5634
Air d?admission....5634
Syst?me de refroidisseur d'air de suralimentation (CAC)....5634
Syst?me d'?chappement....5634
R?servoirs d'air comprim?....5634
Niveau de carburant....5634
Acheminement et ?tat des conduites de carburant....5635
Inspection du filtre ? carburant principal....5635
V?rification de la qualit? du carburant....5637
Fonction....5637
Outils....5637
Proc?dure....5637
3. Branchement de l'appareil ?lectronique de diagnostic des pannes (EST) et enregistrement de donn?es....5638
Fonction....5638
Outils....5638
Proc?dure....5638
4. V?rifier les codes d'anomalie (DTC)....5641
Fonction....5641
Outils....5641
Proc?dure....5641
5. D?marrage du moteur....5642
Fonction....5642
Outils....5642
Proc?dure....5642
Proc?dures d'essai sp?ciales....5644
Circuit d'alimentation....5644
Circuit d'alimentation ? basse pression....5645
Amor?age du circuit d'alimentation en carburant....5646
Fonction....5646
Outils....5646
Proc?dure....5646
Essai de pression d'alimentation en carburant (FDP)....5647
Fonction....5647
Outils....5647
Proc?dure....5647
Test de blocage du carburant....5649
Fonction....5649
Outils....5649
Proc?dure....5649
Test d'a?ration de carburant....5650
Fonction....5651
Outils....5651
Proc?dure....5651
Point d'essai d'a?ration 1....5651
Point d'essai d'a?ration 2....5651
Essai de restriction de carburant....5652
Fonction....5653
Outils....5653
Proc?dure....5653
Point d'essai de restriction 1....5653
Point d'essai de restriction 2....5653
Point d'essai de restriction 3....5653
Circuit d'alimentation haute pression....5654
Test du circuit de pression de rampe d'alimentation (FRP)....5654
Fonction....5654
Outils....5654
Proc?dure....5654
Essai de pression de l'entr?e de la pompe haute pression....5655
Fonction....5655
Outils....5655
Proc?dure....5655
Test de d?bit de retour de pression de la rampe d'alimentation en carburant (FRP)....5656
Fonction....5656
Outils....5656
Proc?dure....5656
Isolation de fuite de pression de la rampe d'alimentation en carburant (FRP)....5657
Fonction....5657
Outils....5657
Proc?dure....5657
un essai de pression de retour de carburant de pompe HP....5658
Fonction....5658
Outils....5658
Proc?dure....5658
Test de d?bit de retour de la pompe HP....5658
Fonction....5658
Outils....5658
Proc?dure....5658
Dispositif de d?marrage ? froid....5660
Essai du dispositif de d?marrage ? froid....5660
Fonction....5660
Outils....5660
Proc?dure....5660
Test de l'allumeur de carburant de d?marrage ? froid (CSFI)....5661
Fonction....5661
Outils....5661
Proc?dure....5661
Test de sol?no?de de carburant de d?marrage ? froid (CSFS) au niveau du circuit d'alimentation....5662
Fonction....5662
Outils....5662
Proc?dure....5662
Test de l'allumeur de carburant de d?marrage ? froid (CSFI) au niveau du circuit d'alimentation....5663
Fonction....5663
Outils....5663
Proc?dure....5663
Table des Mati?res....5664
Formulaire de diagnostic EGED-530....5666
Renseignements sur le v?hicule et page de plainte du formulaire de diagnostic....5667
Instructions sur les essais obligatoires....5668
1. V?rification initiale, cl? de contact en position de marche....5668
Fonction....5668
Outils....5668
Proc?dure....5668
2. Inspection visuelle....5668
Fonction....5668
Outils....5668
Huile-moteur....5669
Niveau du liquide de refroidissement....5669
Syst?me ?lectrique....5669
Air d?admission....5671
Syst?me de refroidisseur d'air de suralimentation (CAC)....5671
Syst?me d'?chappement....5671
R?servoirs d'air du v?hicule....5671
Niveau de carburant....5671
Inspection du filtre ? carburant principal....5671
V?rification de la qualit? du carburant....5673
Fonction....5673
Outils....5673
Proc?dure....5673
3. Branchement de l'appareil ?lectronique de diagnostic des pannes (EST) et enregistrement de donn?es....5674
Fonction....5674
Outils....5674
Proc?dure....5674
4. V?rifier les codes d'anomalie (DTC)....5677
Fonction....5677
Outils....5677
Proc?dure....5677
5. Grand ralenti ? ralenti acc?l?r?....5678
Fonction....5678
Outils....5678
Proc?dure....5678
6. Essai de gestion d'air KOER....5680
Fonction....5680
Outils....5680
Proc?dure....5680
7. Test sur route (pleine charge ? vitesse sur autoroute)....5680
Fonction....5680
Outils....5680
Proc?dure....5680
Proc?dures d'essai sp?ciales....5682
Tests de soupape de r?gulation d'air (ACV)....5682
Fonction....5682
Outils....5682
Clapet de contre-pression d'?chappement (EBPV) ....5682
R?gulateur de soupape de d?charge du turbocompresseur 2 (TC2WC)....5684
Circuit d'alimentation....5685
Circuit d'alimentation ? basse pression....5686
Essai de pression d'alimentation en carburant (FDP)....5687
Fonction....5687
Outils....5687
Proc?dure....5687
Test de blocage du carburant....5689
Fonction....5689
Outils....5689
Proc?dure....5689
Essais de restriction et d'a?ration du carburant....5690
Essai d'a?ration....5690
Fonction....5691
Outils....5691
Point d'essai d'a?ration 1....5691
Proc?dure....5691
Point d'essai d'a?ration 2....5691
Essai d'obstruction....5692
Fonction....5693
Outils....5693
Proc?dure....5693
Point d'essai 1....5693
Point d'essai 2....5693
Point d'essai 3....5693
Circuit d'alimentation haute pression....5694
Essai de pression de l'entr?e de la pompe haute pression....5695
Fonction....5695
Outils....5695
Proc?dure....5695
Test de d?bit de retour de pression de la rampe d'alimentation en carburant (FRP)....5696
Fonction....5696
Outils....5696
Proc?dure....5696
Isolation de fuite de pression de la rampe d'alimentation en carburant (FRP)....5697
Fonction....5697
Outils....5697
Proc?dure....5697
un essai de pression de retour de carburant de pompe HP....5698
Fonction....5698
Outils....5698
Proc?dure....5698
Test du s?parateur du reniflard d'huile du carter moteur....5699
Fonction....5699
Outils....5699
Proc?dure....5699
Essai de pression du carter moteur....5699
Fonction....5699
Outils....5699
Proc?dure....5700
Essai de performances de cylindre ? ?tape 1....5702
Test de compression relative....5702
Fonction....5702
Outils....5702
Proc?dure....5702
Causes possibles....5702
Essai de performances de cylindre ? ?tape 2....5703
Essai de coupure de cylindre....5703
Fonction....5703
Outils....5703
Causes possibles....5703
Proc?dure....5703
Remplacement de l'injecteur....5704
Fonction....5704
Outils....5704
Proc?dure....5704
Essai de la soupape de r?gulation de pression de carburant (FPCV)....5705
Fonction....5705
Outils....5705
Proc?dure....5705
Test de pression du refroidisseur d'air de suralimentation....5705
Proc?dure....5705
Table des Mati?res....5706
Comment utiliser cette section....5708
Emplacement de la page de diagnostic et des codes d'anomalie....5708
Formulaire de diagnostic EGED-500 Utilisation....5719
Exemple de formulaire de diagnostic ....5719
Description du syst?me HD-OBD....5720
Processus de diagnostic avec exemples....5724
Inspection des logements de broches....5724
Diagnostic de circuit....5730
Capteur AAT (temp?rature d'air ambiant)....5730
Outils requis....5730
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5731
Syst?me de traitement postcombustion AFT....5733
Vue d'ensemble....5740
Outils requis....5740
SPN 3251 FMI 0 ? DPFDP excessivement ?LEV?E (filtre bouch?)....5746
Aper?u du code d'anomalie....5746
R?action du t?moin d'anomalie....5746
Codes d'anomalie associ?s....5746
Cycle de conduite pour d?terminer l'?tat de l'anomalie....5746
SPN 3251 FMI 21 ? DPFDP excessivement BASSE (d?faillance du capteur/circuit ou DPF manquant)....5754
Aper?u du code d'anomalie....5754
R?action du t?moin d'anomalie....5754
Codes d'anomalie associ?s....5754
Cycle de conduite pour d?terminer l'?tat de l'anomalie....5754
SPN 3471 FMI 1 ? pression de carburant 1 inf?rieure ? la valeur voulue....5758
Aper?u du code d'anomalie....5758
R?action du t?moin d'anomalie....5758
Codes d'anomalie associ?s....5758
Cycle de conduite pour d?terminer l'?tat de l'anomalie....5758
SPN 3471 FMI 7 ? la soupape de dosage de carburant ne r?pond pas de la mani?re attendue....5765
Aper?u du code d'anomalie....5765
R?action du t?moin d'anomalie....5765
Codes d'anomalie associ?s....5765
Cycle de conduite pour d?terminer l'?tat de l'anomalie....5765
SPN 3719 FMI 0 ? charge de suie du DPF - la plus ?lev?e (niveau 3/3)....5772
Aper?u du code d'anomalie....5772
R?action du t?moin d'anomalie....5772
Codes d'anomalie associ?s....5772
Cycle de conduite pour d?terminer l'?tat de l'anomalie....5772
SPN 3720 FMI 0 - charge de cendres du DPF ? la limite maximale....5779
Aper?u du code d'anomalie....5779
R?action du t?moin d'anomalie....5779
Codes d'anomalie associ?s....5779
Cycle de conduite pour d?terminer l'?tat de l'anomalie....5779
SPN 5298 FMI 2 -Efficacit? r?duite du DOC - d?tar?....5785
Aper?u du code d'anomalie....5785
R?action du t?moin d'anomalie....5785
Codes d'anomalie associ?s....5785
Cycle de conduite pour d?terminer l'?tat de l'anomalie....5785
T?moins du syst?me AFT....5792
Inhibiteurs de r?g?n?ration....5798
Entr?e DPF normale....5803
Sortie DPF normale....5804
Entr?e DPF bouch?e....5805
DPF contamin? par du liquide refroidissement....5806
DPF contamin? par de l'huile....5807
Fuite de suie au niveau de la sortie du DPF....5808
D?g?ts externes sur le DPF....5810
Mesure de la brique du filtre c?ramique DPF....5811
AFTFD (doseur de carburant postcombustion)....5812
Outils requis....5813
AFTFIS (capteur d'entr?e de carburant postcombustion)....5815
Outils requis....5816
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5816
Capteur 2 de pression de carburant postcombustion (AFTFP2)....5819
Outils requis....5820
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5820
Soupape d'arr?t de carburant postcombustion (AFTFSV)....5823
Outils requis....5824
AMS (syst?me de gestion de l'air)....5827
Outils requis....5830
SPN 2659 FMI 20 - fort d?bit de RGE d?tect?....5833
Aper?u du code d'anomalie....5833
R?action du t?moin d'anomalie....5833
Codes d'anomalie associ?s....5833
Cycle de conduite pour d?terminer l'?tat de l'anomalie....5834
Capteur APP (position de la p?dale d'acc?l?ration)....5837
Vue d'ensemble....5838
Outils requis....5838
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5839
Capteur CACOT (temp?rature de sortie du refroidisseur d'air de suralimentation)....5843
Outils requis....5843
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5844
Capteur CCOSS (vitesse du s?parateur d'huile du carter)....5846
Outils requis....5846
Rep?rez le s?parateur d'huile du carter de vilebrequin?: D?faut de rotation....5846
CCS (r?gulateur de vitesse)....5848
Fonction....5848
Fonctionnement du r?gulateur (CCS)....5848
Diagnostics de rep?rage du r?gulateur automatique de vitesse (CCS) - avec le logiciel ServiceMaxx?....5848
CFV (soupape de d?bit de liquide de refroidissement)....5849
Capteur CKP (position du vilebrequin)....5852
Outils requis....5852
Capteur CMP (position de l'arbre ? cames)....5854
Outils requis....5854
CMV (soupape de m?lange de liquide de refroidissement)....5856
Outils requis....5856
CSFI (allumeur de carburant de d?marrage ? froid)....5858
Outils requis....5859
CSFS (?lectrovanne de carburant de d?marrage ? froid)....5865
Outils requis....5865
?quilibrage de cylindre....5868
Outils requis....5869
Fonctionnement de l'?quilibrage de cylindre....5869
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5870
Capteur DOCIT (temp?rature d'entr?e du convertisseur catalytique d'oxydation diesel)....5871
Outils requis....5871
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5872
Capteur DOCOT (temp?rature de sortie du convertisseur catalytique d'oxydation diesel)....5874
Outils requis....5874
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5875
Capteur DPFDP (pression diff?rentielle du filtre ? particules diesel)....5877
Outils requis....5877
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5878
Capteur DPFOT (temp?rature de sortie du filtre ? particules diesel)....5881
Outils requis....5881
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5882
Syst?me de DPF (filtre ? particules diesel)....5884
Outils requis....5885
SPN 3936 FMI 10 - le mode de gestion thermique du DPF n'a pas augment? la temp?rature ? l'entr?e du DOC tel que pr?vu....5886
Aper?u du code d'anomalie....5886
R?action du t?moin d'anomalie....5886
Codes d'anomalie associ?s....5886
Cycle de conduite pour d?terminer l'?tat de l'anomalie....5886
SPN 3936 FMI 20 - fr?quence ?lev?e de r?g?n?ration....5891
Aper?u du code d'anomalie....5891
R?action du t?moin d'anomalie....5891
Codes d'anomalie associ?s....5891
Cycle de conduite pour d?terminer l'?tat de l'anomalie....5891
EBPV (soupape de contre-pression ? l'?chappement)....5899
Outils requis....5899
ECB1 (frein moteur par compression 1)....5902
Outils requis....5902
ECB2 (frein moteur par compression 2)....5905
Outils requis....5905
Commutateur ECL (niveau de liquide de refroidissement)....5908
Outils requis....5908
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5908
Alimentation du module ECM (module de commande du moteur)....5910
Outils requis....5910
Sortie de puissance du module ECM (module de commande du moteur)....5913
Outils requis....5913
Autodiagnostics de l'ECM (Module de commande du moteur)....5918
Outils requis....5918
Proc?dure de r?apprentissage du capteur de position du vilebrequin....5920
Outils requis....5920
Fonction....5920
ECS (syst?me de refroidissement)....5921
Outils requis....5921
Capteur ECT1 (temp?rature du liquide de refroidissement moteur 1)....5923
Outils requis....5923
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5923
Capteur ECT2 (temp?rature du liquide de refroidissement moteur 2)....5926
Outils requis....5926
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5926
Commande de ventilateur de moteur (EFC) ? deux vitesses et variable....5929
Outils requis....5930
Fonction deux vitesses de l'EFC....5930
Fonction variable de l'EFC....5930
EFC ? fonctionnement du circuit du capteur deux vitesses....5930
EFC ? fonctionnement du circuit du capteur variable....5930
Capteur TRGE (temp?rature de recirculation des gaz d'?chappement)....5932
Outils requis....5932
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5933
Soupape RGE (recirculation des gaz d'?chappement)....5935
Outils requis....5936
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5936
Contr?leur du syst?me de recirculation des gaz d'?chappement (RGE)....5939
Outils requis....5939
SPN 3058 FMI 0 - le moteur n'a pas pass? au contr?le de RGE en boucle ouverte lorsque pr?vu....5940
Aper?u du code d'anomalie....5940
R?action du t?moin d'anomalie....5940
Codes d'anomalie associ?s....5940
SPN 3058 FMI 10 - le moteur n'a pas pass? au contr?le de RGE en boucle ferm?e lorsque pr?vu....5943
Aper?u du code d'anomalie....5943
R?action du t?moin d'anomalie....5943
Codes d'anomalie associ?s....5943
Capteur EOL (niveau d'huile moteur)....5946
Outils requis....5946
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5947
Capteur EOP (pression d'huile moteur)....5950
Outils requis....5950
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5950
Capteur EOT (temp?rature d'huile moteur)....5953
Outils requis....5953
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5953
ETV (papillon des gaz)....5956
Outils requis....5956
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5957
EWPS (syst?me d'avertissement de protection du moteur) ....5959
Fonction....5961
Param?tres programmables EWPS....5961
Outils requis....5962
Capteur FDP (pression d'alimentation en carburant)....5963
Outils requis....5963
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5964
FPCV (soupape de r?gulation de la pression de carburant)....5967
Outils requis....5967
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5967
Capteur FRP (pression de la rampe d'alimentation)....5970
Vue d'ensemble....5972
Outils requis....5972
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5973
SPN 157 FMI 20 - d?rive vers le HAUT du signal du capteur FRP....5976
Aper?u du code d'anomalie....5976
R?action du t?moin d'anomalie....5976
Codes d'anomalie associ?s....5976
Cycle de conduite....5976
SPN 157 FMI 21 - d?rive vers le BAS du signal du capteur FRP....5979
Aper?u du code d'anomalie....5979
R?action du t?moin d'anomalie....5979
Codes d'anomalie associ?s....5979
Cycle de conduite....5979
Syst?me FRP (pression de la rampe d'alimentation en carburant)....5982
Outils requis....5982
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5983
Contr?le de frein dur....5985
HS (capteur d'humidit?) / AIT (capteur de temp?rature d'air d'admission)....5986
Outils requis....5986
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5987
IMP (pression du collecteur d'admission)....5990
Vue d'ensemble....5991
Outils requis....5991
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....5992
SPN 102 - FMI 10 IMP - r?action lente de la suralimentation....5995
R?action du t?moin d'anomalie....5995
Codes d'anomalie associ?s....5995
Cycle de conduite....5995
Capteur IMT (temp?rature du collecteur d'admission)....6001
Outils requis....6001
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....6001
Circuits INJ (injecteur)....6004
Outils requis....6005
Syst?me IST (temporisateur de coupure du moteur, faible ralenti)....6012
IST (grand ralenti propre)....6012
Syst?me IST (temporisateur de coupure du moteur, f?d?ral/en option)....6013
Fonctionnement du circuit de capteur IST (f?d?ral?- facultatif)....6013
Communications de la liaison de donn?es J1939....6014
Outils requis....6014
Capteur MAF (d?bit d'air massique)....6017
Fonction....6017
MIL (t?moin d'anomalie)....6018
O2S (sonde d'oxyg?ne)....6019
Outils requis....6021
Fonction....6021
Fonctionnement du circuit de la sonde O2S....6021
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....6022
Messages p?riodiques d'entretien....6026
Fonctionnement des messages d'intervalle d'entretien....6026
Horloge autonome en temps r?el (SART)....6027
Outils requis....6027
Capteur TC1TOP (pression de sortie de la turbine du turbocompresseur 1)....6029
Outils requis....6029
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....6029
TC1WC (commande de la soupape de d?charge du turbocompresseur 1)....6033
Outils requis....6033
TC2WC (commande de la soupape de d?charge du turbocompresseur 2)....6036
Outils requis....6036
TC2CIS (capteur d'entr?e du compresseur 2 du turbocompresseur)....6039
Outils requis....6039
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....6040
Capteur de TOSS / VSS (vitesse de l'arbre de sortie de la transmission / capteur de vitesse du v?hicule)....6043
Vue d'ensemble....6045
Outils requis....6045
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....6046
SPN 191 FMI 1 TOSS / VSS non d?tect? lorsque le v?hicule se d?place....6048
R?action du t?moin d'anomalie....6049
Cycle de conduite pour d?terminer l'?tat de l'anomalie....6049
VREF (tension de r?f?rence)....6053
Outils requis....6054
Capteur WIF (eau dans le carburant)....6063
Outils requis....6063
Diagnostics de rep?rage avec le logiciel ServiceMaxx?....6064
WIFL (t?moin d'eau dans le carburant)....6066
Vue d'ensemble....6066
Outils requis....6066
SPN 97 - FMI 3 - WIFL court-circuit? ? l'alimentation....6067
SPN 97 - FMI 4 - WIFL court-circuit? ? la masse....6069
SPN 97 - FMI 5 - WIFL ouvert / circuit de charge....6071
WTSL (t?moin Attendre avant de d?marrer)....6073
Vue d'ensemble....6073
Outils requis....6074
SPN 1081 - FMI 3 - Circuit WIFL court-circuit? ? l'alimentation....6075
R?action du t?moin d'anomalie....6075
SPN 1081 - FMI 4 - Circuit WTSL court-circuit? ? la masse....6077
R?action du t?moin d'anomalie....6077
SPN 1081 - FMI 5 - WTSL, circuit / charge ouvert(e)....6079
R?action du t?moin d'anomalie....6079
Emplacement du capteur et de l'actionneur....6081
Composants mont?s sur le moteur....6081
Syst?me AFT....6083
Emplacement du frein moteur par compression....6084
Composants mont?s sur le v?hicule....6085
Capteur de temp?rature d'air ambiant....6085
Table des Mati?res....6086
Outils ?lectriques....6088
Bo?te de d?rivation ? 180 broches....6088
Faisceau ? 3 fiches banane....6088
Faisceau de r?sistance 500 ohms....6089
Trousse de sonde d'essai de bornes Big Bore....6089
Multim?tre num?rique (DMM)....6089
EXP-1000 HD par Midtronics....6090
EZ-Tech? Appareil ?lectronique de diagnostic des pannes (EST)....6090
Logiciel ServiceMaxx?....6090
Trousse ? outil pour moteurs MaxxForce? 11 et 13....6091
Kit d'interface NAVCoM....6091
Faisceau de d?rivation 4485A (APP)....6091
Faisceau de d?rivation 4602 (AFTFSV)....6092
Faisceau de d?rivation 4735A (O2S)....6092
Faisceau de d?rivation 4760A (DOCIT, DOCOT, DPFOT et TRGE)....6092
Faisceau de d?rivation 4761A (DPFDP)....6092
Faisceau de d?rivation 4827 (CSFS, ECT1, ECT2, EOL et EOT)....6093
Faisceau de d?rivation 4828 (AFTFD et FPCV)....6093
Faisceau de d?rivation 4829 (FRP)....6093
Faisceau de d?rivation 4830 (AFTFIS, HS/AIT et TC2CIS)....6093
Faisceau de d?rivation 4844 (EFAN)....6094
Faisceau de d?rivation 4850 (IMP)....6094
Faisceau de d?rivation 4870 (CMV)....6094
Faisceau de d?rivation 4871 (AAT et CFV)....6094
Faisceau de d?rivation 4881 (FDP)....6095
Faisceau de d?rivation 4882 (EOP)....6095
Faisceau de d?rivation 4883 (IMT)....6095
Faisceau de d?rivation 4885 (CSR)....6095
Faisceau de d?rivation 4951 (CCOSS)....6096
Faisceau de d?rivation 4993 (CACOT)....6096
Faisceau de d?rivation 6002 (WIF)....6096
Faisceau de d?rivation 6003 (EBPV, TC1TOP, TC1WC et TC2WC)....6096
Faisceau de d?rivation 6004 (ECB)....6097
Faisceau de d?rivation 6016 (ETV et soupape RGE)....6097
Faisceau de d?rivation 6021 (CKP et CMP)....6097
Faisceau de d?rivation 6027 (AFTFP2)....6097
Outils m?caniques....6098
Bouchons d'air/carburant et trousse de connexions....6098
Outil de d?gagement de conduite de liquide de refroidissement du compresseur....6098
Garde d'entr?e d'air....6098
Outil d'essai de fuite des gaz....6099
Outil de source d'alimentation de carburant propre....6099
Trousse d'adaptateurs de sol?no?de de d?marrage ? froid....6100
Manom?tre num?rique....6100
Trousse de d?tection de fuite de refroidisseur RGE....6101
Trousse de frein moteur....6101
Outil de blocage de carburant....6101
Coupelles d'injecteurs de carburant....6101
Outil d'a?ration et de limite d'admission de carburant....6102
Coupleur de conduite de carburant....6102
Outil de d?connexion de ligne de carburant 11,8 mm....6102
Outil de d?connexion de ligne de carburant 16 mm....6102
Manom?tre ? carburant....6103
Bouchons pour rampe haute pression....6103
Testeur de conduite de retour haute pression....6103
Trousse d'essai de pression....6104
Trousse d'essai de pression de radiateur....6105
Manom?tre Slack Tube? Manom?tre....6105
Trousse de d?tection de fuites UV....6106
Analyseur de vide et appareil de v?rification de pompe ? carburant....6107
Table des Mati?res....6108
Abr?viations et acronymes....6110
Abr?viations et acronymes....6110
Table des Mati?res....6116
Terminologie....6118
Termes....6118
Table des Mati?res....6128
Toutes les caract?ristiques nominales....6130
MaxxForce? 11 (10,5?L)....6136
330 ch ? 1700 tr/min....6136
370 ch ? 1700 tr/min....6137
390 ch ? 1700 tr/min....6138
MaxxForce? 13 (12,4?L)....6139
410 ch ? 1700 tr/min....6139
430 ch ? 1700 tr/min....6140
475 ch ? 1700 tr/min....6141
Table des Mati?res....6142
Valeurs de signal....6144
Table des Mati?res....6152
Description....6154
tables....5504
Document d'entretien technique....5504
MaxxForce? 11 et 13....5511
Sp?cifications du sol?no?de du frein moteur....5624
Sp?cifications de pression d'huile de frein moteur....5627
D?bit de retour de carburant normal avec le nombre d'injecteurs connect?s....5697
Exemple....5726
Exemple....5727
Exemple....5728
Exemple....5729
SPN 171 FMI 2 ? le signal AAT est en d?saccord avec les autres capteurs....5731
V?rification du circuit du capteur avec le logiciel ServiceMaxx?....5732
V?rification de la tension du connecteur sans utiliser le logiciel ServiceMaxx?....5732
V?rification de la r?sistance du faisceau de c?bles....5732
SPN 3251 FMI 14 ? flexibles de pression du capteur DPFDP invers?s....5741
SPN 3480 FMI 0 ? AFTFP1 trop ?lev?e lors du dosage....5741
SPN 3480 FMI 1 ? AFTFP1 trop basse lors du dosage....5741
SPN 3481 FMI 7 ? pression de dosage incorrecte, ?v?nements multiples....5742
SPN 3556 FMI 0 ? pression de carburant AFT 2 excessivement haute....5742
SPN 3556 FMI 1 ? pression de carburant AFT 2 inf?rieure ? la valeur voulue....5742
SPN 3556 FMI 7 ? l'injecteur de carburant AFT ne r?pond pas de la mani?re attendue....5742
SPN 3719 FMI 15 ? charge de suie du DPF - la plus faible (niveau 1/3)....5743
SPN 3719 FMI 16 ? charge de suie du DPF - moyenne (niveau 2/3)....5743
SPN 4077 FMI 0 ? AFTFP2 trop ?lev?e lors du dosage....5743
SPN 4077 FMI 1 ? AFTFP2 trop basse lors du dosage....5743
SPN 4766 FMI 10 ? d?faillance de r?troaction de r?g?n?ration DPF....5744
SPN 4766 FMI 20 ? temp?rature de sortie du DOC sup?rieure au maximum voulu....5744
SPN 4766 FMI 21 - temp?rature de sortie du DOC inf?rieure au minimum voulu....5744
SPN 5319 FMI 31 ? r?g?n?ration incompl?te du DPF....5745
Conditions pour le d?marrage d'une r?g?n?ration sur route....5794
Conditions pour le d?marrage d'une r?g?n?ration en stationnement....5795
V?rifications de comparaison des capteurs....5797
Test d'obstruction d'?chappement....5797
V?rifier les inhibiteurs de r?g?n?ration sur route....5799
V?rifier les inhibiteurs de r?g?n?ration en stationnement....5800
V?rifications de r?g?n?ration en stationnement....5802
V?rification de tension du connecteur ? AFTFD d?connect?....5813
V?rification de la tension de fonctionnement....5814
V?rification de la r?sistance de l'actionneur....5814
V?rification de la r?sistance du faisceau de c?bles....5814
V?rification du circuit du capteur....5817
Diagnostics de rep?rage sans le logiciel ServiceMaxx?....5817
V?rification de la r?sistance du faisceau de c?bles....5818
V?rification du circuit du capteur....5821
Diagnostics de rep?rage sans le logiciel ServiceMaxx?....5821
V?rification de la r?sistance du faisceau de c?bles....5822
V?rification de tension du connecteur ? AFTFSV d?connect?....5825
V?rification de la tension de fonctionnement....5825
V?rification de la r?sistance de l'actionneur....5826
V?rification de la r?sistance du faisceau de c?bles....5826
SPN 102 FMI 16 ? surpression dans le collecteur d'admission ....5830
SPN 102 FMI 18 ? souspression dans le collecteur d'admission....5831
SPN 1173 FMI 16 ? signal de temp?rature d'admission du convertisseur du turbocompresseur TC2CIT sup?rieur ? la valeur voulue (....5831
SPN 2630 FMI 16 ? sous-refroidissement du capteur de temp?rature de sortie de refroidisseur d'air de suralimentation (CACOT)....5832
SPN 2659 FMI 21 ? faible d?bit de RGE d?tect?....5832
V?rification du circuit du capteur....5840
Diagnostics de rep?rage sans le logiciel ServiceMaxx?....5841
V?rification de la r?sistance du faisceau de c?bles....5841
V?rification de la tension de fonctionnement....5842
SPN 2630 FMI 2 ? le signal CACOT est en d?saccord avec les autres capteurs....5844
V?rification du circuit du capteur avec le logiciel ServiceMaxx?....5845
V?rification de la tension du connecteur sans utiliser le logiciel ServiceMaxx?....5845
V?rification de la r?sistance du faisceau de c?bles....5845
V?rification de la r?sistance du capteur....5847
V?rification de la tension du connecteur sans le logiciel ServiceMaxx?....5847
V?rification de la r?sistance du faisceau de c?bles....5847
Param?tres programmables....5848
V?rifications de commutateur....5849
V?rification de la tension du connecteur....5850
V?rification de la tension de fonctionnement....5850
V?rification de la r?sistance de l'actionneur....5851
V?rification de la r?sistance du faisceau de c?bles....5851
V?rification de la r?sistance du capteur....5852
V?rification de la r?sistance du faisceau de c?bles....5853
V?rifications de fonctionnement....5853
V?rification de la r?sistance du capteur....5854
V?rification de la r?sistance du faisceau de c?bles....5855
V?rifications de fonctionnement....5855
SPN 636 FMI 2 ? erreur de synchronisation CMP et CKP....5855
V?rification de la tension du connecteur....5857
V?rification de la tension de fonctionnement....5857
V?rification de la r?sistance de l'actionneur....5857
V?rification de la r?sistance du faisceau de c?bles....5858
V?rification par comparaison de capteur apr?s impr?gnation ? froid avec le logiciel ServiceMaxx?....5860
SPN 626 FMI 18 ? panne du dispositif de d?marrage ? froid Manque de chaleur dans la tubulure d'admission ....5860
V?rification de tension de CSFI - Test de l'actionneur....5860
V?rification de l'intensit? pr?lev?e - Test de l'actionneur....5861
V?rifications de tension sur le connecteur du relais....5861
V?rifications de tension sur le relais - test de l'actionneur....5862
V?rification de r?sistance CSFI....5864
V?rification de la r?sistance du faisceau de c?bles....5864
V?rification de tension du connecteur ? CSFS d?connect?....5866
V?rification de la tension de fonctionnement....5866
V?rification de la r?sistance de l'actionneur....5866
V?rification de la r?sistance du faisceau de c?bles....5867
SPN 4765 FMI 2 ? le signal DOCIT est en d?saccord avec les autres capteurs d'?chappement....5872
V?rification du circuit du capteur avec le logiciel ServiceMaxx?....5873
V?rification de la tension du connecteur sans utiliser le logiciel ServiceMaxx?....5873
V?rification de la r?sistance du faisceau de c?bles....5873
SPN 4766 FMI 2 ? le signal DOCOT est en d?saccord avec les autres capteurs d'?chappement....5875
V?rification du circuit du capteur avec le logiciel ServiceMaxx?....5876
V?rification de la tension du connecteur sans utiliser le logiciel ServiceMaxx?....5876
V?rification de la r?sistance du faisceau de c?bles....5876
SPN 3251 FMI 2 ? DPFDP sup?rieure ou inf?rieure au niveau voulu....5878
V?rification du circuit du capteur avec le logiciel ServiceMaxx?....5879
V?rification de la tension du connecteur sans utiliser le logiciel ServiceMaxx?....5879
V?rification de la r?sistance du faisceau de c?bles....5880
SPN 3246 FMI 2 ? le signal DPFOT est en d?saccord avec les autres capteurs d'?chappement....5882
V?rification du circuit du capteur avec le logiciel ServiceMaxx?....5883
V?rification de la tension du connecteur sans utiliser le logiciel ServiceMaxx?....5883
V?rification de la r?sistance du faisceau de c?bles....5883
V?rification de tension du connecteur ? EBVP d?connect?....5900
V?rification de la tension de fonctionnement....5900
V?rification de la r?sistance de l'actionneur....5900
V?rification de la r?sistance du faisceau de c?bles....5901
V?rification de tension du connecteur ? ECB1 d?connect?....5903
V?rification de la tension de fonctionnement....5903
V?rification de la r?sistance de l'actionneur....5903
V?rification de la r?sistance du faisceau de c?bles....5904
V?rification de tension du connecteur ? ECB2 d?connect?....5906
V?rification de la tension de fonctionnement....5906
V?rification de la r?sistance de l'actionneur....5906
V?rification de la r?sistance du faisceau de c?bles....5907
SPN 111 FMI 1 ? faible niveau de liquide de refroidissement....5909
V?rification de la tension du connecteur....5909
V?rification de la r?sistance du faisceau de c?bles....5909
Num?ro de param?tre suspect (SPN) 158 Indicateur de mode de d?faillance (FMI) 15 - tension commut?e du module ECM trop ?lev?e....5911
Num?ro de param?tre suspect (SPN) 158 Indicateur de mode de d?faillance (FMI) 17 - tension commut?e du module ECM trop faible....5911
V?rifications de tension sur le module ECM....5912
V?rifications de tension pour le code d'anomalie SPN 3597 FMI 4 ? sortie de puissance 1 de l'ECM....5914
V?rifications de tension pour le code d'anomalie SPN 3598 FMI 4 ? sortie de puissance 2 de l'ECM....5915
V?rifications de tension pour le code d'anomalie SPN 3599 FMI 4 ? sortie de puissance 3 de l'ECM....5915
V?rification de la r?sistance du faisceau pour le code d'anomalie SPN 3597 FMI 4 ? sortie de puissance 1 de l'ECM....5916
V?rification de la r?sistance du faisceau pour le code d'anomalie SPN 3598 FMI 4 ? sortie de puissance 2 de l'ECM....5917
V?rification de la r?sistance du faisceau pour le code d'anomalie SPN 3599 FMI 4 ? sortie de puissance 3 de l'ECM....5917
Num?ro de param?tre suspect (SPN) 108 Indicateur de mode de d?faillance (FMI) 3 - signal BARO hors sp?cification ?LEV?....5918
Num?ro de param?tre suspect (SPN) 108 Indicateur de mode de d?faillance (FMI) 4 - signal BARO hors sp?cification, FAIBLE....5919
Num?ro de param?tre suspect (SPN) 628 Indicateur de mode de d?faillance (FMI) 12 - erreur de m?moire du module ECM....5919
SPN 629 FMI 2 - erreur de l'ECM - contr?le de niveau 2....5919
Num?ro de param?tre suspect (SPN) 629 Indicateur de mode de d?faillance (FMI) 8 - panne de temporisation moteur coup?....5919
Num?ro de param?tre suspect (SPN) 629 Indicateur de mode de d?faillance (FMI) 12 - erreur de la puce interne du module ECM....5919
Num?ro de param?tre suspect (SPN) 629 Indicateur de mode de d?faillance (FMI) 14 - composant interne du module ECM....5920
SPN 1110 FMI 1 ? l'ECM d?tecte une alimentation en carburant sans demande....5920
V?rification par comparaison de capteur apr?s impr?gnation ? froid avec le logiciel ServiceMaxx?....5922
V?rification du circuit du capteur avec le logiciel ServiceMaxx?....5924
V?rification de la tension du connecteur sans utiliser le logiciel ServiceMaxx?....5925
V?rification de la r?sistance du faisceau de c?bles....5925
SPN 4076 FMI 16 ? le signal de l'ECT2 est en d?saccord avec d'autres capteurs (impr?gnation de froid)....5927
V?rification du circuit du capteur avec le logiciel ServiceMaxx?....5928
V?rification de la tension du connecteur sans utiliser le logiciel ServiceMaxx?....5928
V?rification de la r?sistance du faisceau de c?bles....5928
V?rification de tension au niveau du connecteur EFC (une ou deux vitesses) - Test de l'actionneur....5931
V?rification de la r?sistance du faisceau de c?bles....5931
SPN 412 FMI 2 ? le signal EGRT est en d?saccord avec les autres capteurs....5933
V?rification du circuit du capteur avec le logiciel ServiceMaxx?....5934
V?rification de la tension du connecteur sans utiliser le logiciel ServiceMaxx?....5934
V?rification de la r?sistance du faisceau de c?bles....5934
SPN 27 FMI 7 ? le signal EGRP ne correspond pas ? la position command?e....5937
V?rification de tension du connecteur ? soupape RGE d?connect?e....5937
V?rification de la tension de fonctionnement....5938
V?rification de la r?sistance du faisceau de c?bles....5938
V?rification du circuit du capteur avec le logiciel ServiceMaxx?....5948
V?rification de la tension du connecteur sans utiliser le logiciel ServiceMaxx?....5949
V?rification de la r?sistance du faisceau de c?bles....5949
V?rification du circuit du capteur....5951
V?rification de la tension du connecteur....5952
V?rification de la r?sistance du faisceau de c?bles....5952
V?rification du circuit du capteur avec le logiciel ServiceMaxx?....5954
Diagnostics de rep?rage sans le logiciel ServiceMaxx?....5955
V?rification de la r?sistance du faisceau de c?bles....5955
V?rification de tension du connecteur ? ETV d?connect?....5957
V?rification de la tension de fonctionnement....5958
V?rification de la r?sistance du faisceau de c?bles....5958
SPN 94 FMI 0 ? pression de carburant sup?rieure ? la valeur maximale....5964
V?rification du circuit du capteur avec le logiciel ServiceMaxx?....5965
V?rification de la tension du connecteur sans utiliser le logiciel ServiceMaxx?....5965
V?rification de la r?sistance du faisceau de c?bles....5966
V?rification de tension du connecteur ? FPCV d?connect?....5968
V?rification de la tension de fonctionnement....5968
V?rification de la r?sistance du faisceau de c?bles....5969
V?rification du circuit du capteur avec le logiciel ServiceMaxx?....5974
V?rification de la tension du connecteur sans utiliser le logiciel ServiceMaxx?....5975
V?rification de la r?sistance du faisceau de c?bles....5975
Num?ro de param?tre suspect (SPN) 157 Indicateur de mode de d?faillance (FMI) 0 - d?faillance d'ouverture de la soupape de d?charge FRP....5983
Num?ro de param?tre suspect (SPN) 157 Indicateur de mode de d?faillance (FMI) 14 - soupape de d?charge FRP d?fectueuse....5983
Num?ro de param?tre suspect (SPN) 3055 Indicateur de mode de d?faillance (FMI) 0 - FRP maximale d?pass?e....5983
Num?ro de param?tre suspect (SPN) 3055 Indicateur de mode de d?faillance (FMI) 15 - FRP inf?rieure au minimum avec la commande maximale....5983
SPN 3055 FMI 16 - FRP inattendue ? ex?cutez le test de pompe haute pression....5984
Num?ro de param?tre suspect (SPN) 3055 Indicateur de mode de d?faillance (FMI) 17 - FRP sup?rieure au maximum avec la commande minimale....5984
SPN 172 FMI 2 ? le signal AIT est en d?saccord avec les autres capteurs....5987
V?rification du circuit du capteur avec le logiciel ServiceMaxx?....5988
V?rification de la tension du connecteur sans utiliser le logiciel ServiceMaxx?....5988
V?rification de la r?sistance du faisceau de c?bles....5989
V?rification du circuit du capteur avec le logiciel ServiceMaxx?....5993
V?rification de la tension du connecteur sans utiliser le logiciel ServiceMaxx?....5993
V?rification de la r?sistance du faisceau de c?bles....5994
V?rification par comparaison de capteur apr?s impr?gnation ? froid avec le logiciel ServiceMaxx?....6002
SPN 105 FMI 2 ? le signal de la sonde IMT est en d?saccord avec les autres capteurs....6002
SPN 105 FMI 18 ? le signal de la sonde IMT ne r?agit pas comme pr?vu....6002
V?rification du circuit du capteur avec le logiciel ServiceMaxx?....6003
V?rification de la tension du connecteur sans utiliser le logiciel ServiceMaxx?....6003
V?rification de la r?sistance du faisceau de c?bles....6003
Injecteur 1 ? v?rifications de r?sistance au moyen du faisceau et de l'injecteur....6006
Injecteur 2 ? v?rifications de r?sistance au moyen du faisceau et de l'injecteur....6007
Injecteur 3 ? v?rifications de r?sistance au moyen du faisceau et de l'injecteur....6008
Injecteur 4 ? v?rifications de r?sistance au moyen du faisceau et de l'injecteur....6009
Injecteur 5 ? v?rifications de r?sistance au moyen du faisceau et de l'injecteur....6010
Injecteur 6 ? v?rifications de r?sistance au moyen du faisceau et de l'injecteur....6011
V?rification de la tension du connecteur....6015
V?rification de communication de l'appareil ?lectronique de diagnostic des pannes (EST)....6015
V?rification de la r?sistance du faisceau de c?bles....6016
SPN 724 FMI 20 ? adaptation de l'O2S sup?rieure ? la limite maximale / SPN 724 FMI 21 ? adaptation de l'O2S inf?rieure ? la li....6022
V?rification de la tension du connecteur sans utiliser le logiciel ServiceMaxx?....6023
V?rification de la r?sistance du faisceau de c?bles....6024
Rep?rage de panne du syst?me O2S ....6024
SPN 3223 FMI 1? temp?rature du r?chauffeur d'O2S inf?rieure au minimum....6024
SPN 3223 FMI 17 ? temp?rature du r?chauffeur d'O2S inf?rieure au minimum ? faible alimentation de la batterie....6024
Proc?dure d'?talonnage d'O2S ? avec le logiciel ServiceMaxx?....6025
V?rification de la tension du connecteur....6028
V?rification de la r?sistance du faisceau de c?bles....6028
SPN 5541 FMI 2 ? le signal TC1TOP est en d?saccord avec BARO....6030
V?rification du circuit du capteur avec le logiciel ServiceMaxx?....6031
V?rification de la tension du connecteur sans utiliser le logiciel ServiceMaxx?....6031
V?rification de la r?sistance du faisceau de c?bles....6032
V?rification de tension du connecteur ? TC1WC d?connect?....6034
V?rification de la tension de fonctionnement....6034
V?rification de la r?sistance de l'actionneur....6034
V?rification de la r?sistance du faisceau de c?bles....6035
V?rification de tension du connecteur ? TC2WC d?connect?....6037
V?rification de la tension de fonctionnement....6037
V?rification de la r?sistance de l'actionneur....6037
V?rification de la r?sistance du faisceau de c?bles....6038
SPN 1173 FMI 2 ? le signal de TC2CIT est en d?saccord avec les autres capteurs....6040
V?rification du circuit du capteur....6041
Diagnostics de rep?rage sans le logiciel ServiceMaxx?....6041
V?rification de la r?sistance du faisceau de c?bles....6042
SPN 84 FMI 2 - Anomalie anti-alt?ration de vitesse du v?hicule....6046
V?rification de la tension du connecteur TOSS / VSS sans le logiciel ServiceMaxx ?....6046
V?rification de la continuit? du capteur TOSS / VSS sans le logiciel ServiceMaxx?....6047
V?rification de la r?sistance du faisceau de c?bles....6047
V?rification du fonctionnement TOSS/VSS sans le logiciel ServiceMaxx?....6047
SPN 191 FMI 2 signal TOSS / VSS irr?gulier, intermittent ou incorrect....6048
SPN 191 FMI 3 Signal TOSS / VSS hors de gamme, ?LEV?....6048
SPN 191 FMI 4 Signal TOSS / VSS hors de gamme, BAS....6048
SPN 191 FMI 16 lecture du TOSS / VSS plus ?lev?e que la limite....6049
V?rifications de tension pour le code d'anomalie SPN 3509 FMI 14 ? VREF1....6055
V?rifications de tension pour le code d'anomalie SPN 3510 FMI 14 ? VREF2....6056
V?rifications de tension pour le code d'anomalie SPN 3511 FMI 14 ? VREF3....6057
V?rifications de tension pour le code d'anomalie SPN 3512 FMI 14 ? VREF4....6058
V?rifications de tension pour le code d'anomalie SPN 3513 FMI 14 ? VREF5....6059
V?rifications de tension pour le code d'anomalie SPN 3514 FMI 14 ? VREF6....6060
V?rification de r?sistance du faisceau pour le code d'anomalie SPN 3509 FMI 14 ? VREF1....6060
V?rification de r?sistance du faisceau pour le code d'anomalie SPN 3510 FMI 14 ? VREF2....6060
V?rification de r?sistance du faisceau pour le code d'anomalie SPN 3511 FMI 14 ? VREF3....6061
V?rification de r?sistance du faisceau pour le code d'anomalie SPN 3512 FMI 14 ? VREF4....6061
V?rification de r?sistance du faisceau pour le code d'anomalie SPN 3513 FMI 14 ? VREF5....6062
V?rification de r?sistance du faisceau pour le code d'anomalie SPN 3514 FMI 14 ? VREF6....6062
V?rification de tension....6065
V?rification de r?sistance du connecteur ? la masse....6065
V?rification de la r?sistance du faisceau de c?bles....6065
Cl? sur ON, moteur coup?...6130
D?marrage du moteur....6130
Grand ralenti, pas de charge, temp?rature de fonctionnement du moteur stabilis?....6131
Ralenti acc?l?r?, pas de charge, temp?rature de fonctionnement du moteur stabilis?....6132
Pleine charge, vitesse nominale sur dynamom?tre, temp?rature de fonctionnement du moteur stabilis?....6132
Caract?ristiques des composants....6133
?tat de sortie de l'actionneur....6134
Dispositif de d?marrage ? froid....6135
Pression de carter....6135
Prolongement de la tige d'EBPV....6135
Prolongement de la tige de la soupape de d?charge du turbocompresseur (TC2WC)....6135
0000001746 - Engine Service Manual MaxxForce 15L Diesel Engine....6157
toc....6159
Table of Contents....6159
Safety Terminology....6163
Safety Instructions....6163
Work Area....6163
Safety Equipment....6163
Protective Measures....6163
Vehicle....6163
Engine....6163
Fire Prevention....6163
Batteries....6163
Compressed Air....6164
Tools....6164
Fluids Under Pressure....6164
Fuel....6164
Removal of Tools, Parts, and Equipment....6164
Table of Contents....6165
Engine Identification....6167
Engine Serial Number....6167
Engine Serial Number Example....6167
Engine Serial Number Codes....6167
Engine Emission Label....6167
Engine Accessory Labels and Identification Plates....6168
Engine Specifications....6169
Engine Description....6169
Optional Features....6170
Chassis Mounted Features....6170
The High-Pressure Charge Air Cooler (HPCAC) mounted on the vehicle cooling module, is connected between the outlet of the high-pressure turbocharger and the inlet to the engine throttle valve assembly. The HPCAC is an air-to-air cooler that uses ambient a....6170
Engine Component Locations....6171
Air Management System (AMS)....6176
Air Flow....6176
Air Management Components....6177
Turbochargers....6177
Interstage Cooler (ISC)....6178
High-Pressure Charge Air Cooler (HPCAC)....6179
Air Control Valve....6179
Exhaust Gas Recirculation (EGR) System....6180
EGR System Overview....6180
EGR Flow....6181
EGR Control....6181
EGR Open Loop System....6181
EGR Closed Loop System....6181
Aftertreatment (AFT) System....6182
Sensors....6182
Down Stream Injection (DSI)....6182
Pre-Diesel Oxidation Catalyst (PDOC)....6182
Diesel Oxidation Catalyst (DOC)....6182
Diesel Particulate Filter (DPF)....6183
AFT Conditions and Responses....6183
Aftertreatment Fuel Injection Components....6184
Fuel Management System....6186
DSI and Fuel Doser....6187
Cold Start System....6187
Fuel Filter and Housing....6187
Chassis Mounted Components....6187
Fuel Filter and Water Separator Assembly....6187
Fuel Primer Pump Assembly....6188
Engine Mounted Components....6189
ECM....6190
Fuel Filter....6190
Fuel Pump....6190
Rail Assembly (Fuel Common Rail)....6190
Fuel Rail Pressure (FRP) Sensor....6190
Pressure Relief Valve....6190
Injector....6190
Engine Lubrication System....6191
Oil Flow and Components....6192
Remote Mounted Centrifugal Oil Filter (Optional)....6194
Engine Cooling System....6195
Cooling System Components....6195
Cooling System Flow....6196
Thermostat Operation....6198
Coolant Control Valve (CCV) Assembly Operation....6198
CFV....6198
CMV....6199
MaxxForce? Engine Brake System....6200
Engine Brake System Components....6200
Engine Brake Operation....6201
Open Crankcase Breather System....6202
Open Crankcase Breather System Components....6202
Open Crankcase Breather System Operation....6203
Cold Start Assist System....6204
Cold Start Fuel Igniter (CSFI)....6205
Cold Start Relay (CSR)....6205
Cold Start Fuel Solenoid (CSFS)....6205
Cold Start Assist System Operation....6205
Electronic Control System....6206
Electronic Control System Components....6206
Operation and Function....6206
Reference Voltage (VREF)....6206
Signal Conditioner....6206
Microprocessor....6206
Diagnostic Trouble Codes....6206
Microprocessor Memory....6206
ROM....6206
RAM....6207
Actuator Control....6207
Actuators....6207
Coolant Flow Valve and Coolant Mixer Valve....6207
Exhaust Gas Recirculation (EGR) Valve Assembly....6207
Air Control Valve....6207
Cold Start Relay (CSR)....6207
Cold Start Fuel Solenoid (CSFS)....6207
Engine Throttle Valve (ETV)....6208
Fuel Pressure Control Valve (FPCV)....6208
Engine and Vehicle Sensors....6208
Thermistor Sensor....6208
Aftertreatment Temperature Sensors....6208
Charge Air Cooler Outlet Temperature (CACOT) Sensor....6209
Engine Coolant Temperature 1 (ECT1) Sensor....6209
Engine Oil Temperature (EOT) Sensor....6209
Intake Manifold Temperature (IMT) Sensor....6209
Variable Resistance Sensor....6209
Exhaust Gas Differential Pressure (EGDP) Sensor....6209
Engine Fuel Delivery Pressure (FDP) Sensor....6210
Engine Oil Pressure (EOP) Sensor....6210
Fuel Rail Pressure (FRP) Sensor....6210
Intake Manifold Pressure (IMP) Sensor....6210
Magnetic Pickup Sensor....6210
Crankshaft Position (CKP) Sensor....6210
Camshaft Position (CMP) Sensor....6210
Vehicle Speed Sensor (VSS)....6210
Potentiometer....6211
Accelerator Pedal Position (APP) Sensors ....6211
Switches....6211
Driveline Disengagement Switch (DDS)....6211
Engine Coolant Level (ECL) Switch....6211
Oxygen Sensor (O2S) ....6212
Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....6212
Table of Contents....6213
Engine Preparation....6215
Clean Engine....6215
Drain Engine Coolant....6216
Drain Oil....6218
Removing Engine from Vehicle....6218
Removal....6219
Electrical Connections....6219
Aftertreatment System Components....6219
Turbocharger System Components....6219
EGR Coolant Tubes....6219
Oil Cooler and Filter Housing....6219
Mounting Engine On Stand....6219
Table of Contents....6223
Engine Electronic Components....6225
Engine Sensor Harness Assembly....6228
Description of Engine Sensors, Valves, and Actuators....6229
5 mm 60 Degree Speed Sensor used to sense Crankshaft Position (CKP)....6229
5 mm 60 Degree Speed Sensor used to sense Camshaft Position (CMP)....6229
6 Bar Pressure sensor used to sense Engine Oil Pressure (EOP)....6229
15 Bar Pressure Sensor used to sense Fuel Delivery Pressure (FDP)....6230
Charge Pressure Sensor used as Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....6230
Coolant Control Valve (CCV) Assembly....6230
Coolant Pressure Sensor used to sense Engine Coolant Pressure (ECP1)....6231
Crankcase Pressure (CCP) Sensor ....6231
EGR Temperature (EGRT) Sensor....6231
Engine Throttle Valve (ETV) Assembly....6232
Exhaust Gas Recirculation (EGR) Valve Assembly....6232
Fuel Rail Pressure (FRP) Sensor....6233
Intake Manifold Pressure (IMP) Sensor....6233
Mass Air Flow (MAF) Sensor....6233
Oxygen Sensor (O2S)....6233
Temperature Sensor used to sense Engine Coolant Temperature 1 (ECT1) and 2 (ECT2)....6234
Temperature Sensor used to sense Engine Oil Temperature (EOT)....6234
Temperature Sensor used to sense Charge Air Cooler Outlet Temperature (CACOT)....6234
Temperature Sensor used to sense Intake Manifold Temperature (IMT)....6235
Wastegate Control Valve (Air Control Valve)....6235
Removal....6236
Crankshaft Position (CKP) Sensor....6236
Camshaft Position (CMP) Sensor....6236
Engine Oil Pressure (EOP) Sensor....6237
Fuel Delivery Pressure (FDP) Sensor....6237
Body Harness Interconnect....6238
Coolant Control Valve (CCV) Assembly Connectors....6238
Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....6239
Engine Coolant Pressure 1 (ECP1) Sensor....6239
Crankcase Pressure (CCP) Sensor....6240
Engine Control Module (ECM) Connections....6240
EGR Temperature (EGRT) Sensor....6241
Exhaust Gas Recirculation (EGR) Valve Assembly Connector....6241
Engine Throttle Valve (ETV) Assembly Connector....6242
Fuel Rail Pressure (FRP) Sensor....6242
High-Pressure Fuel Pump Connector....6243
Intake Manifold Pressure (IMP) Sensor....6243
Mass Air Flow (MAF) Sensor....6244
Cold Start Fuel Solenoid (CSFS) Valve Connector....6244
Charge Air Cooler Output Temperature (CACOT) Sensor....6245
Engine Coolant Temperature 1 (ECT1) Sensor....6245
Engine Coolant Temperature 2 (ECT2) Sensor....6246
Engine Oil Temperature (EOT) Sensor....6246
Intake Manifold Temperature (IMT) Sensor....6247
Air Control Valve Connector....6247
Engine Sensor Harness Assembly....6248
Engine Control Module (ECM) and ECM Support....6250
Harness Support (EGR Cooler)....6250
Harness Support (Fuel Pump)....6251
Oxygen Sensor (O2S)....6251
Oil Pressure Sensor Support....6252
Cleaning and Inspection....6253
Main Engine Wiring Harness....6253
Sensors and Valves....6253
Installation....6254
Engine Control Module (ECM) and ECM Support....6254
Harness Support (EGR Cooler)....6255
Harness Support (Fuel Pump)....6255
Oxygen Sensor (O2S)....6255
Oil Pressure Sensor Support....6256
Engine Sensor Harness Assembly....6256
Crankshaft Position (CKP) Sensor....6258
Camshaft Position (CMP) Sensor....6259
Engine Oil Pressure (EOP) Sensor....6259
Fuel Delivery Pressure (FDP) Sensor....6259
Body Harness Interconnect....6260
Coolant Control Valve (CCV) Assembly Connectors....6260
Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....6261
Engine Coolant Pressure 1 (ECP1) Sensor....6261
Crankcase Pressure (CCP) Sensor....6261
Engine Control Module (ECM) Connections....6262
EGR Temperature (EGRT) Sensor....6263
Exhaust Gas Recirculation (EGR) Valve Assembly Connector....6263
Engine Throttle Valve (ETV) Assembly Connector....6264
Fuel Rail Pressure (FRP) Sensor....6264
High-Pressure Fuel Pump Connector....6265
Intake Manifold Pressure (IMP) Sensor....6265
Mass Air Flow (MAF) Sensor....6266
Cold Start Fuel Solenoid (CSFS) Valve Connector....6266
Charge Air Cooler Outlet Temperature (CACOT) Sensor....6267
Engine Coolant Temperature 1 (ECT1) Sensor....6267
Engine Coolant Temperature 2 (ECT2) Sensor....6268
Engine Oil Temperature (EOT) Sensor....6268
Intake Manifold Temperature (IMT) Sensor....6269
Air Control Valve Connector....6269
Table of Contents....6271
Exploded View....6273
Removal....6274
Cold Start Relay (CSR)....6274
Relay Support Assembly....6275
Solenoid to Injector Tube....6275
Filter to Solenoid Tube....6276
Cold Start Fuel Solenoid (CSFS)....6276
Cold Start Fuel Igniter (CSFI)....6276
Installation....6277
Cold Start Fuel Igniter (CSFI)....6277
Cold Start Fuel Solenoid (CSFS)....6277
Filter to Solenoid Tube....6278
Solenoid to Injector Tube....6278
Relay Support Assembly....6279
Cold Start Relay (CSR)....6280
Table of Contents....6283
Exploded Views....6285
Removal....6287
Pre-Diesel Oxidation Catalyst (PDOC)....6287
Down Stream Injection (DSI) Assembly and Doser Fuel to Injector Tube Assembly....6288
Injector Unit Feed Tube Assembly and Doser Fuel from Valve Tube Assembly....6289
Doser Coolant Supply Tube Assembly and Doser Coolant Return Tube Assembly....6290
Fuel Doser Assembly....6291
Turbocharger Exhaust Duct....6291
Inspection and Cleaning....6292
Fuel Doser....6292
Installation....6292
Turbocharger Exhaust Duct....6292
Fuel Doser Assembly....6293
Doser Coolant Supply Tube Assembly and Doser Coolant Return Tube Assembly....6294
Injector Unit Feed Tube Assembly and Doser Fuel from Valve Tube Assembly ....6294
Down Stream Injection (DSI) Assembly and Doser Fuel to Injector Tube Assembly....6295
Pre-Diesel Oxidation Catalyst (PDOC)....6296
Table of Contents....6299
Exploded Views....6301
Removal....6305
Turbocharger Oil Drain Tube Assembly....6305
High-Pressure (HP) Compressor Outlet Duct....6306
Air Inlet Duct....6306
Turbocharger to Intercooler Tube....6307
Turbocharger Interstage Cooler (ISC) Assembly....6308
Intercooler Support (Outer)....6310
Air Control Valve....6310
Turbocharger Heat Shields and High-Pressure (HP) Turbocharger Wastegate Actuator....6312
Turbocharger Oil Supply Tube Assemblies....6313
Turbochargers....6314
Disassembly....6316
Turbochargers....6316
Cleaning and Inspection....6316
Turbochargers and Related Parts Cleaning....6316
Turbochargers Inspection....6316
Turbocharger Interstage Cooler Assembly (ISC) Pressure Test....6317
Assembly....6319
Turbochargers....6319
Installation....6319
Turbochargers....6319
Turbocharger Oil Supply Tube Assemblies....6321
Turbocharger Heat Shields and High-Pressure (HP) Turbocharger Wastegate Actuator....6322
Air Control Valve....6323
Intercooler Support (Outer)....6324
Turbocharger Interstage Cooler (ISC) Assembly....6324
Turbocharger to Intercooler Tube....6327
Air Inlet Duct....6328
High-Pressure (HP) Compressor Outlet Duct....6328
Turbocharger Oil Drain Tube Assembly....6329
Table of Contents....6331
Exploded Views....6333
Removal....6335
Power Steering Pump....6335
Air Compressor Coolant Tubes....6335
Air Compressor ....6336
Cleaning....6337
All Components....6337
Installation....6338
Air Compressor ....6338
Air Compressor Coolant Tubes....6340
Power Steering Pump....6340
Table of Contents....6343
Exploded Views....6345
Periodic Service....6348
Fuel Filter Replacement....6348
Removal....6349
Pump to Rail Fuel Tube Assemblies and Rail to Injector Tube Assemblies....6349
Fuel Rail ....6352
Fuel Return Tube Assembly....6352
Fuel Filter Housing Assembly....6353
High-Pressure Fuel Pump....6355
Cleaning and Inspection....6356
Installation....6357
High-Pressure Fuel Pump....6357
Fuel Filter Housing Assembly....6358
Fuel Return to Tank Tube Assembly....6359
Fuel Rail....6360
Rail to Injector Tube Assemblies....6361
Pump to Rail Fuel Tube Assemblies....6362
Table of Contents....6365
Exploded Views....6367
Removal....6374
EGR Cooler Assembly Draining....6374
Coolant Manifold, ISC Coolant Supply Tube Assembly and CCV LTR Bypass Tube Assembly....6375
Coolant Control Valve (CCV) Assembly and Coolant Adapter....6377
Heater Core Return Adapter and Temperature Sensor Fitting....6378
Intercooler Support (Inner)....6378
EGRV Coolant Return Tube and EGRV Coolant Supply Tube....6379
EGR Coolant Tube Assembly (front) and EGR2 Coolant Supply Tube Assembly....6381
EGR Coolant Tube Assembly (rear), EGR Coolant Tube Assembly and EGR Tube Assembly....6382
Coolant Adapter and EGR Coolant Return Tube Assembly....6383
EGR Crossover Tube....6384
EGR Cooler Inlet Elbow....6385
EGR Cooler Supply Tube and EGR Valve Assembly....6386
EGR Cooler Assembly....6387
EGR Cooler Supports....6388
Cleaning, Inspection, and Testing....6389
Exhaust Gas Recirculation (EGR) System Components....6389
EGR Valve Assembly....6389
EGR Cooler Assembly Pressure Test....6390
Tool Assembly....6390
Tool Installation....6392
EGR Cooler Leak Test....6395
Tool Removal....6397
Installation....6399
EGR Cooler Supports....6399
EGR Cooler Assembly....6400
EGR Cooler Supply Tube and EGR Valve Assembly....6401
EGR Cooler Inlet Elbow....6402
EGR Crossover Tube....6403
Coolant Adapter and EGR Coolant Return Tube Assembly....6404
EGR Coolant Tube Assembly (rear), EGR Coolant Tube Assembly and EGR Tube Assembly....6405
EGR Coolant Tube Assembly (front) and EGR2 Coolant Supply Tube Assembly....6407
EGRV Coolant Return Tube and EGRV Coolant Supply Tube....6409
Intercooler Support (Inner)....6411
Heater Core Return Adapter and Temperature Sensor Fitting....6411
Coolant Control Valve (CCV) Assembly and Coolant Adapter....6412
Coolant Manifold, ISC Coolant Supply Tube Assembly and CCV LTR Bypass Tube Assembly....6413
Table of Contents....6417
Exploded Views....6419
Removal....6423
Engine Oil Cooler Assembly and Oil Filter Base Assembly....6423
Breather Tube and Valve Cover Adapter....6427
Breather Draft Tube and Breather Drain Tube....6428
Breather Filter Assembly and Oil Breather Support....6429
Disassemble....6430
Oil Filter Base Assembly Pressure Valves....6430
Cleaning, Inspection, and Testing....6430
Engine Oil Cooler Assembly Cleaning....6430
Assemble....6431
Oil Filter Base Assembly Pressure Valves....6431
Installation....6432
Breather Filter Assembly and Oil Breather Support....6432
Breather Draft Tube and Breather Drain Tube....6432
Breather Tube and Valve Cover Adapter....6433
Engine Oil Cooler Assembly and Oil Filter Base Assembly....6434
Table of Contents....6441
Exploded Views....6443
Removal....6445
Exhaust Manifold....6445
Air Inlet....6447
Cleaning, Inspection, and Testing....6449
All Components....6449
Exhaust Manifold....6449
Air Inlet....6449
Installation....6450
Air Inlet....6450
Exhaust Manifold....6451
Table of Contents....6455
Exploded Views....6457
Removal....6464
Fan Drive (High or Low Mount Fan)....6464
Thermostat Housing and Thermostats....6466
Water Pump Inlet and Water Outlet Pipe....6467
Belt Tensioners and Idler Pulleys....6469
A/C (Freon) Compressor Support....6470
Water Pump....6471
Damper....6471
Front Engine Mount Support....6472
Crankshaft Front Seal....6472
Front Cover ....6472
Timing Gears and Supports....6475
Cleaning, Inspection, and Testing....6484
Front Cover....6484
Timing Gears....6484
Installation....6485
Timing Gears and Supports....6485
Front Cover ....6492
Camshaft Gear....6495
Timing Gear Lash....6496
Crankshaft Front Seal....6499
Front Engine Mount Support....6499
Damper....6500
Water Pump....6500
A/C (Freon) Compressor Support....6501
Belt Tensioners and Idler Pulleys....6502
Water Pump Inlet and Water Outlet Pipe....6502
Thermostat Housing and Thermostats....6504
Fan Drive (High and Low Mount Fan)....6505
Table of Contents....6511
Exploded Views....6513
Periodic Service....6516
Engine Brake Lash Adjustment....6516
Removal....6520
Valve Brake Actuator Assembly....6520
Lost Motion Pedestal....6521
Cleaning and Inspection....6523
Valve Brake Actuator Assembly....6523
Installation....6524
Lost Motion Pedestal....6524
Valve Brake Actuator Assembly....6524
Table of Contents....6529
Exploded Views....6531
Periodic Service....6539
Valve Lash Adjustment....6539
Removal....6544
Valve Cover....6544
Valve Cover Base....6547
Engine Brakes....6550
Fuel Injectors....6550
Rocker Arms....6551
Camshaft and Bearings....6553
Camshaft....6553
Camshaft Bearings....6556
Cylinder Head....6557
Replacing O-ring Boss Plugs and Cylinder head Cup Plugs....6560
O-ring boss plugs....6560
Cup plugs....6560
Cleaning, Inspection, and Testing....6562
Camshaft Lobes and Journals Measurement....6562
Cylinder Head and Crankcase Components....6562
Camshaft Bearings....6563
Fuel Injector Bore....6563
Fuel Injector Harness....6563
Measuring Valve Seat Leakage....6563
Measuring Rocker Shaft....6564
Inspection and Measurement of Rocker Arms....6564
Measuring Cylinder Head Warpage....6565
Measuring Cylinder Head Thickness....6565
Inspecting Cylinder Head for Cracks....6566
Installation....6567
Cylinder Head....6567
Camshaft and Bearings....6570
Camshaft Bearings....6570
Camshaft....6572
Rocker Arms....6575
Fuel Injectors....6576
Engine Brakes....6578
Valve Cover Base....6578
Valve Cover....6583
Table of Contents....6589
Exploded Views....6591
Removal....6595
Oil Filler Pipe Assembly....6595
Oil Level Gauge and Oil Level Gauge Tube Assembly (Early Production)....6595
Oil Level Gauge and Oil Level Gauge Tube Assembly (Late Production)....6596
Oil Pan....6598
Oil Pick Up Tube and Oil Sending Tube Assemblies....6599
Oil Pump....6600
Oil Pan Plate Assembly....6601
Cleaning and Inspection....6602
Oil Pan....6602
Oil Pick Up Tube....6602
Oil Sending Tube Assembly....6602
Installation....6603
Oil Pan Plate Assembly....6603
Oil Pump....6603
Oil Pick Up Tube and Oil Sending Tube Assemblies....6604
Oil Pan....6605
Oil Level Gauge and Oil Level Gauge Tube Assembly (Late Production)....6608
Oil Level Gauge and Oil Level Gauge Tube Assembly (Early Production)....6610
Oil Filler Pipe Assembly....6611
Table of Contents....6613
Exploded Views....6615
Removal....6618
Preliminary Checks ? Flywheel Assembly....6618
Rear Engine Mounts....6618
Flywheel Assembly....6619
Crankshaft Rear Seal....6620
Flywheel Housing....6620
Clean, Inspect, and Measure....6624
All Components....6624
Flywheel Assembly Face Runout (Axial Eccentricity)....6624
Flywheel Assembly Bore Runout (Radial Eccentricity)....6624
Flywheel Housing Face Runout (Axial Eccentricity)....6625
Flywheel Housing Bore Runout (Radial Eccentricity)....6626
Recondition....6627
Flywheel Assembly....6627
Installation....6629
Flywheel Housing....6629
Crankshaft Rear Seal....6632
Flywheel Assembly....6633
Rear Engine Mounts....6635
Table of Contents....6637
Exploded Views....6639
Removal....6641
Preliminary Checks....6641
Piston and Connecting Rod....6642
Piston Disassembly....6643
Cylinder Sleeves....6644
Cleaning and Inspection....6645
Cleaning....6645
Piston Inspection....6645
Piston Ring Inspection....6646
Connecting Rod Inspection....6646
Connecting Rod Bore Check....6647
Piston Pin Inspection....6647
Cylinder Sleeve Bore Inspection....6648
Cylinder Sleeve Projection Measurement....6648
Installation....6652
Cylinder Sleeves....6652
Piston Assembly....6652
Piston and Connecting Rod....6653
Table of Contents....6659
Exploded Views....6661
Removal....6664
Crankshaft Bearing Caps, Crankshaft, and Main Bearings....6665
Piston Cooling Jet....6667
Crankcase Dowel Pins, Plugs and Fittings....6668
Cleaning, Inspection, and Testing....6671
Crankshaft End Play....6671
Crankcase....6671
Crankshaft....6672
Main Bearings....6673
Piston Cooling Jet....6675
Installation....6676
Crankcase Dowel Pins, Plugs and Fittings....6676
Piston Cooling Jet....6678
Crankshaft Bearing Caps, Crankshaft, and Main Bearings....6679
Table of Contents....6689
Abbreviations and Acronyms....6691
Table of Contents....6697
Terminology....6699
Terms....6699
Table of Contents....6709
Fuel System....6711
Exhaust Gas Recirculation (EGR) System....6711
Air Inlet and Exhaust Manifolds....6711
Front Cover, High Mount Fan Drive, Cooling System, and Related Components....6711
Engine Brake....6711
Cylinder Head, Camshaft and Valve Train....6712
Flywheel and Flywheel Housing....6713
Power Cylinders....6714
Crankcase and Crankshaft....6715
Table of Contents....6717
General Torque....6719
Bolt Identification....6719
General Torque Guidelines....6720
Standard Torque Charts....6721
Using a Torque Wrench Extension....6723
Special Torques....6724
Mounting Engine on Stand....6724
Engine Electrical....6724
Cold Start Assist....6724
Aftertreatment System....6725
Turbochargers....6725
Air Compressor and Power Steering....6725
Fuel System....6726
Exhaust Gas Recirculation (EGR) System....6727
Oil Cooler, Filter Housing and Crankcase Ventilation....6727
Air Inlet and Exhaust Manifolds....6728
Front Cover, High Mount Fan Drive, Cooling System, Related Components....6729
Engine Brake....6730
Cylinder Head, Camshaft and Valve Train....6730
Oil Pan, Oil Pickup Tube and Oil Pump....6730
Flywheel and Flywheel Housing....6731
Power Cylinders....6731
Crankcase and Crankshaft....6731
Table of Contents....6733
Special Tools....6735
Mounting Engine on Stand....6735
Engine Electrical....6735
Aftertreatment System....6735
Turbochargers....6735
Fuel System....6736
Exhaust Gas Recirculation (EGR) System....6736
Oil Cooler, Filter Housing and Crankcase Ventilation....6736
Air Inlet and Exhaust Manifolds....6736
Front Cover, High Mount Fan Drive, Cooling System, and Related Components....6737
Engine Brake....6737
Cylinder Head, Camshaft and Valve Train....6738
Oil Pan , Oil Suction Tube and Oil Pump....6739
Flywheel and Flywheel Housing....6739
Power Cylinders....6739
Crankcase and Crankshaft....6740
Special Tools ....6741
Essential Tools....6741
tables....6161
Technical Service Literature....6161
MaxxForce? 15 Diesel Engine....6169
Table 1....6541
Table 2....6541
Table 3....6542
Table 4....6542
Cylinder Head, Camshaft and Valve Train....6585
Standard Torque Values ? Class 10.9 Metric Flange Head Bolts and Studs....6721
Thread Diameter (mm)....6721
Thread Pitch (mm)....6721
Torque....6721
Standard Torque Values ? Standard (SAE) Flange Head Bolts and Studs....6722
Thread Diameter (mm)....6722
Thread Pitch (in)....6722
Torque....6722
0000001746 - MaxxForce 15L Diesel Engine Service Manual....6748
toc....6750
Table of Contents....6750
Safety Terminology....6754
Safety Instructions....6754
Work Area....6754
Safety Equipment....6754
Protective Measures....6754
Vehicle....6754
Engine....6754
Fire Prevention....6754
Batteries....6754
Compressed Air....6755
Tools....6755
Fluids Under Pressure....6755
Fuel....6755
Removal of Tools, Parts, and Equipment....6755
Table of Contents....6756
Engine Identification....6758
Engine Serial Number....6758
Engine Serial Number Example....6758
Engine Serial Number Codes....6758
Engine Emission Label....6758
Engine Accessory Labels and Identification Plates....6759
Engine Specifications....6760
Engine Description....6760
Optional Features....6761
Chassis Mounted Features....6761
The High-Pressure Charge Air Cooler (HPCAC) mounted on the vehicle cooling module, is connected between the outlet of the high-pressure turbocharger and the inlet to the engine throttle valve assembly. The HPCAC is an air-to-air cooler that uses ambient a....6761
Engine Component Locations....6762
Air Management System (AMS)....6767
Air Flow....6767
Air Management Components....6768
Turbochargers....6768
Interstage Cooler (ISC)....6769
High-Pressure Charge Air Cooler (HPCAC)....6770
Air Control Valve....6770
Exhaust Gas Recirculation (EGR) System....6771
EGR System Overview....6771
EGR Flow....6772
EGR Control....6772
EGR Open Loop System....6772
EGR Closed Loop System....6772
Aftertreatment (AFT) System....6773
Sensors....6773
Down Stream Injection (DSI)....6773
Pre-Diesel Oxidation Catalyst (PDOC)....6773
Diesel Oxidation Catalyst (DOC)....6773
Diesel Particulate Filter (DPF)....6774
AFT Conditions and Responses....6774
Aftertreatment Fuel Injection Components....6775
Fuel Management System....6777
DSI and Fuel Doser....6778
Cold Start System....6778
Fuel Filter and Housing....6778
Chassis Mounted Components....6778
Fuel Filter and Water Separator Assembly....6778
Fuel Primer Pump Assembly....6779
Engine Mounted Components....6780
ECM....6781
Fuel Filter....6781
Fuel Pump....6781
Rail Assembly (Fuel Common Rail)....6781
Fuel Rail Pressure (FRP) Sensor....6781
Pressure Relief Valve....6781
Injector....6781
Engine Lubrication System....6782
Oil Flow and Components....6783
Remote Mounted Centrifugal Oil Filter (Optional)....6785
Engine Cooling System....6786
Cooling System Components....6786
Cooling System Flow....6787
Thermostat Operation....6789
Coolant Control Valve (CCV) Assembly Operation....6789
CFV....6789
CMV....6790
MaxxForce? Engine Brake System....6791
Engine Brake System Components....6791
Engine Brake Operation....6792
Open Crankcase Breather System....6793
Open Crankcase Breather System Components....6793
Open Crankcase Breather System Operation....6794
Cold Start Assist System....6795
Cold Start Fuel Igniter (CSFI)....6796
Cold Start Relay (CSR)....6796
Cold Start Fuel Solenoid (CSFS)....6796
Cold Start Assist System Operation....6796
Electronic Control System....6797
Electronic Control System Components....6797
Operation and Function....6797
Reference Voltage (VREF)....6797
Signal Conditioner....6797
Microprocessor....6797
Diagnostic Trouble Codes....6797
Microprocessor Memory....6797
ROM....6797
RAM....6798
Actuator Control....6798
Actuators....6798
Coolant Flow Valve and Coolant Mixer Valve....6798
Exhaust Gas Recirculation (EGR) Valve Assembly....6798
Air Control Valve....6798
Cold Start Relay (CSR)....6798
Cold Start Fuel Solenoid (CSFS)....6798
Engine Throttle Valve (ETV)....6799
Fuel Pressure Control Valve (FPCV)....6799
Engine and Vehicle Sensors....6799
Thermistor Sensor....6799
Aftertreatment Temperature Sensors....6799
Charge Air Cooler Outlet Temperature (CACOT) Sensor....6800
Engine Coolant Temperature 1 (ECT1) Sensor....6800
Engine Oil Temperature (EOT) Sensor....6800
Intake Manifold Temperature (IMT) Sensor....6800
Variable Resistance Sensor....6800
Exhaust Gas Differential Pressure (EGDP) Sensor....6800
Engine Fuel Delivery Pressure (FDP) Sensor....6801
Engine Oil Pressure (EOP) Sensor....6801
Fuel Rail Pressure (FRP) Sensor....6801
Intake Manifold Pressure (IMP) Sensor....6801
Magnetic Pickup Sensor....6801
Crankshaft Position (CKP) Sensor....6801
Camshaft Position (CMP) Sensor....6801
Vehicle Speed Sensor (VSS)....6801
Potentiometer....6802
Accelerator Pedal Position (APP) Sensors ....6802
Switches....6802
Driveline Disengagement Switch (DDS)....6802
Engine Coolant Level (ECL) Switch....6802
Oxygen Sensor (O2S) ....6803
Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....6803
Table of Contents....6804
Engine Preparation....6806
Clean Engine....6806
Drain Engine Coolant....6807
Drain Oil....6809
Removing Engine from Vehicle....6809
Removal....6810
Electrical Connections....6810
Aftertreatment System Components....6810
Turbocharger System Components....6810
EGR Coolant Tubes....6810
Oil Cooler and Filter Housing....6810
Mounting Engine On Stand....6810
Table of Contents....6814
Engine Electronic Components....6816
Engine Sensor Harness Assembly....6819
Description of Engine Sensors, Valves, and Actuators....6820
5 mm 60 Degree Speed Sensor used to sense Crankshaft Position (CKP)....6820
5 mm 60 Degree Speed Sensor used to sense Camshaft Position (CMP)....6820
6 Bar Pressure sensor used to sense Engine Oil Pressure (EOP)....6820
15 Bar Pressure Sensor used to sense Fuel Delivery Pressure (FDP)....6821
Charge Pressure Sensor used as Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....6821
Coolant Control Valve (CCV) Assembly....6821
Coolant Pressure Sensor used to sense Engine Coolant Pressure (ECP1)....6822
Crankcase Pressure (CCP) Sensor ....6822
EGR Temperature (EGRT) Sensor....6822
Engine Throttle Valve (ETV) Assembly....6823
Exhaust Gas Recirculation (EGR) Valve Assembly....6823
Fuel Rail Pressure (FRP) Sensor....6824
Intake Manifold Pressure (IMP) Sensor....6824
Mass Air Flow (MAF) Sensor....6824
Oxygen Sensor (O2S)....6824
Temperature Sensor used to sense Engine Coolant Temperature 1 (ECT1) and 2 (ECT2)....6825
Temperature Sensor used to sense Engine Oil Temperature (EOT)....6825
Temperature Sensor used to sense Charge Air Cooler Outlet Temperature (CACOT)....6825
Temperature Sensor used to sense Intake Manifold Temperature (IMT)....6826
Wastegate Control Valve (Air Control Valve)....6826
Removal....6827
Crankshaft Position (CKP) Sensor....6827
Camshaft Position (CMP) Sensor....6827
Engine Oil Pressure (EOP) Sensor....6828
Fuel Delivery Pressure (FDP) Sensor....6828
Body Harness Interconnect....6829
Coolant Control Valve (CCV) Assembly Connectors....6829
Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....6830
Engine Coolant Pressure 1 (ECP1) Sensor....6830
Crankcase Pressure (CCP) Sensor....6831
Engine Control Module (ECM) Connections....6831
EGR Temperature (EGRT) Sensor....6832
Exhaust Gas Recirculation (EGR) Valve Assembly Connector....6832
Engine Throttle Valve (ETV) Assembly Connector....6833
Fuel Rail Pressure (FRP) Sensor....6833
High-Pressure Fuel Pump Connector....6834
Intake Manifold Pressure (IMP) Sensor....6834
Mass Air Flow (MAF) Sensor....6835
Cold Start Fuel Solenoid (CSFS) Valve Connector....6835
Charge Air Cooler Output Temperature (CACOT) Sensor....6836
Engine Coolant Temperature 1 (ECT1) Sensor....6836
Engine Coolant Temperature 2 (ECT2) Sensor....6837
Engine Oil Temperature (EOT) Sensor....6837
Intake Manifold Temperature (IMT) Sensor....6838
Air Control Valve Connector....6838
Engine Sensor Harness Assembly....6839
Engine Control Module (ECM) and ECM Support....6841
Harness Support (EGR Cooler)....6841
Harness Support (Fuel Pump)....6842
Oxygen Sensor (O2S)....6842
Oil Pressure Sensor Support....6843
Cleaning and Inspection....6844
Main Engine Wiring Harness....6844
Sensors and Valves....6844
Installation....6845
Engine Control Module (ECM) and ECM Support....6845
Harness Support (EGR Cooler)....6846
Harness Support (Fuel Pump)....6846
Oxygen Sensor (O2S)....6846
Oil Pressure Sensor Support....6847
Engine Sensor Harness Assembly....6847
Crankshaft Position (CKP) Sensor....6849
Camshaft Position (CMP) Sensor....6850
Engine Oil Pressure (EOP) Sensor....6850
Fuel Delivery Pressure (FDP) Sensor....6850
Body Harness Interconnect....6851
Coolant Control Valve (CCV) Assembly Connectors....6851
Turbocharger 2 Compressor Inlet Sensor (TC2CIS)....6852
Engine Coolant Pressure 1 (ECP1) Sensor....6852
Crankcase Pressure (CCP) Sensor....6852
Engine Control Module (ECM) Connections....6853
EGR Temperature (EGRT) Sensor....6854
Exhaust Gas Recirculation (EGR) Valve Assembly Connector....6854
Engine Throttle Valve (ETV) Assembly Connector....6855
Fuel Rail Pressure (FRP) Sensor....6855
High-Pressure Fuel Pump Connector....6856
Intake Manifold Pressure (IMP) Sensor....6856
Mass Air Flow (MAF) Sensor....6857
Cold Start Fuel Solenoid (CSFS) Valve Connector....6857
Charge Air Cooler Outlet Temperature (CACOT) Sensor....6858
Engine Coolant Temperature 1 (ECT1) Sensor....6858
Engine Coolant Temperature 2 (ECT2) Sensor....6859
Engine Oil Temperature (EOT) Sensor....6859
Intake Manifold Temperature (IMT) Sensor....6860
Air Control Valve Connector....6860
Table of Contents....6862
Exploded View....6864
Removal....6865
Cold Start Relay (CSR)....6865
Relay Support Assembly....6866
Solenoid to Injector Tube....6866
Filter to Solenoid Tube....6867
Cold Start Fuel Solenoid (CSFS)....6867
Cold Start Fuel Igniter (CSFI)....6867
Installation....6868
Cold Start Fuel Igniter (CSFI)....6868
Cold Start Fuel Solenoid (CSFS)....6868
Filter to Solenoid Tube....6869
Solenoid to Injector Tube....6869
Relay Support Assembly....6870
Cold Start Relay (CSR)....6871
Table of Contents....6874
Exploded Views....6876
Removal....6878
Pre-Diesel Oxidation Catalyst (PDOC)....6878
Down Stream Injection (DSI) Assembly and Doser Fuel to Injector Tube Assembly....6879
Injector Unit Feed Tube Assembly and Doser Fuel from Valve Tube Assembly....6880
Doser Coolant Supply Tube Assembly and Doser Coolant Return Tube Assembly....6881
Fuel Doser Assembly....6882
Turbocharger Exhaust Duct....6882
Inspection and Cleaning....6883
Fuel Doser....6883
Installation....6883
Turbocharger Exhaust Duct....6883
Fuel Doser Assembly....6884
Doser Coolant Supply Tube Assembly and Doser Coolant Return Tube Assembly....6885
Injector Unit Feed Tube Assembly and Doser Fuel from Valve Tube Assembly ....6885
Down Stream Injection (DSI) Assembly and Doser Fuel to Injector Tube Assembly....6886
Pre-Diesel Oxidation Catalyst (PDOC)....6887
Table of Contents....6890
Exploded Views....6892
Removal....6896
Turbocharger Oil Drain Tube Assembly....6896
High-Pressure (HP) Compressor Outlet Duct....6897
Air Inlet Duct....6897
Turbocharger to Intercooler Tube....6898
Turbocharger Interstage Cooler (ISC) Assembly....6899
Intercooler Support (Outer)....6901
Air Control Valve....6901
Turbocharger Heat Shields and High-Pressure (HP) Turbocharger Wastegate Actuator....6903
Turbocharger Oil Supply Tube Assemblies....6904
Turbochargers....6905
Disassembly....6907
Turbochargers....6907
Cleaning and Inspection....6907
Turbochargers and Related Parts Cleaning....6907
Turbochargers Inspection....6907
Turbocharger Interstage Cooler Assembly (ISC) Pressure Test....6908
Assembly....6910
Turbochargers....6910
Installation....6910
Turbochargers....6910
Turbocharger Oil Supply Tube Assemblies....6912
Turbocharger Heat Shields and High-Pressure (HP) Turbocharger Wastegate Actuator....6913
Air Control Valve....6914
Intercooler Support (Outer)....6915
Turbocharger Interstage Cooler (ISC) Assembly....6915
Turbocharger to Intercooler Tube....6918
Air Inlet Duct....6919
High-Pressure (HP) Compressor Outlet Duct....6919
Turbocharger Oil Drain Tube Assembly....6920
Table of Contents....6922
Exploded Views....6924
Removal....6926
Power Steering Pump....6926
Air Compressor Coolant Tubes....6926
Air Compressor ....6927
Cleaning....6928
All Components....6928
Installation....6929
Air Compressor ....6929
Air Compressor Coolant Tubes....6931
Power Steering Pump....6931
Table of Contents....6934
Exploded Views....6936
Periodic Service....6939
Fuel Filter Replacement....6939
Removal....6940
Pump to Rail Fuel Tube Assemblies and Rail to Injector Tube Assemblies....6940
Fuel Rail ....6943
Fuel Return Tube Assembly....6943
Fuel Filter Housing Assembly....6944
High-Pressure Fuel Pump....6946
Cleaning and Inspection....6947
Installation....6948
High-Pressure Fuel Pump....6948
Fuel Filter Housing Assembly....6949
Fuel Return to Tank Tube Assembly....6950
Fuel Rail....6951
Rail to Injector Tube Assemblies....6952
Pump to Rail Fuel Tube Assemblies....6953
Table of Contents....6956
Exploded Views....6958
Removal....6965
EGR Cooler Assembly Draining....6965
Coolant Manifold, ISC Coolant Supply Tube Assembly and CCV LTR Bypass Tube Assembly....6966
Coolant Control Valve (CCV) Assembly and Coolant Adapter....6968
Heater Core Return Adapter and Temperature Sensor Fitting....6969
Intercooler Support (Inner)....6969
EGRV Coolant Return Tube and EGRV Coolant Supply Tube....6970
EGR Coolant Tube Assembly (front) and EGR2 Coolant Supply Tube Assembly....6972
EGR Coolant Tube Assembly (rear), EGR Coolant Tube Assembly and EGR Tube Assembly....6973
Coolant Adapter and EGR Coolant Return Tube Assembly....6974
EGR Crossover Tube....6975
EGR Cooler Inlet Elbow....6976
EGR Cooler Supply Tube and EGR Valve Assembly....6977
EGR Cooler Assembly....6978
EGR Cooler Supports....6979
Cleaning, Inspection, and Testing....6980
Exhaust Gas Recirculation (EGR) System Components....6980
EGR Valve Assembly....6980
EGR Cooler Assembly Pressure Test....6981
Tool Assembly....6981
Tool Installation....6983
EGR Cooler Leak Test....6986
Tool Removal....6988
Installation....6990
EGR Cooler Supports....6990
EGR Cooler Assembly....6991
EGR Cooler Supply Tube and EGR Valve Assembly....6992
EGR Cooler Inlet Elbow....6993
EGR Crossover Tube....6994
Coolant Adapter and EGR Coolant Return Tube Assembly....6995
EGR Coolant Tube Assembly (rear), EGR Coolant Tube Assembly and EGR Tube Assembly....6996
EGR Coolant Tube Assembly (front) and EGR2 Coolant Supply Tube Assembly....6998
EGRV Coolant Return Tube and EGRV Coolant Supply Tube....7000
Intercooler Support (Inner)....7002
Heater Core Return Adapter and Temperature Sensor Fitting....7002
Coolant Control Valve (CCV) Assembly and Coolant Adapter....7003
Coolant Manifold, ISC Coolant Supply Tube Assembly and CCV LTR Bypass Tube Assembly....7004
Table of Contents....7008
Exploded Views....7010
Removal....7014
Engine Oil Cooler Assembly and Oil Filter Base Assembly....7014
Breather Tube and Valve Cover Adapter....7018
Breather Draft Tube and Breather Drain Tube....7019
Breather Filter Assembly and Oil Breather Support....7020
Disassemble....7021
Oil Filter Base Assembly Pressure Valves....7021
Cleaning, Inspection, and Testing....7021
Engine Oil Cooler Assembly Cleaning....7021
Assemble....7022
Oil Filter Base Assembly Pressure Valves....7022
Installation....7023
Breather Filter Assembly and Oil Breather Support....7023
Breather Draft Tube and Breather Drain Tube....7023
Breather Tube and Valve Cover Adapter....7024
Engine Oil Cooler Assembly and Oil Filter Base Assembly....7025
Table of Contents....7032
Exploded Views....7034
Removal....7036
Exhaust Manifold....7036
Air Inlet....7038
Cleaning, Inspection, and Testing....7040
All Components....7040
Exhaust Manifold....7040
Air Inlet....7040
Installation....7041
Air Inlet....7041
Exhaust Manifold....7042
Table of Contents....7046
Exploded Views....7048
Removal....7055
Fan Drive (High or Low Mount Fan)....7055
Thermostat Housing and Thermostats....7057
Water Pump Inlet and Water Outlet Pipe....7058
Belt Tensioners and Idler Pulleys....7060
A/C (Freon) Compressor Support....7061
Water Pump....7062
Damper....7062
Front Engine Mount Support....7063
Crankshaft Front Seal....7063
Front Cover ....7063
Timing Gears and Supports....7066
Cleaning, Inspection, and Testing....7075
Front Cover....7075
Timing Gears....7075
Installation....7076
Timing Gears and Supports....7076
Front Cover ....7083
Camshaft Gear....7086
Timing Gear Lash....7087
Crankshaft Front Seal....7090
Front Engine Mount Support....7090
Damper....7091
Water Pump....7091
A/C (Freon) Compressor Support....7092
Belt Tensioners and Idler Pulleys....7093
Water Pump Inlet and Water Outlet Pipe....7093
Thermostat Housing and Thermostats....7095
Fan Drive (High and Low Mount Fan)....7096
Table of Contents....7102
Exploded Views....7104
Periodic Service....7107
Engine Brake Lash Adjustment....7107
Removal....7111
Valve Brake Actuator Assembly....7111
Lost Motion Pedestal....7112
Cleaning and Inspection....7114
Valve Brake Actuator Assembly....7114
Installation....7115
Lost Motion Pedestal....7115
Valve Brake Actuator Assembly....7115
Table of Contents....7120
Exploded Views....7122
Periodic Service....7130
Valve Lash Adjustment....7130
Removal....7135
Valve Cover....7135
Valve Cover Base....7138
Engine Brakes....7141
Fuel Injectors....7141
Rocker Arms....7142
Camshaft and Bearings....7144
Camshaft....7144
Camshaft Bearings....7147
Cylinder Head....7148
Replacing O-ring Boss Plugs and Cylinder head Cup Plugs....7151
O-ring boss plugs....7151
Cup plugs....7151
Cleaning, Inspection, and Testing....7153
Camshaft Lobes and Journals Measurement....7153
Cylinder Head and Crankcase Components....7153
Camshaft Bearings....7154
Fuel Injector Bore....7154
Fuel Injector Harness....7154
Measuring Valve Seat Leakage....7154
Measuring Rocker Shaft....7155
Inspection and Measurement of Rocker Arms....7155
Measuring Cylinder Head Warpage....7156
Measuring Cylinder Head Thickness....7156
Inspecting Cylinder Head for Cracks....7157
Installation....7158
Cylinder Head....7158
Camshaft and Bearings....7161
Camshaft Bearings....7161
Camshaft....7163
Rocker Arms....7166
Fuel Injectors....7167
Engine Brakes....7169
Valve Cover Base....7169
Valve Cover....7174
Table of Contents....7180
Exploded Views....7182
Removal....7186
Oil Filler Pipe Assembly....7186
Oil Level Gauge and Oil Level Gauge Tube Assembly (Early Production)....7186
Oil Level Gauge and Oil Level Gauge Tube Assembly (Late Production)....7187
Oil Pan....7189
Oil Pick Up Tube and Oil Sending Tube Assemblies....7190
Oil Pump....7191
Oil Pan Plate Assembly....7192
Cleaning and Inspection....7193
Oil Pan....7193
Oil Pick Up Tube....7193
Oil Sending Tube Assembly....7193
Installation....7194
Oil Pan Plate Assembly....7194
Oil Pump....7194
Oil Pick Up Tube and Oil Sending Tube Assemblies....7195
Oil Pan....7196
Oil Level Gauge and Oil Level Gauge Tube Assembly (Late Production)....7199
Oil Level Gauge and Oil Level Gauge Tube Assembly (Early Production)....7201
Oil Filler Pipe Assembly....7202
Table of Contents....7204
Exploded Views....7206
Removal....7209
Preliminary Checks ? Flywheel Assembly....7209
Rear Engine Mounts....7209
Flywheel Assembly....7210
Crankshaft Rear Seal....7211
Flywheel Housing....7211
Clean, Inspect, and Measure....7215
All Components....7215
Flywheel Assembly Face Runout (Axial Eccentricity)....7215
Flywheel Assembly Bore Runout (Radial Eccentricity)....7215
Flywheel Housing Face Runout (Axial Eccentricity)....7216
Flywheel Housing Bore Runout (Radial Eccentricity)....7217
Recondition....7218
Flywheel Assembly....7218
Installation....7220
Flywheel Housing....7220
Crankshaft Rear Seal....7223
Flywheel Assembly....7224
Rear Engine Mounts....7226
Table of Contents....7228
Exploded Views....7230
Removal....7232
Preliminary Checks....7232
Piston and Connecting Rod....7233
Piston Disassembly....7234
Cylinder Sleeves....7235
Cleaning and Inspection....7236
Cleaning....7236
Piston Inspection....7236
Piston Ring Inspection....7237
Connecting Rod Inspection....7237
Connecting Rod Bore Check....7238
Piston Pin Inspection....7238
Cylinder Sleeve Bore Inspection....7239
Cylinder Sleeve Projection Measurement....7239
Installation....7243
Cylinder Sleeves....7243
Piston Assembly....7243
Piston and Connecting Rod....7244
Table of Contents....7250
Exploded Views....7252
Removal....7255
Crankshaft Bearing Caps, Crankshaft, and Main Bearings....7256
Piston Cooling Jet....7258
Crankcase Dowel Pins, Plugs and Fittings....7259
Cleaning, Inspection, and Testing....7262
Crankshaft End Play....7262
Crankcase....7262
Crankshaft....7263
Main Bearings....7264
Piston Cooling Jet....7266
Installation....7267
Crankcase Dowel Pins, Plugs and Fittings....7267
Piston Cooling Jet....7269
Crankshaft Bearing Caps, Crankshaft, and Main Bearings....7270
Table of Contents....7280
Abbreviations and Acronyms....7282
Table of Contents....7288
Terminology....7290
Terms....7290
Table of Contents....7300
Fuel System....7302
Exhaust Gas Recirculation (EGR) System....7302
Air Inlet and Exhaust Manifolds....7302
Front Cover, High Mount Fan Drive, Cooling System, and Related Components....7302
Engine Brake....7302
Cylinder Head, Camshaft and Valve Train....7303
Flywheel and Flywheel Housing....7304
Power Cylinders....7305
Crankcase and Crankshaft....7306
Table of Contents....7308
General Torque....7310
Bolt Identification....7310
General Torque Guidelines....7311
Standard Torque Charts....7312
Using a Torque Wrench Extension....7314
Special Torques....7315
Mounting Engine on Stand....7315
Engine Electrical....7315
Cold Start Assist....7315
Aftertreatment System....7316
Turbochargers....7316
Air Compressor and Power Steering....7316
Fuel System....7317
Exhaust Gas Recirculation (EGR) System....7318
Oil Cooler, Filter Housing and Crankcase Ventilation....7318
Air Inlet and Exhaust Manifolds....7319
Front Cover, High Mount Fan Drive, Cooling System, Related Components....7320
Engine Brake....7321
Cylinder Head, Camshaft and Valve Train....7321
Oil Pan, Oil Pickup Tube and Oil Pump....7321
Flywheel and Flywheel Housing....7322
Power Cylinders....7322
Crankcase and Crankshaft....7322
Table of Contents....7324
Special Tools....7326
Mounting Engine on Stand....7326
Engine Electrical....7326
Aftertreatment System....7326
Turbochargers....7326
Fuel System....7327
Exhaust Gas Recirculation (EGR) System....7327
Oil Cooler, Filter Housing and Crankcase Ventilation....7327
Air Inlet and Exhaust Manifolds....7327
Front Cover, High Mount Fan Drive, Cooling System, and Related Components....7328
Engine Brake....7328
Cylinder Head, Camshaft and Valve Train....7329
Oil Pan , Oil Suction Tube and Oil Pump....7330
Flywheel and Flywheel Housing....7330
Power Cylinders....7330
Crankcase and Crankshaft....7331
Special Tools ....7332
Essential Tools....7332
tables....6752
Technical Service Literature....6752
MaxxForce? 15 Diesel Engine....6760
Table 1....7132
Table 2....7132
Table 3....7133
Table 4....7133
Cylinder Head, Camshaft and Valve Train....7176
Standard Torque Values ? Class 10.9 Metric Flange Head Bolts and Studs....7312
Thread Diameter (mm)....7312
Thread Pitch (mm)....7312
Torque....7312
Standard Torque Values ? Standard (SAE) Flange Head Bolts and Studs....7313
Thread Diameter (mm)....7313
Thread Pitch (in)....7313
Torque....7313
0000001921 - Manuel de Reparation Moteurs MaxxForce 11 et 13....7339
toc....7341
Faits saillants?:....7341
Terminologie de s?curit?....7347
Consignes de s?curit?....7347
Zone de travail....7347
?quipement de s?curit?....7347
Mesures de protection....7347
V?hicule....7347
Moteur....7347
Pr?vention des incendies....7348
Batteries....7348
Air comprim?....7348
Outils....7348
Liquides sous pression....7348
Carburant....7348
Retrait d'outils, de pi?ces et d'?quipement....7348
Table des Mati?res....7349
Identification du moteur....7351
Num?ro de s?rie du moteur....7351
Exemples de num?ro de s?rie moteur....7351
Codes du num?ro de s?rie du moteur....7351
?tiquette d'?missions du moteur ....7351
?tiquettes et plaques signal?tiques des accessoires moteur....7352
Sp?cifications du moteur....7352
Diagnostics embarqu?s ?Heavy Duty On Board Diagnostics? (HD-OBD)....7354
Description du moteur....7354
?quipement en option....7355
?quipement mont? sur le ch?ssis....7355
Emplacement des composants du moteur....7357
Syst?me de gestion d'air....7361
D?bit d'air....7362
Turbocompresseurs....7363
Soupape de commande d'air (ACV)....7365
Contr?le de la suralimentation....7365
Refroidisseur d'air de suralimentation basse pression (LPCAC)....7366
Refroidisseur d'air de suralimentation haute pression (HPCAC)....7366
Capteur de pression de suralimentation haute pression (HPBP) ....7366
Capteur de temp?rature de suralimentation haute pression (HPBT) ....7366
Capteur de pression de suralimentation basse pression (LPBP) et capteur de temp?rature de suralimentation basse pression (LPBT) ....7366
Syst?me de recirculation des gaz d'?chappement (RGE)....7368
Aper?u du syst?me RGE....7369
D?bit RGE....7369
Commande du syst?me RGE....7369
Commande de la SRGE....7369
RGE ? Boucle ouverte....7370
RGE ? Boucle ferm?e ....7370
Refroidissement du d?bit de RGE....7370
Syst?me postcombustion (AFT)....7371
Filtre ? particules diesel (DPF)....7372
Convertisseur catalytique d'oxydation diesel (DOC)....7372
?tats et r?ponses du syst?me postcombustion (AFT)....7372
Injection de carburant en aval....7373
Doseur d'injection en aval (DSI)....7374
Ensemble d'injecteur d'hydrocarbure (HCI)....7374
S?parateur d'huile du carter....7375
Syst?me de gestion du carburant....7377
Circuit d'alimentation....7377
D?bit de carburant....7378
Circuit d'alimentation ? basse pression....7380
Filtre/s?parateur d'eau mont? sur le ch?ssis....7380
Ensemble de pompe d'amor?age de carburant....7381
Pompe ? carburant basse pression (BP)....7381
Ensemble du filtre de carburant....7381
Circuit d'alimentation haute pression....7382
Pompe haute pression (HP)....7384
Soupape de commande de pression du carburant (FPCV)....7384
Rampe d'alimentation en carburant....7384
Capteur de pression de la rampe d'alimentation en carburant (FRP)....7384
Soupape de d?charge....7384
Injecteurs....7384
Dispositif de d?marrage ? froid....7384
Composants du dispositif de d?marrage ? froid....7384
Allumeur de d?marrage ? froid (CSFI)....7384
Relais de d?marrage ? froid (CSR)....7385
?lectrovanne de d?marrage ? froid (CSS)....7385
Fonctionnement du dispositif de d?marrage ? froid....7385
Circulation d'huile et composants....7386
S?parateur d'huile du carter....7388
Filtre ? huile centrifuge distant (en option)....7389
Circuit de refroidissement du moteur....7391
D?bit du syst?me de refroidissement....7391
Fonctionnement du thermostat....7392
Fonctionnement de la soupape de commande du liquide de refroidissement (CCV)....7394
Soupape de d?bit de liquide de refroidissement (CFV)....7394
Soupape de m?langeur de refroidissement (CMV)....7394
Syst?me de freinage du moteur....7395
Composants du syst?me de commande de freinage du moteur....7395
Fonctionnement du syst?me de frein moteur....7397
Le syst?me de commande ?lectronique....7398
Composants du syst?me de commande ?lectronique....7398
Fonctionnement et fonction....7398
Tension de r?f?rence (Vref)....7398
Conditionneur de signaux....7398
Microprocesseur....7398
Codes d?anomalie....7398
M?moire du microprocesseur....7398
M?moire morte (ROM)....7398
RAM....7398
Commande d'actionneur....7400
Actionneurs....7400
Soupape de commande du liquide de refroidissement (CCV)....7400
Commande de la soupape de contre-pression ? l'?chappement (EBPV)....7400
Soupape de recirculation des gaz d'?chappement (RGE) ....7400
Soupape de commande d'air (ACV)....7400
Relais de d?marrage ? froid (CSR)....7400
?lectrovanne de d?marrage ? froid (CSS)....7402
Papillon des gaz (ETV)....7402
Soupape de commande de pression du carburant (FPCV)....7402
Doseur de carburant postcombustion (AFTFD)....7403
Soupape d'arr?t postcombustion (AFTSV)....7403
Capteurs du moteur et du v?hicule....7403
Capteurs ? thermistance....7403
Capteurs de temp?rature postcombustion....7404
Capteurs de temp?rature du liquide de refroidissement du moteur (ECT)....7404
Capteur de temp?rature de l'huile moteur (EOT)....7404
Capteur d'entr?e du compresseur de turbocompresseur 2 (TC2CIS)....7404
Capteur de temp?rature de sortie du refroidisseur d'air de suralimentation (CACOT)....7405
Capteur de temp?rature du collecteur d'admission (IMT)....7405
Capteur de temp?rature de recirculation des gaz d'?chappement (EGRT)....7405
Capteur de temp?rature de l'air ambiant (AAT)....7405
Capteurs ? capacit? variable....7405
Capteur de pression diff?rentielle DPF (DPFDP)....7405
Capteur de pression de carburant (EFP)....7406
Capteur de pression d'huile moteur (EOP)....7406
Capteur de pression de la rampe d'alimentation en carburant (FRP)....7406
Capteur de pression du collecteur d'admission (IMP)....7406
Capteur d'entr?e de carburant postcombustion....7406
Capteur de pression du carburant postcombustion 2 (AFP2)....7406
Pression de sortie de la turbine du turbocompresseur 1 (TC1TOP)....7406
Capteurs magn?tiques....7407
Capteur de position du vilebrequin (CKP)....7407
Capteur de position de l'arbre ? cames (CMP)....7407
Capteur de vitesse du v?hicule (VSS)....7407
Capteur de vitesse du s?parateur d'huile du carter (CCOSS)....7407
Capteurs ? potentiom?tre....7408
Position de p?dale d'acc?l?rateur (APP)....7408
Commutateurs....7408
Commutateur de d?sengagement de la transmission (DDS)....7408
Commutateur de niveau de liquide de refroidissement du moteur (ECL)....7409
Capteur de niveau d'huile (OLS)....7409
Capteurs suppl?mentaires....7409
Capteur d'oxyg?ne (O2S)....7409
Capteur d'humidit? (HS)....7409
Table des Mati?res....7411
Montage du moteur....7413
Nettoyage du moteur....7413
Montage du moteur sur le support....7413
Table des Mati?res....7419
Emplacement des composants ?lectroniques....7421
Composants ?lectroniques du c?t? avant droit....7421
Composants ?lectroniques du c?t? arri?re gauche....7422
Description des capteurs, soupapes et actionneurs du moteur....7423
Capteur de position du vilebrequin (CKP)....7423
Capteur de position de l'arbre ? cames (CMP)....7423
Capteurs de temp?rature du liquide de refroidissement du moteur (ECT)....7423
Capteur de temp?rature de l'huile moteur (EOT)....7424
Capteur de pression d'huile moteur (EOP)....7424
Capteur de vitesse du s?parateur d'huile du carter (CCOSS)....7424
Capteur de pression d'alimentation en carburant (FDP)....7425
Soupape de commande de pression du carburant (FPCV)....7425
D?bitm?tre d'air massique (MAF)....7425
Capteur d'humidit?/de temp?rature d'entr?e d'air (IAT)....7426
Capteur de temp?rature de sortie du refroidisseur d'air de suralimentation (CACOT)....7426
Capteur de pression du collecteur d'admission (IMP)....7426
Capteur de pression de la rampe d'alimentation en carburant (FRP)....7427
Capteur de temp?rature du collecteur d'admission (IMT)....7427
Capteur d'oxyg?ne (O2S)....7428
Papillon des gaz (ETV)....7428
Soupape de commande du liquide de refroidissement (CCV)....7429
Ensemble de la soupape de commande d'air (ACV)....7429
Soupape de recirculation des gaz d'?chappement (RGE)....7430
Capteur de temp?rature de recirculation des gaz d'?chappement (EGRT)....7430
Capteur d'entr?e du compresseur de turbocompresseur 2 (TC2CIS)....7430
D?pose....7431
Mises en garde et avertissements....7431
Capteur de position du vilebrequin (CKP)....7431
Capteur de position de l'arbre ? cames (CMP)....7432
Capteur de temp?rature du liquide de refroidissement du moteur 1 (ECT1)....7432
Capteur de temp?rature du liquide de refroidissement du moteur 2 (ECT2)....7432
Capteur de temp?rature de l'huile moteur (EOT)....7433
Capteur de pression d'huile moteur (EOP)....7433
Capteur de vitesse du s?parateur d'huile du carter (CCOSS)....7434
Capteur de pression d'alimentation en carburant (FDP)....7434
Soupape de commande de pression du carburant (FPCV)....7435
Capteur de d?bit d'air massique (MAF) (selon l'?quipement)....7435
Capteur d'humidit?/temp?rature d'air d'admission (IAT)....7436
Capteur de temp?rature de sortie du refroidisseur d'air de suralimentation (CACOT)....7436
Capteur de pression du collecteur d'admission (IMP)....7437
Capteur de pression de la rampe d'alimentation en carburant (FRP)....7437
Capteur de temp?rature du collecteur d'admission (IMT)....7438
Capteur d'oxyg?ne (O2S)....7438
Papillon des gaz (ETV)....7439
Soupape de commande du liquide de refroidissement (CCV)....7439
Soupape de commande d'air (ACV)....7440
Soupape de recirculation des gaz d'?chappement (RGE)....7440
Capteur de temp?rature de recirculation des gaz d'?chappement (EGRT)....7441
Capteur d'entr?e du compresseur de turbocompresseur 2 (TC2CIS)....7441
Connexions du module ECM du faisceau de c?blage....7441
Faisceau (de c?blage) des injecteurs du moteur....7442
Faisceau (de c?blage) du capteur de moteur....7444
Module de commande du moteur (ECM) et support....7447
Nettoyage et inspection....7448
Faisceaux de c?blage de l'injection du moteur et du capteur du moteur....7448
Capteurs et soupapes....7448
Module de commande du moteur (ECM)....7448
Pose....7449
Module de commande du moteur (ECM) et support....7449
Faisceau (de c?blage) du capteur de moteur....7450
Faisceau (de c?blage) des injecteurs du moteur....7453
Connexions du module ECM du faisceau de c?blage....7455
Capteur d'entr?e du compresseur de turbocompresseur 2 (TC2CIS)....7455
Capteur de temp?rature de recirculation des gaz d'?chappement (EGRT)....7456
Soupape de recirculation des gaz d'?chappement (RGE)....7456
Soupape de commande d'air (ACV)....7457
Soupape de commande du liquide de refroidissement (CCV)....7457
Papillon des gaz (ETV)....7458
Capteur d'oxyg?ne (O2S)....7458
Capteur de temp?rature du collecteur d'admission (IMT)....7459
Capteur de pression de la rampe d'alimentation en carburant (FRP)....7459
Capteur de pression du collecteur d'admission (IMP)....7460
Capteur de temp?rature de sortie du refroidisseur d'air de suralimentation (CACOT)....7460
Capteur d'humidit?/de temp?rature d'entr?e d'air (IAT)....7461
Capteur de d?bit d'air massique (MAF) (selon l'?quipement)....7461
Soupape de commande de pression du carburant (FPCV)....7462
Capteur de pression d'alimentation en carburant (FDP)....7462
Capteur de vitesse du s?parateur d'huile du carter (CCOSS)....7463
Capteur de pression d'huile moteur (EOP)....7463
Capteur de temp?rature de l'huile moteur (EOT)....7464
Capteur de temp?rature du liquide de refroidissement du moteur 2 (ECT2)....7464
Capteur de temp?rature du liquide de refroidissement du moteur 1 (ECT1)....7465
Capteur de position de l'arbre ? cames (CMP)....7465
Capteur de position du vilebrequin (CKP)....7466
Table des Mati?res....7469
Vue ?clat?e....7471
Composants du dispositif d'aide au d?marrage ? froid....7471
D?pose....7472
Ensemble de relais....7472
Bougie de pr?chauffage et tuyau de d?marrage ? froid de l'alimentation en carburant....7473
Durite de sol?no?de d'alimentation en carburant....7473
Bougie de pr?chauffage....7474
Pose....7475
Bougie de pr?chauffage....7475
Durite de sol?no?de d'alimentation en carburant....7476
Bougie de pr?chauffage et tuyau de d?marrage ? froid de l'alimentation en carburant....7477
Ensemble de relais....7478
Table des Mati?res....7481
Illustrations....7483
Composants d'alimentation en carburant du catalyseur et du syst?me de postcombustion....7483
D?pose....7486
Tubes et durite du filtre de sortie d'alimentation....7486
Bo?tier de soupapes de l'unit? de dosage....7489
Catalyseur d'oxydation pr?-diesel (PDOC)....7490
Ensemble de tube d'alimentation en liquide de refroidissement HCI....7491
Ensemble de tube de retour de liquide de refroidissement HCI ....7492
Ensemble d'injecteur d'hydrocarbure (HCI) ....7493
Nettoyage et inspection....7493
Nettoyage d'injecteur d'hydrocarbures....7493
Pose....7494
Bo?tier de soupapes de l'unit? de dosage....7494
Ensemble d'injecteur d'hydrocarbure (HCI)....7495
Ensemble de tube de retour de liquide de refroidissement HCI....7496
Ensemble de tube d'alimentation en liquide de refroidissement HCI....7497
Catalyseur d'oxydation pr?-diesel (PDOC)....7498
Ensemble de tube de carburant HCI ....7499
Table des Mati?res....7503
Vues ?clat?es....7505
Syst?me de commande....7505
D?pose....7506
Avertissements....7506
Soupape de commande d'air (ACV)....7507
Actionneur de soupape de contre-pression ? l'?chappement et tubes du capteur de pression de sortie de turbine TC1....7508
Soupape de contre-pression ? l'?chappement....7509
Pose....7510
Soupape de contre-pression ? l'?chappement....7510
Soupape de commande d'air (ACV)....7511
Actionneur de soupape de contre-pression ? l'?chappement et tubes du capteur de pression de sortie de turbine TC1....7512
Table des Mati?res....7517
Vues ?clat?es....7519
Turbocompresseurs et ensemble de refroidisseur d'air de suralimentation....7519
Tube de liquide de refroidissement, tuyaux de liquide de refroidissement et refroidisseur d'air de suralimentation basse pression (LPCAC)...7520
Tube d'alimentation en huile et support de fixation du turbocompresseur....7521
Tubes de retour d'huile du turbocompresseur....7522
Entr?es d'air, actionneur de la soupape de d?charge haute pression et soupape de commande d'air....7523
Turbocompresseurs....7524
D?pose....7525
Flexible de d?charge haute pression (HP)....7525
Refroidisseur d'air de suralimentation basse pression (LPCAC)....7526
Tubes et tuyaux de liquide de refroidissement du refroidisseur d'air de suralimentation (LPCAC)....7527
Conduit de sortie et conduit d'admission d'air du compresseur haute pression (HP)....7529
Conduit d'alimentation en air du turbocompresseur haute pression....7529
Tubes de retour d'huile et d'alimentation en huile du turbocompresseur....7530
?crans thermiques de turbocompresseur....7531
Support de fixation de turbocompresseur....7532
Actionneur de la soupape de d?charge du turbocompresseur haute pression (HP)....7532
Montage du turbocompresseur....7533
D?sassemblage....7534
Turbocompresseurs....7534
Nettoyage et inspection....7535
Nettoyage des turbocompresseurs et des pi?ces connexes....7535
Inspection des turbocompresseurs....7535
Essai de pression du Refroidisseur d'air de suralimentation basse pression (LPCAC)....7535
Pose....7538
Montage du turbocompresseur....7538
Support de fixation de turbocompresseur....7540
Actionneur de la soupape de d?charge du turbocompresseur haute pression (HP)....7540
?crans thermiques de turbocompresseur....7541
Tubes de retour d'huile et d'alimentation en huile du turbocompresseur....7541
Conduit d'alimentation en air du turbocompresseur haute pression....7543
Conduit de sortie et conduit d'admission d'air du compresseur haute pression (HP)....7543
Tubes et tuyaux de liquide de refroidissement du refroidisseur d'air de suralimentation (LPCAC)....7544
Refroidisseur d'air de suralimentation basse pression (LPCAC)....7546
Flexible de d?charge haute pression (HP)....7547
Table des Mati?res....7549
Vues ?clat?es....7551
Servodirection et compresseur d'air ? un cylindre....7551
Servodirection et compresseur d'air ? deux cylindres....7553
D?pose....7554
Tubes de pression de servodirection....7554
Coudes de servodirection....7555
Pompe de servodirection....7556
Flexibles de liquide de refroidissement du compresseur d'air....7556
Compresseur d'air....7557
Nettoyage....7557
Tous les composants....7557
Pose....7559
Compresseur d'air ....7559
Flexibles de liquide de refroidissement du compresseur d'air....7560
Pompe de servodirection....7560
Coudes de servodirection....7562
Tubes de pression de servodirection....7562
Table des Mati?res....7565
Vues ?clat?es....7567
Conduites de carburant haute pression....7567
Conduites (de retour) d'alimentation et de vidange du carburant....7568
Ensemble de bo?tier du filtre ? carburant....7569
Pompe ? carburant haute pression et bo?tier d'entra?nement....7570
D?pose....7571
Conduites de carburant haute pression....7572
Injecteur et conduites (de retour) de vidange du carburant....7575
Ensemble de la rampe d'alimentation en carburant....7576
Ensemble de pompe d'amor?age de carburant....7576
Conduites (de retour) d'alimentation et de vidange du carburant....7577
Ensemble de pompe d'amor?age de carburant....7579
Ensemble de bo?tier du filtre ? carburant....7580
Remplacement du tuyau vertical du filtre ? carburant....7581
Poulie (de courroie d'entra?nement) de pompe haute pression....7581
Bo?tier de poulie (de courroie d'entra?nement) de pompe haute pression et joint radial de demi-arbre....7582
Pompe ? carburant haute pression (HPFP) et bo?tier d'entra?nement....7582
Injecteurs de carburant....7586
Nettoyage et inspection....7589
Composants du circuit d'alimentation basse pression et haute pression....7589
Al?sage de l'injecteur de carburant....7589
Faisceau de c?blage des injecteurs de carburant....7589
Pose....7590
Injecteurs de carburant....7590
Pompe ? carburant haute pression (HPFP) et bo?tier d'entra?nement....7595
Bo?tier de poulie (de courroie d'entra?nement) de pompe haute pression et joint radial de demi-arbre....7597
Poulie (de courroie d'entra?nement) de pompe haute pression....7598
Ensemble de bo?tier du filtre ? carburant....7598
Ensemble de pompe d'amor?age de carburant....7599
Conduites (de retour) d'alimentation et de vidange du carburant....7600
Ensemble de la rampe d'alimentation en carburant....7602
Injecteur et conduites (de retour) de vidange du carburant....7603
Conduites de carburant haute pression....7603
Filtre et filtre ? carburant....7606
Amor?age du circuit d'alimentation en carburant....7606
M?thode de l'outil d'amor?age du circuit d'alimentation en carburant....7606
M?thode de la pompe de l'amorceur manuel....7613
Table des Mati?res....7617
Vues ?clat?es....7619
Ensemble du module de lubrification....7619
Module de lubrification....7620
D?pose....7621
Couvercle du filtre ? huile et filtre....7621
Centrifugeuse d'huile....7622
Ensemble du module de lubrification....7623
Refroidisseur d'huile....7625
Soupape de d?charge d'huile....7626
Nettoyage, inspection et essais....7627
Refroidisseur d'huile....7627
Essai d'?tanch?it? du refroidisseur d'huile....7627
Tubes de rallonge....7627
Centrifugeuse d'huile....7627
Pose....7628
Soupape de d?charge d'huile....7628
Refroidisseur d'huile....7628
Ensemble du module de lubrification....7629
Centrifugeuse d'huile....7631
Couvercle du filtre ? huile et filtre....7631
Table des Mati?res....7635
Vues ?clat?es....7637
Collecteur et coude de liquide de refroidissement RGE....7637
D?pose....7642
Collecteur de liquide de refroidissement....7642
Coude du liquide de refroidissement ....7643
Support du refroidisseur du RGE....7644
Tubes de sortie RGE....7644
Couvercle du module RGE....7645
?cran de protection thermique (cylindres 4-6)....7645
Tube d'entr?e RGE....7646
?cran RGE de protection thermique....7647
Soupape RGE ? deux volets....7647
Ensemble de refroidisseur RGE....7648
D?montage et montage du refroidisseur du RGE....7649
Remplacement du c?t? haute temp?rature ou basse temp?rature du refroidisseur du RGE....7649
Nettoyage, inspection et essais....7655
Nettoyage des composants du syst?me RGE....7655
Nettoyage de l'ensemble du refroidisseur du RGE....7655
Essai d'?tanch?it? de l'ensemble de refroidisseur RGE....7663
Pose....7664
Ensemble de refroidisseur RGE....7664
Soupape RGE ? deux volets....7664
?cran RGE de protection thermique....7666
Tube d'entr?e RGE....7667
?cran de protection thermique (cylindres 4-6)....7668
Couvercle du module RGE....7668
Tubes de sortie RGE....7669
Support du refroidisseur du RGE....7669
Coude du liquide de refroidissement....7670
Collecteur de liquide de refroidissement....7670
Table des Mati?res....7673
Vues ?clat?es....7675
Collecteur d'?chappement....7675
Conduit horizontal d'admission d'air ? papillon....7676
Conduit vertical d'admission d'air ? papillon....7677
D?pose....7678
Collecteur d'?chappement....7678
Conduit d'admission d'air ? papillon....7679
Nettoyage, inspection et essais....7680
Conduit d'admission d'air ? papillon et collecteurs d'?chappement....7680
Essai de gauchissement de collecteur pour les collecteurs d'?chappement....7680
Pose....7682
Conduit d'admission d'air ? papillon....7682
Collecteur d'?chappement....7683
Table des Mati?res....7687
Vues ?clat?es....7689
Syst?me d'entra?nement de ventilateur sur?lev? et Amortisseur de vibrations....7689
Syst?me d'entra?nement des accessoires (typique)....7690
Thermostat et collecteur de sortie de liquide de refroidissement (ventilateur surbaiss?)....7691
Thermostat et collecteur de sortie de liquide de refroidissement (ventilateur sur?lev?)....7692
Ensemble de pompe ? eau, Soupape de commande de liquide de refroidissement (CCV), Bo?tier de distribution d'eau, Bo?tier de thermostat et Collecteur de retour du refroidisseur du RGE....7693
Couvercle avant de ventilateur entra?n? par courroie (ventilateur sur?lev?)....7694
Couvercle avant de ventilateur entra?n? par engrenages (ventilateur surbaiss?)....7695
Entra?nement du ventilateur surbaiss? (typique)....7696
D?pose....7697
Poulie (ventilateur surbaiss?)....7697
Support du tendeur (ventilateur sur?lev?)....7698
Entra?nement de ventilateur sur?lev?....7698
Collecteur de sortie de liquide de refroidissement et ensemble de thermostat....7699
Tendeur automatique de courroie et poulies folles....7700
Ensemble de pompe ? eau et poulie....7700
Amortisseur de vibrations....7701
Ensemble de la soupape de commande du liquide de refroidissement (CCV)....7702
Bo?tier de thermostat....7702
Bo?tier de distribution d'eau....7703
Joint radial de demi-arbre de couvercle avant de ventilateur entra?n? par courroie ou par engrenages....7704
Couvercle avant de ventilateur entra?n? par courroie ou par engrenages....7704
Joint radial de demi-arbre (entra?nement de ventilateur surbaiss?)....7705
M?canisme d'entra?nement de ventilateur surbaiss?....7706
Nettoyage, inspection et essais....7707
Pose....7708
M?canisme d'entra?nement de ventilateur surbaiss?....7708
Joint radial de demi-arbre (entra?nement de ventilateur surbaiss?)....7708
Couvercle avant de ventilateur entra?n? par courroie ou par engrenages....7709
Joint radial de demi-arbre de couvercle avant de ventilateur entra?n? par courroie ou par engrenages....7709
Bo?tier de distribution d'eau....7710
Bo?tier de thermostat....7710
Ensemble de la soupape de commande du liquide de refroidissement (CCV)....7711
Amortisseur de vibrations....7712
Ensemble de pompe ? eau et poulie....7713
Tendeur automatique de courroie et poulie folle....7713
Collecteur de sortie de liquide de refroidissement et ensemble de thermostat....7714
Entra?nement de ventilateur sur?lev?....7715
Support du tendeur (ventilateur sur?lev?)....7716
Poulie (ventilateur surbaiss?)....7716
Table des Mati?res....7719
Vues ?clat?es....7721
Ensemble de bo?tier de frein moteur MaxxForce?....7722
Faisceau de c?blage de l'injecteur du moteur avec fils du sol?no?de du frein moteur....7723
D?pose....7724
Ensemble de bo?tier de frein moteur....7724
D?sassemblage....7725
Sol?no?de....7725
Soupape de commande....7725
Piston ma?tre....7726
Piston esclave....7726
Nettoyage et inspection....7728
Contr?le de l'ensemble de sol?no?de....7728
Assemblage....7729
Piston esclave....7729
Piston ma?tre....7730
Soupape de commande....7731
Sol?no?de....7731
Pose....7732
Ensemble de bo?tier de frein moteur....7732
Jeu du frein sur ?chappement....7733
Table des Mati?res....7735
Vues ?clat?es....7737
Couvre-culasse et base....7737
Ensemble de culbuteur non freinage et balanciers....7738
Pignon interm?diaire de l'arbre ? cames et de la culasse....7739
Culasse....7740
Entretien p?riodique....7741
Proc?dure de rotation du vilebrequin....7741
Proc?dure cylindre n?1 au PMH....7741
Proc?dure de chevauchement des soupapes....7742
Proc?dure de r?glage du jeu des soupapes....7743
D?pose....7745
Couvre-culasse sup?rieur et base....7745
Culbuteur (moteur non frein)....7746
Arbre ? cames....7747
Culasse....7751
Pignon interm?diaire de la culasse....7753
Nettoyage, inspection et essai....7755
Composants de la culasse et du carter....7755
Paliers d'arbre ? cames....7755
Al?sage de l'injecteur de carburant....7756
Essai de fuite des soupapes....7756
Pose....7758
Pignon interm?diaire de la culasse....7758
Culasse....7758
Arbre ? cames....7763
Culbuteur (moteur non frein)....7765
Couvre-culasse sup?rieur et base....7766
Table des Mati?res....7771
Vues ?clat?es....7773
Bo?tier de volant-moteur et volant-moteur (transmission manuelle)....7773
Volant-moteur et ensemble de plaque tuyau (transmission automatique)....7774
Supports moteur arri?re....7775
D?pose....7776
Contr?les et mesures pr?alables....7776
Ensemble de volant-moteur (Transmission manuelle)....7776
Faux-rond de la surface du volant-moteur....7776
Palier guide....7777
Volant-moteur (Transmission manuelle)....7777
Volant-moteur et plaque tuyau (Transmission automatique)....7778
Joint radial de segment pour arbre....7778
Anneaux de levage....7779
Carter de volant....7779
Nettoyage et inspection....7781
Tous les composants....7781
Ensembles de volant-moteur et de plaque tuyau....7781
Remise en ?tat....7781
Volant....7781
Pose....7783
Carter de volant....7783
Anneaux de levage....7784
Joint radial de segment pour arbre....7785
Ensemble de volant-moteur (Transmission manuelle)....7785
Palier guide (volant-moteur)....7786
Volant-moteur et plaque tuyau (Transmission automatique)....7786
Table des Mati?res....7789
Vues ?clat?es....7791
Carter d'huile (carter avant illustr?, carter arri?re similaire, typique)....7791
Tube d'aspiration d'huile - carter d'huile avant (typique)....7792
D?pose....7793
Carter d'huile....7793
Tube d'aspiration d'huile ? carter avant....7794
R?cup?ration d'huile....7796
Tube d'aspiration d'huile ? carter arri?re....7797
Nettoyage et inspection....7798
Carter d'huile....7798
Tube d?aspiration d?huile....7798
Pose....7799
Tube d'aspiration d'huile ? carter avant....7799
Tube d'aspiration d'huile ? carter arri?re....7799
R?cup?ration d'huile....7800
Carter d'huile....7803
Table des Mati?res....7807
Vues ?clat?es....7809
Pompe ? huile....7809
Pignons de distribution avant (typique)....7810
Pignons de distribution arri?re....7811
D?pose....7812
Contr?les pr?alables....7812
Pompe ? huile....7814
Pignons du carter avant....7815
Pignons de distribution arri?re....7815
Nettoyage et inspection....7817
Pignons de distribution....7817
Pompe ? huile....7817
Pose....7818
Pignons de distribution arri?re....7818
Pignons de distribution avant....7820
Pompe ? huile....7820
Table des Mati?res....7823
Vues ?clat?es....7825
Piston et bielle (typique) et chemise de cylindre....7825
D?pose....7827
Contr?les pr?alables....7827
Piston et bielle....7828
D?montage de piston....7829
Chemises de cylindre....7830
Nettoyage et inspection....7832
Nettoyage....7832
Inspection des pistons....7832
Inspection du segment de piston....7834
V?rification des bielles....7835
V?rification de l'al?sage de bielle....7836
Inspection des axes de piston....7837
Inspection des enveloppes de cylindre....7837
Pose....7839
Chemises de cylindre....7839
Montage du piston....7839
Piston et bielle....7840
Proc?dure de rodage du moteur....7843
Table des Mati?res....7847
Vue ?clat?e....7849
Carter et vilebrequin....7849
D?pose....7850
Contr?les pr?alables....7851
Vilebrequin....7851
Gicleurs pour refroidissement des pistons....7852
Nettoyage, inspection et essais....7853
Carter de moteur....7853
Mesure du vilebrequin....7853
Mesure des paliers principaux....7855
Gicleurs pour refroidissement des pistons....7856
Pose....7857
Gicleurs pour refroidissement des pistons....7857
Vilebrequin....7857
Table des Mati?res....7861
Abr?viations et acronymes....7863
Abr?viations et acronymes....7863
Table des Mati?res....7869
Terminologie....7871
Termes....7871
Table des Mati?res....7885
Circuit d'alimentation....7887
Conduit d'admission d'air et collecteurs d'?chappement....7887
Frein sur ?chappement....7887
Culasse, arbre ? cames et dispositif de commande des soupapes....7887
Volant-moteur et bo?tier de volant-moteur....7888
Pompe ? huile, entra?nement de ventilateur surbaiss?, et pignons de distribution....7888
V?rins....7888
Carter et vilebrequin....7890
Table des Mati?res....7891
Couple standard....7893
Identification du boulon....7893
Directives g?n?rales de couple....7894
Tableau des couples de serrage type....7895
Utilisation d?une extension de cl? dynamom?trique....7896
Couples particuliers....7897
Montage du moteur sur le support....7897
Syst?me ?lectrique du moteur....7897
Dispositif de d?marrage ? froid....7898
Syst?me de postcombustion....7899
Commande de contre-pression des gaz d'?chappement....7900
Turbocompresseurs....7900
Compresseur d'air et pompe de servodirection/? carburant....7901
Circuit d'alimentation....7901
Ensemble du module de lubrification....7902
Syst?me de recirculation des gaz d'?chappement (RGE)....7903
Conduit d'admission d'air et collecteurs d'?chappement....7904
Couvercle avant, entra?nement de ventilateur sur?lev?, syst?me de refroidissement, composants connexes....7904
Frein sur ?chappement....7906
Culasse, arbre ? cames et dispositif de commande des soupapes....7906
Volant-moteur et bo?tier de volant-moteur....7907
Carter d'huile et tube d'aspiration d'huile....7908
Pompe ? huile et pignons de distribution....7908
V?rins....7909
Carter et vilebrequin....7909
Table des Mati?res....7911
Outils sp?ciaux....7913
Coordonn?es....7913
Montage du moteur sur le support....7913
Syst?me ?lectrique du moteur....7913
Syst?me de postcombustion....7913
Commande de contre-pression des gaz d'?chappement....7913
Turbocompresseurs....7914
Compresseur d'air et servodirection....7914
Circuit d'alimentation....7915
Refroidisseur d'huile, bo?tier de filtre et ventilation du carter....7915
Syst?me de recirculation des gaz d'?chappement (RGE)....7916
Conduit d'admission d'air ? papillon et collecteur d'?chappement....7916
Couvercle avant, entra?neur de ventilateur, circuit de refroidissement et composants connexes....7916
Frein sur ?chappement Jacobs? sur MaxxForce?....7917
Culasse, arbre ? cames et dispositif de commande des soupapes....7917
Volant-moteur et bo?tier de volant-moteur....7918
Pompe ? huile, entra?nement de ventilateur et pignons de distribution....7918
V?rins....7919
Carter et vilebrequin....7919
Outils sp?ciaux ....7920
Outils essentiels....7920
tables....7342
R?sum? des modifications....7342
Moteurs diesel MaxxForce? 11 et 13....7352
Montage du moteur sur le support....7417
Montage du moteur sur le support....7417
Syst?me ?lectrique du moteur....7467
Syst?me ?lectrique du moteur....7468
Dispositif de d?marrage ? froid....7479
Syst?me de postcombustion....7501
Syst?me de postcombustion....7501
Commande de contre-pression des gaz d'?chappement....7515
Commande de contre-pression des gaz d'?chappement....7515
Turbocompresseurs....7548
Turbocompresseurs....7548
Compresseur d'air et pompe de servodirection/? carburant....7564
Compresseur d'air....7564
Circuit d'alimentation....7615
Circuit d'alimentation....7615
Circuit d'alimentation....7616
Ensemble du module de lubrification....7633
Refroidisseur d'huile....7633
Syst?me RGE....7671
Syst?me RGE....7672
Collecteurs d'?chappement....7686
Conduit d'admission d'air ? papillon et collecteurs d'?chappement....7686
Conduit d'admission d'air ? papillon et collecteurs d'?chappement....7686
Couvercle avant, entra?neur de ventilateur, circuit de refroidissement et composants connexes....7717
Couvercle avant, entra?neur de ventilateur, circuit de refroidissement et composants connexes....7718
Frein sur ?chappement....7734
Frein sur ?chappement....7734
Frein sur ?chappement....7734
Culasse, arbre ? cames et dispositif de commande des soupapes....7768
Culasse, arbre ? cames et dispositif de commande des soupapes....7768
Culasse, arbre ? cames et dispositif de commande des soupapes....7769
Volant-moteur et bo?tier de volant-moteur....7788
Volant-moteur et bo?tier de volant-moteur....7788
Volant-moteur et bo?tier de volant-moteur....7788
Composants du carter d'huile....7805
Pompe ? huile et pignons de distribution....7822
Pompe ? huile et pignons de distribution....7822
Pompe ? huile et pignons de distribution....7822
V?rins....7844
V?rins....7845
V?rins....7846
Carter et vilebrequin....7860
Carter et vilebrequin....7860
Carter et vilebrequin....7860
Circuit d'alimentation....7887
Collecteurs d'?chappement....7887
Frein sur ?chappement....7887
Culasse, arbre ? cames et dispositif de commande des soupapes....7887
Volant-moteur et bo?tier de volant-moteur....7888
Pompe ? huile, entra?nement de ventilateur surbaiss?, et pignons de distribution....7888
V?rins....7888
Carter et vilebrequin....7890
Valeurs de couple type - Classe 10.9 Boulons et goujons ? embase m?triques....7895
Diam?tre du filetage (mm)....7895
Pas du filetage (mm)....7895
Couple de serrage....7895
Montage du moteur sur le support....7897
Syst?me ?lectrique du moteur....7897
Dispositif de d?marrage ? froid....7898
Syst?me de postcombustion....7899
Commande de contre-pression des gaz d'?chappement....7900
Turbocompresseurs....7900
Compresseur d'air et pompe de servodirection/? carburant....7901
Circuit d'alimentation....7901
Ensemble du module de lubrification....7902
Syst?me RGE....7903
Conduit d'admission d'air ? papillon et collecteurs d'?chappement....7904
Couvercle avant, entra?neur de ventilateur, circuit de refroidissement et composants connexes....7905
Frein sur ?chappement....7906
Culasse, arbre ? cames et dispositif de commande des soupapes....7907
Volant-moteur et bo?tier de volant-moteur....7907
Composants du carter d'huile....7908
Pompe ? huile et pignons de distribution....7908
V?rins....7909
Carter et vilebrequin....7909
Montage du moteur sur le support....7913
Syst?me ?lectrique du moteur....7913
Syst?me de postcombustion....7913
Commande de contre-pression des gaz d'?chappement....7913
Turbocompresseurs....7914
Compresseur d'air et servodirection....7914
Circuit d'alimentation....7915
Refroidisseur d'huile, bo?tier de filtre et ventilation du carter....7915
Syst?me RGE....7916
Conduit d'admission d'air ? papillon et collecteur d'?chappement....7916
Couvercle avant, entra?neur de ventilateur, circuit de refroidissement et composants connexes....7916
Frein sur ?chappement Jacobs? sur MaxxForce?....7917
Culasse, arbre ? cames et dispositif de commande des soupapes....7917
Volant-moteur et bo?tier de volant-moteur....7918
Pompe ? huile, entra?nement de ventilateur et pignons de distribution....7918
V?rins....7919
Carter et vilebrequin....7919
0000001922 - Manual de Servicio Del Motor MaxxForce 11 y 13....7928
0000002861 - 2013 HD-OBD Diagnostic Reference Manual....8543
toc....8545
Table of Contents....8545
Foreword....8547
Safety information....8548
Safety Terminology....8548
Safety Instructions....8548
Work Area....8548
Safety Equipment....8548
Protective Measures....8548
Vehicle....8549
Engine....8549
Fire Prevention....8549
Batteries....8549
Compressed Air....8549
Tools....8550
Fluids Under Pressure....8550
Fuel....8550
Removal of Tools, Parts, and Equipment....8550
On Board Diagnostics (OBD) Overview....8551
Diagnostic Trouble Code overview....8552
Warranty information....8553
5.1. Drive cycles....8553
Road Testing is not covered by warranty, see the CTS-1100 Warranty and Procedure Manual for more Information...8553
drive cycles....8554
6.1. MaxxForce? 11 and 13 (EPA 10) with HD-OBD....8554
6.2. N13 with SCR (EPA 10) with HD-OBD....8555
Failure Mode Indicator (FMI) Hierarchy....8557
Definitions / Acronyms....8558
0000002941 - Electronic Control System Diagnostics Maxxforce 11 and 13 Beginning with 2010 Model Year....8559
0000003081 - Aftertreatment Symptom-Based Diagnostic and Inspection Manual MaxxForce DT, 9, 10, 11, 13 and 15 (EPA 10)....8561
toc....8563
Table of Contents....8563
Foreword....8565
Safety information....8566
Safety Terminology....8566
Safety Instructions....8566
Work Area....8566
Safety Equipment....8566
Protective Measures....8566
Vehicle....8567
Engine....8567
Fire Prevention....8567
Batteries....8567
Compressed Air....8567
Tools....8568
Fluids Under Pressure....8568
Fuel....8568
Removal of Tools, Parts, and Equipment....8568
MaxxForce? DT, 9 and 10 Aftertreatment System Diagnostics....8569
3.1. Start Diagnostics here: Engine and Aftertreatment System Operational Checks....8569
Overview....8569
Tools Required....8569
Operational Checks ? Start Aftertreatment Diagnostics Here....8570
3.2. Symptom 1 (Medium Duty): Frequent Parked Regens With No Active Fault Codes (More Than One Parked Regen Per Day)....8573
3.3. Symptom 2 (Medium Duty): Engine No Start / Starts and Stalls....8583
3.4. Symptom 3 (Medium Duty): SPN 3719 or SPN 3936 Active Only or Frequent Regens (More Than One Parked Regen Per Day)....8591
3.5. Symptom 4 (Medium Duty): SPN 3719 Or SPN 3936 and Other Active Fault Codes....8603
3.6. Symptom 5 (Medium Duty) : Black Smoke....8613
MaxxForce? DT, 9 and 10 ServiceMaxx? Snapshots....8621
4.1. Graph 1: Air Management System Test (Good)....8621
Graph Analysis:....8621
Actions:....8622
4.2. Graph 2: Air Management System Test (bad)....8623
Graph Analysis:....8623
Actions:....8623
4.3. Graph 3: 0 to 60 mph Test (ICP Desired and ICP)....8624
Graph Analysis....8624
Actions....8624
4.4. Graph 4: 0 to 60 mph Test (Engine Speed, Engine Load, IMP, EBP, and APP1)....8625
Graph Analysis....8625
Actions....8626
4.5. Graph 5: Normal Exhaust Gas Temperatures (Efficient DOC AND Unrestricted AFI) ....8627
Graph Analysis:....8627
Actions:....8628
4.6. Graph 6: Erratic exhaust Gas Temperatures ....8629
Graph Analysis:....8629
Actions:....8629
4.7. Graph 7: Low Exhaust Gas Temperatures (Restricted AFI)....8630
Graph Analysis:....8630
Actions:....8631
4.8. Soot Load Level vs. Exhaust Gas Target Temperature Chart....8632
Aftertreatment System Operation....8633
5.1. MaxxForce? DT, 9 and 10 ....8633
Component Descriptions (Theory of Operation)....8636
6.1. MaxxForce? DT, 9 and 10 ....8636
Diesel Oxidation Catalyst (DOC)....8636
Diesel Particulate Filter (DPF)....8636
Downstream Injection (DSI) Unit....8637
Engine Control Module (ECM)....8638
Engine Throttle Valve (ETV)....8639
Exhaust Back Pressure Valve (EBPV)....8640
Exhaust Gas Recirculation (EGR) Valve....8641
Pre-Diesel Oxidation Catalyst (PDOC)....8642
Aftertreatment System Fault Codes....8645
7.1. MaxxForce? DT, 9 and 10 (EPA 10)....8645
Aftertreatment System Event Chart....8648
8.1. MaxxForce? DT, 9 and 10....8648
MaxxForce? 11,13 and 15 Aftertreatment System Diagnostics....8649
9.1. Start Diagnostics Here: Engine and Aftertreatment System Operational Checks....8649
Overview....8649
Tools Required....8649
Operational Checks ? Start Aftertreatment Diagnostics Here....8650
9.2. Symptom 1 (Heavy Duty): Frequent Parked Regens With No Active Fault Codes (More Than One Parked Regen Per Day)....8653
9.3. Symptom 2 (Heavy Duty): Engine No Start / Starts and Stalls....8661
9.4. Symptom 3 (Heavy Duty): SPN 3719 Active Only or Frequent Regens (More Than One Parked Regen Per Day)....8667
9.5. Symptom 4 (Heavy Duty): SPN 3719 and Other Active Fault Codes ....8676
9.6. Symptom 5 (Heavy duty): Black Smoke ....8685
MaxxForce? 11, 13 and 15 ServiceMaxx? Snapshots....8693
10.1. Graph 1: Air Management System Test (Good)....8693
Graph Analysis:....8693
Actions:....8694
10.2. Graph 2: Air Management System Test (Bad)....8695
Graph Analysis:....8695
Actions:....8696
10.3. Graph 3: Lug Down Test (Engine Speed, FRP, and FRPD)....8697
Graph Analysis:....8697
Actions:....8698
10.4. Graph 4: Lug Down Test (Engine Speed and TC1TOP)....8699
Graph Analysis:....8699
Actions:....8699
10.5. Graph 5: Lug Down Test (Engine Speed, APP1, Vehicle Speed, and IMP)....8700
Graph Analysis:....8700
10.6. Graph 6: Normal Exhaust Gas Temperatures (Efficient DOC AND Unrestricted AFI)....8702
Graph Analysis:....8702
Actions:....8703
10.7. Graph 7: Inverted exhaust Gas Temperatures (Inefficient DOC)....8704
Graph Analysis:....8704
Actions:....8705
10.8. Graph 8: Low Exhaust Gas Temperatures (Restricted AFI)....8706
Graph Analysis:....8706
Actions:....8707
Aftertreatment System Operation....8708
11.1. MaxxForce? 11, 13 and 15 ....8708
Component Descriptions (Theory of Operation)....8711
12.1. MaxxForce? 11 and 13 ....8711
Air Control Valve (ACV) Assembly....8711
Diesel Oxidation Catalyst (DOC)....8712
Diesel Particulate Filter (DPF)....8712
Downstream Injection (DSI) Unit....8713
Engine Control Module (ECM)....8714
Engine Throttle Valve (ETV)....8715
Exhaust Back Pressure Valve (EBPV)....8716
Exhaust Gas Recirculation (EGR) Valve....8717
Pre-Diesel Oxidation Catalyst (PDOC)....8718
Turbochargers....8719
Aftertreatment System Fault Codes....8720
13.1. MaxxForce? 11, 13 and 15....8720
Aftertreatment System Event Chart....8724
14.1. MaxxForce? 11, 13 and 15....8724
Regen Inhibitors and Entry Conditions....8725
15.1. Regen Inhibitors....8725
Overview....8725
15.2. Entry Conditions....8729
Overview....8729
DPF and DOC Reuse Guidelines....8732
16.1. MaxxForce? DT, 9, and 10; MaxxForce? 11, 13 and 15....8732
Diesel Particulate Filter (DPF) Inlet - Clean....8733
Diesel Particulate Filter (DPF) Inlet - Dirty, but Reusable....8734
Diesel Particulate Filter (DPF) Inlet - Face Plugged....8735
Diesel Particulate Filter (DPF) - Melted....8736
Diesel Particulate Filter (DPF) - Cracked but Reusable....8737
Diesel Particulate Filter (DPF) Inlet- Ash on Face....8738
Diesel Particulate Filter (DPF) - Excessive Brick Shift....8739
Diesel Particulate Filter (DPF) - Moderate Brick Shift....8740
Diesel Oxidation Catalyst (DOC) Outlet - Dirty but Reusable....8741
Diesel Oxidation Catalyst (DOC) - Separation....8742
Diesel Oxidation Catalyst (DOC) - Melted....8743
Diesel Oxidation Catalyst (DOC) or Diesel Particulate Filter (DPF) - Damaged Sensor Port Threads....8744
Abbreviations and Acronyms....8745
Terminology....8754
tables....8584
Table 21Example TC1TOP (Actual) Calculations....8584
Signal Values:....8588
Signal Values:....8589
Table 182Check Active Regen Inhibitors....8726
Table 183Check Parked Regen Inhibitors....8727
Table 184Parked Regen Checks....8728
Table 185Entry Conditions for an Active Regen....8729
Table 187Entry Conditions for a Parked Regen....8731
0000003941 - Manual de Diagn?stico Motor MaxxForce 11 y 13....8767
toc....8769
Contenido....8769
Terminolog?a de seguridad....8773
Instrucciones de seguridad....8773
?rea de trabajo....8773
Equipo de seguridad....8773
Medidas de protecci?n....8773
Veh?culo....8774
Motor....8774
Prevenci?n de incendios....8774
Bater?as....8774
Aire comprimido....8774
Herramientas....8775
L?quidos bajo presi?n....8775
Combustible....8775
Extracci?n de herramientas, piezas y equipo....8775
Contenido....8777
Identificaci?n del motor....8779
N?mero de serie del motor....8779
Ejemplos de n?mero de serie del motor....8779
C?digos del n?mero de serie del motor....8779
Etiqueta de emisiones del motor....8780
Etiquetas de accesorios del motor y placas de identificaci?n....8781
Especificaciones del motor....8781
Diagn?sticos a bordo para carga pesada (HD-OBD)....8783
Descripci?n del motor....8783
Equipos opcionales....8784
Equipo montado en el chasis....8785
Ubicaci?n de los componentes del motor....8786
Sistema de gesti?n del aire comprimido....8790
Flujo de aire....8791
Turbocompresores....8792
V?lvula de control de aire (ACV)....8793
Control de la presi?n de sobrealimentaci?n....8794
Enfriador de aire de carga de presi?n baja (LPCAC)....8794
Enfriador de aire de carga de alta presi?n (HPCAC)....8794
Sensor de presi?n de refuerzo de presi?n alta (HPBP)....8794
Sensor de temperatura de refuerzo de presi?n alta (HPBT)....8795
Sensores de presi?n de refuerzo de presi?n baja (LPBP) y de temperatura de refuerzo de presi?n baja (LPBT)....8795
Sistema de recirculaci?n de gas de escape (EGR)....8796
Informaci?n general del sistema EGR....8797
Flujo de EGR....8797
Control del sistema EGR....8797
Control de EGRV....8798
EGR ? Circuito abierto....8799
EGR ? Circuito cerrado ....8799
Enfriamiento del flujo de EGR....8799
Sistema de postratamiento (AFT)....8800
Filtro de part?culas di?sel (DPF)....8801
Catalizador de oxidaci?n di?sel (DOC, Diesel Oxidation Catalyst)....8801
Condiciones y respuestas del sistema de postratamiento (AFT)....8801
Inyecci?n de combustible corriente abajo....8802
Unidad de inyecci?n de corriente abajo (DSI)....8803
Inyector de combustible de postratamiento (AFI)....8803
Separador de aceite del c?rter....8804
Sistema de manejo de combustible....8806
Componentes del sistema de combustible....8806
Flujo de combustible....8807
Sistema de combustible de baja presi?n....8809
Separador de agua/filtro montado en el chasis....8810
Conjunto de la bomba de cebado de combustible....8810
Bomba de combustible de baja presi?n (LP)....8810
Conjunto del filtro de combustible....8810
Sistema de combustible de alta presi?n....8811
Bomba de presi?n alta (HP)....8812
V?lvula de control de presi?n de combustible (FPCV)....8812
Riel de combustible....8812
Sensor de presi?n del riel de combustible (FRP)....8812
V?lvula de limitaci?n de presi?n del riel....8812
Inyectores....8812
Sistema del calentador de aire de admisi?n....8813
Componentes del sistema de calefactor de aire de admisi?n....8813
Encendido del combustible del calefactor de aire de admisi?n (IAHFI)....8813
Rel? del calefactor de aire de admisi?n (IAHR)....8814
V?lvula de solenoide de combustible del calefactor de aire de admisi?n (IAHFS) ....8814
Operaci?n del sistema del calefactor de aire de admisi?n....8814
Componentes y flujo de aceite....8816
Separador de aceite del c?rter....8818
Filtro de aceite centr?fugo montado remotamente (opcional)....8819
Sistema de enfriamiento del motor....8820
Flujo del sistema de enfriamiento....8820
Funcionamiento del termostato....8821
Funcionamiento del ensamble de la v?lvula de control del refrigerante (CCV)....8822
V?lvula de flujo del refrigerante (CFV)....8822
V?lvula mezcladora de refrigerante (CMV)....8822
Sistema de frenos del motor....8823
Componentes del sistema de control del freno del motor....8823
Descripci?n del sistema del freno del motor....8824
Funcionamiento del sistema de freno de motor....8824
Sistema de control electr?nico....8826
Componentes del sistema de controles electr?nicos....8826
Operaci?n y funcionamiento....8826
Voltaje de referencia (VREF)....8826
Condicionante de se?al....8826
Microprocesador....8826
C?digos de diagn?stico de problemas....8826
Memoria del microprocesador....8826
ROM....8827
?mbolo....8827
Control del actuador....8828
los actuadores....8828
V?lvula de control de refrigerante (CCV)....8828
Control de la v?lvula de contrapresi?n de escape (EBPV)....8828
V?lvula de Recirculaci?n de los gases de escape (EGR)....8829
V?lvula de control de aire (ACV)....8829
Rel? del calefactor de aire de admisi?n (IAHR)....8829
V?lvula del solenoide de combustible del calefactor de aire de admisi?n (IAHFS)....8829
V?lvula del acelerador del motor (ETV)....8829
V?lvula de control de presi?n de combustible (FPCV)....8829
Dosificador de combustible de postratamiento (AFTFD)....8831
V?lvula de cierre de combustible de postratamiento (AFTFSV)....8831
Sensores del veh?culo y motor....8831
Sensores termistores....8831
Sensores de temperatura de tratamiento posterior....8832
Sensores de temperatura del refrigerante del motor (ECT)....8832
Sensor de temperatura del aceite del motor (EOT, Engine Oil Temperature)....8832
Sensor de entrada del compresor del turbocargador 2 (TC2CIS)....8833
Sensor de temperatura de salida del enfriador del aire de carga (CACOT)....8833
Sensor de temperatura del m?ltiple de admisi?n (IMT)....8833
Sensor de temperatura de recirculaci?n de gases de escape (EGRT)....8833
Sensor de temperatura del aire ambiente (AAT)....8833
Sensores de capacitancia variable....8834
Sensor de presi?n diferencial del DPF (DPFDP)....8834
Sensor de presi?n de distribuci?n de combustible (FDP)....8834
Sensor de presi?n del aceite del motor (Engine oil pressure, EOP)....8835
Sensor de presi?n del riel de combustible (FRP)....8835
Sensor de presi?n del m?ltiple de admisi?n (IMP)....8835
Sensor de entrada de combustible de postratamiento (AFTFIS)....8835
Sensor de presi?n de combustible de postratamiento 2 (AFTFP2)....8835
Presi?n de salida de la turbina del turbocargador 1 (TC1TOP)....8835
Sensores del captador magn?tico....8836
Sensor de posici?n del cig?e?al (CKP, Crankshaft Position)....8837
Sensor de posici?n del ?rbol de levas (CMP, Camshaft Position)....8837
Sensor de velocidad del veh?culo (VSS)....8837
Sensor de velocidad del separador de aceite del c?rter (CCOSS)....8837
Sensores del potenci?metro....8838
Posici?n del pedal del acelerador (APP)....8838
Interruptores....8839
Interruptor de desconexi?n de la l?nea de la transmisi?n (DDS)....8839
Interruptor de nivel de refrigerante del motor (ECL)....8839
Sensor de nivel de aceite (OLS)....8840
Sensores adicionales....8840
Sensor de ox?geno (O2S)....8840
Sensor de humedad (HS)....8840
Contenido....8841
Funciones del control electr?nico est?ndar....8843
Sistema de postratamiento (AFT)....8843
Protecci?n contra temperatura ambiente baja (CAP)....8843
Calentador de aire de entrada....8843
Compensaci?n de la temperatura del refrigerante (CTC)....8843
Placa de datos....8844
Veloc?metro y tac?metro electr?nicos....8845
Inhibidor de giro del motor (ECI)....8845
Control electr?nico del regulador del motor....8845
Control del ventilador del motor (EFC)....8845
Sistema de registro de eventos....8845
Avance en ralent? r?pido....8846
Enlace de datos J1939....8847
Protecci?n de la contrase?a....8847
Diagn?sticos de servicio....8847
Informe del viaje....8847
Configuraci?n del veh?culo....8848
Funciones de control electr?nico opcionales....8849
Control de crucero....8849
Recompensa del conductor....8849
Frenado de motor MaxxForce?....8849
Sistema de advertencia y protecci?n del motor (EWPS)....8849
Protecci?n de la reducci?n de cambios (GDP)....8850
Temporizador de apagado por ralent? (IST)....8850
Cambio progresivo....8850
Toma de fuerza (PTO) - En cabina....8850
Control remoto de toma de fuerza (PTO)....8851
Intervalo de servicio....8851
Control de tracci?n....8851
Indicador de marcha superior....8852
Limitador de velocidad en carretera....8852
Contenido....8853
Archivos de la sesi?n....8855
C?digo de problema de diagn?stico (DTC)....8855
N?mero de par?metro sospechoso (SPN)....8855
Indicador del modo de falla (FMI)....8855
Pendiente....8856
Activo....8856
Activado anteriormente....8856
Datos del marco congelado....8856
Funciones programables del ECM....8856
Conectar la EST con el software ServiceMaxx? al motor....8856
Pruebas del compartimiento de servicio....8856
Pruebas con el motor apagado....8856
Prueba del actuador....8857
Prueba de monitoreo continuo....8857
Servicio DPF....8857
Prueba de compresi?n relativa....8858
Pruebas con el motor en funcionamiento....8858
Prueba de administraci?n de aire....8858
Prueba de la bomba de alta presi?n....8859
Prueba del disyuntor del cilindro....8860
Prueba de corte de cilindro m?ltiple....8860
Prueba de comparaci?n del sensor de funcionamiento en caliente....8862
Prop?sito....8862
Herramientas necesarias....8862
Prueba de limpieza del filtro integrado....8864
Procedimientos de la herramienta de servicio....8864
Procedimiento con el motor apagado....8864
Calentador de aire de entrada....8864
Calibraci?n del sensor de ox?geno....8864
Regulaci?n de la cantidad de inyecci?n....8865
Procedimientos con el motor en funcionamiento....8865
Ventilador del motor....8865
Contenido....8867
Sistema de refrigerante....8869
P?rdida de refrigerante....8869
Situaci?n....8869
Posibles causas....8869
Herramientas....8869
Procedimiento....8870
Desborde de refrigerante....8871
Situaci?n....8871
Posibles causas....8871
Herramientas....8871
Procedimiento....8872
Fuga de refrigerante al escape....8875
S?ntomas....8875
Posibles causas....8875
Herramientas....8875
Inspecci?n de fuga de refrigerante del inyector de combustible postratamiento (AFI)....8875
Inspecci?n de fugas en el enfriador de recirculaci?n del gas de escape....8876
Fuga de refrigerante al combustible....8877
S?ntoma....8877
Posibles causas....8877
Herramientas....8877
Procedimiento....8877
Fuga de refrigerante a la admisi?n....8878
S?ntoma....8878
Posibles causas....8878
Herramientas....8878
Procedimiento....8878
Fuga de refrigerante al aceite lubricante....8879
S?ntoma....8879
Posibles causas....8879
Herramientas....8879
Inspecci?n de la contaminaci?n del aceite lubricante....8880
Prueba de fugas de la culata de cilindros....8881
Procedimiento....8881
Sobretemperatura del refrigerante....8882
Situaci?n....8882
Posibles causas....8882
Herramientas....8883
Inspecci?n de las condiciones de sobrecalentamiento del refrigerante....8883
Sobrecalentamiento del refrigerante ? enfriamiento del motor....8885
Procedimiento....8885
Componentes del sistema de enfriamiento....8887
Flujo del sistema de enfriamiento....8888
Funcionamiento del termostato....8888
Ensamble de la v?lvula de control del refrigerante (CCV) y funcionamiento de la v?lvula del mezclador de refrigerante (CMV)....8889
Prueba de la v?lvula de control del refrigerante (CCV)....8890
Sistema de lubricaci?n....8894
Inspecci?n visual del nivel de aceite....8894
Mantenimiento incorrecto....8894
Diluci?n del refrigerante....8894
Fuga del l?quido de la direcci?n hidr?ulica al aceite de lubricaci?n....8894
S?ntoma....8894
Posibles causas....8894
Procedimiento....8894
Aceite de lubricaci?n al refrigerante....8895
S?ntoma....8895
Posibles causas....8895
Herramientas....8895
Procedimiento....8895
Aceite de lubricaci?n a la admisi?n....8896
S?ntoma....8896
Posibles causas....8896
Procedimiento....8896
Aceite de lubricaci?n al escape....8896
S?ntoma....8896
Posibles causas....8896
Procedimiento....8897
Baja presi?n del aceite....8897
Situaci?n....8898
Posibles causas....8898
Herramientas....8898
Procedimiento....8899
Sistema de combustible....8902
Consumo excesivo de combustible....8902
S?ntoma....8902
Posibles causas....8902
Efectos del operador....8902
Efectos de aplicaci?n....8902
Efectos del chasis....8903
Efectos del motor....8903
Procedimiento....8903
Combustible en el refrigerante....8904
S?ntoma....8904
Posibles causas....8904
Herramientas....8904
Procedimiento....8904
Combustible en el aceite de lubricaci?n....8906
S?ntomas....8906
Posibles causas....8906
Herramientas....8906
Procedimiento....8906
Combustible a la admisi?n....8907
S?ntomas....8907
Posibles causas....8907
Procedimiento....8907
Combustible a escape....8907
S?ntoma....8907
Posibles causas....8907
Herramientas....8907
Procedimiento....8908
Aireaci?n y presi?n del combustible....8908
Situaci?n....8908
Posible causa:....8908
Procedimiento....8908
Agua en combustible....8909
S?ntomas....8909
Posibles causas....8909
Herramientas....8909
Procedimiento....8909
Cebado del sistema de combustible....8910
Procedimiento....8910
Sistema de frenos del motor....8912
Inspecci?n de freno del motor....8912
Situaci?n....8912
Posibles causas....8912
Herramientas....8913
Pasos preliminares....8913
El freno de motor no se enciende/baja la velocidad para encender....8914
El freno de motor no se apaga/baja la velocidad para apagarse....8914
El motor fallo en el arranque....8915
Debilidad del freno de motor en efecto o bajo en la potencia del freno de motor....8915
Freno de motor lento para operar o d?bil en efecto....8915
La presi?n del aceite cae debajo del m?nimo requerido para el funcionamiento del freno de motor....8917
Uno o m?s cilindros caen para detener el frenado o detener el motor....8917
El motor pierde potencia....8917
Contenido....8919
Diagn?sticos de formulario EGED-475....8921
P?gina de quejas e informaci?n del veh?culo del formulario de diagn?sticos....8922
Procedimientos de prueba necesarios....8925
1. Revisi?n inicial de encendido con llave....8926
Prop?sito....8926
Herramientas....8926
Procedimiento....8926
2. Inspecci?n visual....8926
Prop?sito....8926
Herramientas....8926
Aceite de motor....8926
Nivel del refrigerante del motor....8928
Sistema el?ctrico....8928
Aire de la admisi?n....8928
Sistema del enfriador de aire de carga (CAC)....8928
Sistema de escape....8928
Tanques de aire....8929
Nivel de combustible....8929
Condici?n y enrutamiento de la tuber?a de combustible....8929
Inspecci?n del filtro de combustible primario....8929
Verificaci?n de la calidad de combustible....8931
Prop?sito....8931
Herramientas....8931
Procedimiento....8931
3. Registro de datos y conexi?n de la herramienta de servicio electr?nico (EST)....8933
Prop?sito....8933
Herramientas....8933
Procedimiento....8933
4. Revise si hay C?digos de problema de diagn?sticos (DTC)....8937
Prop?sito....8937
Herramientas....8937
Procedimiento....8937
5. Giro del motor....8939
Prop?sito....8939
Herramientas....8939
Procedimiento....8939
Procedimientos de prueba especiales....8941
Sistema de combustible....8941
Sistema de combustible de baja presi?n....8942
Cebado del sistema de combustible....8943
Prop?sito....8943
Herramientas....8943
Procedimiento....8943
Prueba de presi?n de suministro de combustible (FDP)....8945
Prop?sito....8945
Herramientas....8945
Procedimiento....8945
Prueba del cabezal desactivado de combustible....8947
Prop?sito....8947
Herramientas....8947
Procedimiento....8947
Prueba de aireaci?n de combustible....8948
Prop?sito....8949
Herramientas....8949
Procedimiento....8949
Punto de prueba de aireaci?n 1....8949
Punto de prueba de aireaci?n 2....8949
Prueba de restricci?n de combustible....8950
Prop?sito....8951
Herramientas....8951
Procedimiento....8951
Punto 1 de la prueba de restricci?n....8951
Punto 2 de la prueba de restricci?n....8951
Punto 3 de la prueba de restricci?n....8951
Sistema de combustible de alta presi?n....8953
Prueba de circuito de presi?n del riel de combustible (FRP)....8953
Prop?sito....8953
Herramientas....8953
Procedimiento....8954
Prueba de presi?n de entrada de la bomba a alta presi?n....8954
Prop?sito....8954
Herramientas....8954
Procedimiento....8954
Prueba de flujo de retorno de presi?n del riel de combustible (FRP)....8956
Prop?sito....8956
Herramientas....8956
Prueba de flujo de retorno de presi?n del riel de combustible (FRP) Parte 1....8956
Prueba de flujo de retorno de presi?n del riel de combustible (FRP) Parte 2....8956
Aislamiento de fugas de presi?n del riel de combustible (FRP)....8958
Prop?sito....8958
Herramientas....8958
Procedimiento....8958
Prueba de presi?n de retorno del combustible de la bomba HP....8960
Prop?sito....8960
Herramientas....8960
Procedimiento....8960
Prueba del flujo de retorno de la bomba HP....8961
Prop?sito....8961
Herramientas....8961
Procedimiento....8961
Sistema del calentador de aire de admisi?n....8962
Prueba del sistema del calefactor de aire de admisi?n....8962
Prop?sito....8962
Herramientas....8962
Procedimiento....8962
Prueba del Encendido de combustible del calefactor de aire de admisi?n (IAHFI)....8964
Prop?sito....8964
Herramientas....8964
Procedimiento....8964
Suministro de combustible en la Prueba del solenoide de combustible del calefactor de aire de admisi?n (IAHFS)....8965
Prop?sito....8965
Herramientas....8965
Procedimiento....8965
Suministro de combustible en la prueba del encendido del combustible del calefactor de aire de admisi?n (IAHFI)....8967
Prop?sito....8967
Herramientas....8967
Procedimiento....8967
Contenido....8969
Diagn?sticos de formulario EGED-530....8971
P?gina de quejas e informaci?n del veh?culo del formulario de diagn?sticos....8972
Procedimientos de prueba necesarios....8975
1. Revisi?n inicial de encendido con llave....8975
Prop?sito....8975
Herramientas....8975
Procedimiento....8976
2. Inspecci?n visual....8976
Prop?sito....8976
Herramientas....8976
Aceite de motor....8977
Nivel del refrigerante del motor....8977
Sistema el?ctrico....8978
Aire de la admisi?n....8979
Sistema del enfriador de aire de carga (CAC)....8979
Sistema de escape....8979
Tanques de aire del veh?culo....8979
Nivel de combustible....8979
Inspecci?n del filtro de combustible primario....8980
Verificaci?n de la calidad de combustible....8981
Prop?sito....8981
Herramientas....8981
Procedimiento....8981
3. Registro de datos y conexi?n de la herramienta de servicio electr?nico (EST)....8983
Prop?sito....8983
Herramientas....8983
Procedimiento....8983
4. Revise si hay C?digos de problema de diagn?sticos (DTC)....8986
Prop?sito....8986
Herramientas....8986
Procedimiento....8986
5. Ralent? bajo a ralent? elevado del motor....8988
Prop?sito....8988
Herramientas....8988
Procedimiento....8988
6. Prueba de administraci?n de aire de KOER (Llave en contacto y motor encendido)....8991
Prop?sito....8991
Herramientas....8991
Procedimiento....8991
7. Prueba en carretera (Carga completa para velocidad de autopista)....8992
Prop?sito....8992
Herramientas....8992
Procedimiento....8992
Procedimientos de prueba especiales....8994
Pruebas de la v?lvula de control de aire (ACV)....8994
Prop?sito....8994
Herramientas....8994
V?lvula de contrapresi?n del escape (EBPV)....8994
Control de compuerta de descarga del turbocargador 2 (TC2WC)....8995
Sistema de combustible....8997
Sistema de combustible de baja presi?n....8998
Prueba de presi?n de suministro de combustible (FDP)....8999
Prop?sito....8999
Herramientas....8999
Procedimiento....8999
Prueba del cabezal desactivado de combustible....9001
Prop?sito....9001
Herramientas....9001
Procedimiento....9001
Pruebas de aireaci?n y restricci?n del combustible....9003
Prueba de aireaci?n....9003
Prop?sito....9004
Herramientas....9004
Punto de prueba de aireaci?n 1....9004
Procedimiento....9004
Punto de prueba de aireaci?n 2....9004
Prueba de restricci?n....9005
Prop?sito....9006
Herramientas....9006
Procedimiento....9006
Punto de prueba 1....9006
Punto de prueba 2....9006
Punto de prueba 3....9006
Sistema de combustible de alta presi?n....9008
Prueba de presi?n de entrada de la bomba a alta presi?n....9009
Prop?sito....9009
Herramientas....9009
Procedimiento....9009
Prueba de flujo de retorno de presi?n del riel de combustible (FRP)....9010
Prop?sito....9010
Herramientas....9010
Prueba de flujo de retorno de presi?n del riel de combustible (FRP) Parte 1....9010
Prueba de flujo de retorno de presi?n del riel de combustible (FRP) Parte 2....9010
Aislamiento de fugas de presi?n del riel de combustible (FRP)....9012
Prop?sito....9012
Herramientas....9012
Procedimiento....9012
Prueba de presi?n de retorno del combustible de la bomba HP....9013
Prop?sito....9013
Herramientas....9013
Procedimiento....9013
Prueba del separador del respiradero de aceite del c?rter....9015
Prop?sito....9015
Herramientas....9015
Procedimiento....9015
Prueba de presi?n del c?rter....9016
Prop?sito....9016
Herramientas....9016
Procedimiento....9016
Prueba de rendimiento del cilindro ? Paso 1....9019
Prueba de compresi?n relativa....9019
Prop?sito....9019
Herramientas....9019
Procedimiento....9019
Posibles causas....9020
Prueba de rendimiento del cilindro ? Paso 2....9021
Prueba del disyuntor del cilindro....9021
Prop?sito....9021
Herramientas....9021
Posibles causas....9021
Procedimiento....9021
Reemplazo de inyectores....9023
Prop?sito....9023
Herramientas....9023
Procedimiento....9023
Prueba de la v?lvula de control de presi?n de combustible (FPCV)....9025
Prop?sito....9025
Herramientas....9025
Procedimiento....9025
Prueba de la presi?n del enfriador de aire de carga (CAC)....9025
Procedimiento....9025
Contenido....9027
Ubicaciones de los C?digos de falla de diagn?stico (DTC) y de la subsecci?n de la p?gina de diagn?stico....9029
Uso del Formulario de diagn?stico 0000002941....9041
Ejemplo del formulario de diagn?stico....9041
Descripci?n del sistema de HD-OBD....9042
Proceso del procedimiento de diagn?stico con ejemplos....9046
Inspecci?n de un agarre seguro....9046
Diagn?sticos del circuito....9052
Sensor de la AAT (Temperatura de aire ambiente)....9052
Informaci?n general....9053
Herramientas necesarias....9053
SPN 171 FMI 2 - Se?al err?tica, intermitente o incorrecta de AAT....9054
Informaci?n general de la falla....9054
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9054
Fallas asociadas....9054
Datos de fallas....9054
Ciclo de conducci?n para determinar el estado de la falla....9054
Posibles causas....9055
SPN 171 FMI 3- Se?al de AAT fuera de rango ALTO....9057
Informaci?n general de la falla....9057
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9057
Ciclo de conducci?n para determinar el estado de la falla....9057
Posibles causas....9057
SPN 171 FMI 4- Se?al de AAT fuera de rango BAJO....9060
Informaci?n general de la falla....9060
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9060
Ciclo de conducci?n para determinar el estado de la falla....9060
Posibles causas....9060
Sistema AFT (postratamiento)....9062
Informaci?n general....9069
Herramientas necesarias....9069
SPN 3251 FMI 0 - DPFDP excesivamente ALTO (filtro restringido)....9070
Informaci?n general de falla....9070
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9070
Fallas asociadas....9070
Ciclo de conducci?n para determinar el estado de falla....9070
Mangueras de presi?n invertidas del sensor de la DPFDP....9077
SPN 3251 FMI 21 - DPFDP excesivamente BAJO (falla del sensor/circuito o DPF faltante)....9078
Informaci?n general de falla....9078
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9078
Fallas asociadas....9078
Ciclo de conducci?n para determinar el estado de falla....9078
SPN 3471 FMI 1 - Presi?n de combustible 1 debajo de lo deseado....9082
Informaci?n general de la falla....9082
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9082
Fallas asociadas....9082
Ciclo de conducci?n para determinar el estado de falla....9082
SPN 3471 FMI 7 - La v?lvula dosificadora de combustible no responde como se esperaba....9088
Informaci?n general de la falla....9088
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9088
Fallas asociadas....9088
Ciclo de conducci?n para determinar el estado de falla....9088
SPN 3480 FMI 0 - AFTFP1 demasiado alta mientras dosifica....9095
Informaci?n general de la falla....9095
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9095
Fallas asociadas....9095
Ciclo de conducci?n para determinar el estado de falla....9095
SPN 3480 FMI 1- AFTFP1 demasiado bajo mientras dosifica....9099
Informaci?n general de la falla....9099
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9099
Fallas asociadas....9099
Ciclo de conducci?n para determinar el estado de falla....9099
SPN 3481 FMI 7 - Presi?n de dosificaci?n incorrecta, varios eventos....9103
Informaci?n general de la falla....9103
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9103
Fallas asociadas....9103
Ciclo de conducci?n para determinar el estado de falla....9103
SPN 3556 FMI 0 - Presi?n de combustible de AFT 2 excesivamente alta....9107
Informaci?n general sobre la falla....9107
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9107
Fallas asociadas....9107
Ciclo de conducci?n para determinar el estado de falla....9107
SPN 3556 FMI 1- Presi?n de combustible de AFT 2 debajo de lo deseado....9111
Informaci?n general sobre la falla....9111
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9111
Fallas asociadas....9111
Ciclo de conducci?n para determinar el estado de falla....9111
SPN 3556 FMI 7 - Inyector de combustible de AFT no responde como se esperaba....9115
Informaci?n general de la falla....9115
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9115
Fallas asociadas....9115
Ciclo de conducci?n para determinar el estado de falla....9115
SPN 3750 FMI 31 - Regen de DPF inhibido debido a bajas temperaturas de escape....9121
Informaci?n general de falla....9121
Reacci?n de la luz indicadora de mal funcionamiento (MIL)....9121
Fallas asociadas....9121
Ciclo de conducci?n para determinar el estado de la falla....9121
Datos de falla....9121
Posibles causas....9121
SPN 4077 FMI 0 - AFTFP2 demasiado alta mientras dosifica....9123
Informaci?n general sobre la falla....9123
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9123
Fallas asociadas....9123
Ciclo de conducci?n para determinar el estado de falla....9123
SPN 4077 FMI 1 - AFTFP2 demasiado bajo mientras dosifica....9127
Informaci?n general sobre la falla....9127
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9127
Fallas asociadas....9127
Ciclo de conducci?n para determinar el estado de falla....9127
SPN 4766 FMI 10 - Falla de retroalimentaci?n de regeneraci?n de DPF....9131
Informaci?n general de falla....9131
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9131
Fallas asociadas....9131
Ciclo de conducci?n para determinar el estado de falla....9131
SPN 4766 FMI 20 - Temperatura de salida de DOC sobre el m?ximo deseado....9138
Informaci?n general de la falla....9138
Reacci?n de la Luz indicadora de mal funcionamiento (MIL) ....9138
Fallas asociadas....9138
Ciclo de conducci?n para determinar el estado de falla....9138
SPN 4766 FMI 21 - Temperatura de salida de DOC debajo del m?nimo deseado....9145
Informaci?n general de la falla....9145
Reacci?n de la Luz indicadora de mal funcionamiento (MIL) ....9145
Fallas asociadas....9145
Ciclo de conducci?n para determinar el estado de falla....9145
SPN 5298 FMI 2 - Eficiencia reducida de DOC ? disminuci?n....9152
Informaci?n general de la falla....9152
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9152
Fallas asociadas....9152
Ciclo de conducci?n para determinar el estado de falla....9152
SPN 5319 FMI 31 - Regeneraci?n incompleta de DPF....9159
Informaci?n general de falla....9160
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9160
Fallas asociadas....9160
Datos de la falla....9160
Ciclo de conducci?n para determinar el estado de la falla....9160
Posibles causas....9160
Informaci?n general del sistema de tratamiento posterior....9164
Tipos de regeneraciones....9164
Inhibidores de regen....9169
Informaci?n general....9170
Entrada normal de DPF....9175
Salida normal de DPF....9175
Entrada de DPF restringida....9177
DPF contaminado con refrigerante....9178
DPF contaminado con aceite....9179
Fuga de holl?n en la salida de DPF....9180
Da?o externo a DPF....9181
Medida de bloque del filtro de cer?mica de DPF....9182
AFTFD (Dosificador de combustible posterior al tratamiento)....9183
Herramientas necesarias....9184
AFTFIS (Sensor de entrada de combustible posterior al tratamiento)....9186
Informaci?n general....9187
Herramientas necesarias....9187
3480 FMI 2 - AFTFP1 se?al err?tica, intermitente o incorrecta....9189
Informaci?n general de la falla....9189
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9189
Fallas asociadas....9189
Ciclo de conducci?n para determinar el estado de la falla....9189
Posibles causas....9190
3480 FMI 3 - AFTFP1 Se?al fuera de rango ALTO....9192
Informaci?n general de la falla....9192
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9192
Fallas asociadas....9192
Datos de la falla....9192
Ciclo de conducci?n para determinar el estado de la falla....9192
Posibles causas....9193
3480 FMI 4 - AFTFP1 se?al fuera de rango BAJO....9195
Informaci?n general de la falla....9195
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9195
Fallas asociadas....9195
Datos de la falla....9195
Ciclo de conducci?n para determinar el estado de la falla....9195
Posibles causas....9195
Diagn?stico paso a paso con el software ServiceMaxx?....9198
AFTFP2 (sensor 2 de presi?n de combustible de tratamiento posterior)....9200
Herramientas necesarias....9201
Diagn?stico paso a paso con el software ServiceMaxx?....9201
AFTFSV (V?lvula de corte de tratamiento posterior)....9204
Herramientas necesarias....9204
3482 FMI 3 - V?lvula de corte de combustible de AFT con corto a PWR (circuito abierto o alta resistencia)....9206
Informaci?n general de la falla....9206
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9206
Ciclo de conducci?n para determinar el estado de la falla....9206
Posibles causas....9207
3482 FMI 4- V?lvula de corte de combustible de AFT con corto a GND....9209
Informaci?n general de la falla....9209
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9209
Ciclo de conducci?n para determinar el estado de la falla....9209
Posibles causas....9209
AMS (Sistema de administraci?n de aire)....9211
Herramientas necesarias....9213
SPN 2659 FMI 20 - EGR velocidad de flujo alto detectada....9216
Informaci?n general de la falla....9216
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9217
Fallas asociadas....9217
Ciclo de conducci?n para determinar el estado de falla....9217
Sensor APP (posici?n de pedal del acelerador)....9219
Informaci?n general....9219
Herramientas necesarias....9220
Diagn?stico paso a paso con el software ServiceMaxx?....9220
Sensor CACOT (temperatura de salida del enfriador de aire de carga)....9224
Informaci?n general....9225
Herramientas necesarias....9226
Diagn?stico paso a paso con el software ServiceMaxx?....9227
SPN 2630 FMI 16 - Bajo enfriamiento de CACOT....9229
Informaci?n general de la falla....9229
Reacci?n de la Luz indicadora de mal funcionamiento (MIL) ....9229
Fallas asociadas....9229
Ciclo de conducci?n para determinar el estado de falla....9229
Posibles causas....9230
Sensor CCOSS (Velocidad del separador de aceite del c?rter)....9233
Herramientas necesarias....9233
Separador de aceite del c?rter detallado: sin falla de giro....9234
CCS (Sistema de control de velocidad de crucero)....9235
Funci?n....9235
Funcionamiento de CCS....9235
Diagn?sticos paso a paso de CCS ? con el software ServiceMaxx?....9235
CFV (V?lvula de flujo del refrigerante)....9237
Sensor CKP (posici?n del cig?e?al)....9239
Informaci?n general....9240
Herramientas necesarias....9240
SPN 637 FMI 8 - ruido de se?al de CKP....9242
Informaci?n general de la falla....9242
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9242
Ciclo de conducci?n para determinar el estado de la falla....9242
Posibles causas....9242
SPN 637 FMI 10 - se?al de CKP inactiva....9246
Informaci?n general de la falla....9246
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9246
Ciclo de conducci?n para determinar el estado de la falla....9246
Posibles causas....9246
Sensor CMP (posici?n del ?rbol de levas)....9250
Informaci?n general....9252
Herramientas necesarias....9252
SPN 636 FMI 2 - CMP y error de sincronizaci?n de CKP....9254
Informaci?n general de la falla....9254
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9254
Ciclo de conducci?n para determinar el estado de la falla....9254
Posibles causas....9254
SPN 636 FMI 8 - ruido de se?al de CMP....9259
Informaci?n general de la falla....9259
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9259
Ciclo de conducci?n para determinar el estado de la falla....9259
Posibles causas....9259
SPN 636 FMI 10 - se?al de CMP inactiva....9263
Informaci?n general de la falla....9263
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9263
Ciclo de conducci?n para determinar el estado de la falla....9263
Posibles causas....9263
CMV (V?lvula mezcladora de refrigerante)....9267
Herramientas necesarias....9267
IAHFI (deflagrador de combustible del calefactor de aire de entrada)....9270
Informaci?n general....9271
Herramientas necesarias....9271
5548 FMI 4- Deflagrador de combustible del calefactor del aire de entrada con corto a GND....9272
Informaci?n general de la falla....9272
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9272
Ciclo de conducci?n para determinar el estado de la falla....9272
Posibles causas....9272
Verificaci?n de comparaci?n del sensor de enfriamiento con el software ServiceMaxx?....9275
IAHFS (Solenoide de combustible del calefactor de aire de entrada)....9280
Herramientas necesarias....9280
Balance del cilindro....9283
Informaci?n general....9287
Herramientas necesarias....9288
SPN 651 FMI 13- Inyector 1 error de par?metro programable....9289
Informaci?n general de la falla....9289
Reacci?n de la luz indicadora de mal funcionamiento (MIL)....9289
Ciclo de conducci?n para determinar el estado de la falla....9289
Posibles causas....9289
SPN 651 FMI 16- Inyector 1 Error de sincronizaci?n alta/cantidad de combustible....9291
Informaci?n general de la falla....9291
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9291
Fallas asociadas....9291
Ciclo de conducci?n para determinar el estado de la falla....9291
Posibles causas....9291
SPN 651 FMI 18- Inyector 1 Error bajo de sincronizaci?n/cantidad....9294
Informaci?n general de la falla....9294
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9294
Fallas asociadas....9294
Ciclo de conducci?n para determinar el estado de la falla....9294
Posibles causas....9294
SPN 652 FMI 13- Inyector 2 error de par?metro programable....9297
Informaci?n general de la falla....9297
Reacci?n de la luz indicadora de mal funcionamiento (MIL)....9297
Ciclo de conducci?n para determinar el estado de la falla....9297
Posibles causas....9297
SPN 652 FMI 16- Inyector 2 Error de sincronizaci?n alta/cantidad de combustible....9299
Informaci?n general de la falla....9299
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9299
Fallas asociadas....9299
Ciclo de conducci?n para determinar el estado de la falla....9299
Posibles causas....9299
SPN 652 FMI 18- Inyector 2 Error bajo de sincronizaci?n/cantidad....9302
Informaci?n general de la falla....9302
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9302
Fallas asociadas....9302
Ciclo de conducci?n para determinar el estado de la falla....9302
Posibles causas....9302
SPN 653 FMI 13- Inyector 3 error de par?metro programable....9305
Informaci?n general de la falla....9305
Reacci?n de la luz indicadora de mal funcionamiento (MIL)....9305
Ciclo de conducci?n para determinar el estado de la falla....9305
Posibles causas....9305
SPN 653 FMI 16- Inyector 3 Error de sincronizaci?n alta/cantidad de combustible....9307
Informaci?n general de la falla....9307
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9307
Fallas asociadas....9307
Ciclo de conducci?n para determinar el estado de la falla....9307
Posibles causas....9307
SPN 653 FMI 18- Inyector 3 Error bajo de sincronizaci?n/cantidad....9310
Informaci?n general de la falla....9310
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9310
Fallas asociadas....9310
Ciclo de conducci?n para determinar el estado de la falla....9310
Posibles causas....9310
SPN 654 FMI 13- Inyector 4 error de par?metro programable....9313
Informaci?n general de la falla....9313
Reacci?n de la luz indicadora de mal funcionamiento (MIL)....9313
Ciclo de conducci?n para determinar el estado de la falla....9313
Posibles causas....9313
SPN 654 FMI 16- Inyector 1 Error de sincronizaci?n alta/cantidad de combustible....9315
Informaci?n general de la falla....9315
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9315
Fallas asociadas....9315
Ciclo de conducci?n para determinar el estado de la falla....9315
Posibles causas....9315
SPN 654 FMI 18- Inyector 4 Error bajo de sincronizaci?n/cantidad....9318
Informaci?n general de la falla....9318
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9318
Fallas asociadas....9318
Ciclo de conducci?n para determinar el estado de la falla....9318
Posibles causas....9318
SPN 655 FMI 13- Inyector 5 error de par?metro programable....9321
Informaci?n general de la falla....9321
Reacci?n de la luz indicadora de mal funcionamiento (MIL)....9321
Ciclo de conducci?n para determinar el estado de la falla....9321
Posibles causas....9321
SPN 655 FMI 16- Inyector 5 Error de sincronizaci?n alta/cantidad de combustible....9323
Informaci?n general de la falla....9323
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9323
Fallas asociadas....9323
Ciclo de conducci?n para determinar el estado de la falla....9323
Posibles causas....9323
SPN 655 FMI 18- Inyector 5 Error bajo de sincronizaci?n/cantidad....9326
Informaci?n general de la falla....9326
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9326
Fallas asociadas....9326
Ciclo de conducci?n para determinar el estado de la falla....9326
Posibles causas....9326
SPN 656 FMI 13- Inyector 6 error de par?metro programable....9329
Informaci?n general de la falla....9329
Reacci?n de la luz indicadora de mal funcionamiento (MIL)....9329
Ciclo de conducci?n para determinar el estado de la falla....9329
Posibles causas....9329
SPN 656 FMI 16- Inyector 6 Error de sincronizaci?n alta/cantidad de combustible....9331
Informaci?n general de la falla....9331
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9331
Fallas asociadas....9331
Ciclo de conducci?n para determinar el estado de la falla....9331
Posibles causas....9331
SPN 656 FMI 18- Inyector 6 Error bajo de sincronizaci?n/cantidad....9334
Informaci?n general de la falla....9334
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9334
Fallas asociadas....9334
Ciclo de conducci?n para determinar el estado de la falla....9334
Posibles causas....9334
SPN 1322 FMI 31- Falla de encendido - Cilindros m?ltiples....9337
Informaci?n general de la falla....9337
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9337
Fallas asociadas....9337
Ciclo de conducci?n para determinar el estado de la falla....9337
Posibles causas....9337
SPN 1323 FMI 31- Fallo de encendido - Cilindro 1....9341
Informaci?n general de la falla....9341
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9341
Fallas asociadas....9341
Ciclo de conducci?n para determinar el estado de la falla....9341
Posibles causas....9341
SPN 1324 FMI 31- Fallo de encendido - Cilindro 2....9344
Informaci?n general de la falla....9344
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9344
Fallas asociadas....9344
Ciclo de conducci?n para determinar el estado de la falla....9344
Posibles causas....9344
SPN 1325 FMI 31- Fallo de encendido - Cilindro 3....9347
Informaci?n general de la falla....9347
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9347
Fallas asociadas....9347
Ciclo de conducci?n para determinar el estado de la falla....9347
Posibles causas....9347
SPN 1326 FMI 31- Fallo de encendido - Cilindro 4....9350
Informaci?n general de la falla....9350
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9350
Fallas asociadas....9350
Ciclo de conducci?n para determinar el estado de la falla....9350
Posibles causas....9350
SPN 1327 FMI 31- Fallo de encendido - Cilindro 5....9353
Informaci?n general de la falla....9353
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9353
Fallas asociadas....9353
Ciclo de conducci?n para determinar el estado de la falla....9353
Posibles causas....9353
SPN 1328 FMI 31- Fallo de encendido - Cilindro 6....9356
Informaci?n general de la falla....9356
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9356
Fallas asociadas....9356
Ciclo de conducci?n para determinar el estado de la falla....9356
Posibles causas....9356
Sensor DOCIT (Temperatura de entrada del catalizador de oxidaci?n diesel)....9359
Informaci?n general....9360
Herramientas necesarias....9361
SPN 4765 FMI 2 La se?al de DOCIT no coincide con otros sensores de escape....9362
Informaci?n general de la falla....9362
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9362
Fallas asociadas....9362
Ciclo de conducci?n para determinar el estado de la falla....9362
Posibles causas....9363
SPN 4765 FMI 3 Se?al de DOCIT fuera de rango ALTO....9365
Descripci?n general de la falla....9365
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9365
Ciclo de conducci?n para determinar el estado de la falla....9365
Posibles causas....9365
SPN 4765 FMI 4 Se?al de DOCIT fuera de rango BAJA....9368
Descripci?n general de la falla....9368
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9368
Ciclo de conducci?n para determinar el estado de la falla....9368
Posibles causas....9368
SPN 4765 FMI 20 - Se?al de DOCIT desviada ALTA....9370
Descripci?n general de la falla....9370
Reacci?n de la Luz indicadora de mal funcionamiento (MIL) ....9370
Fallas asociadas....9370
Ciclo de conducci?n para determinar el estado de la falla....9370
SPN 4765 FMI 21 - Se?al de DOCIT desviada BAJA....9372
Descripci?n general de la falla....9372
Reacci?n de la Luz indicadora de mal funcionamiento (MIL) ....9372
Fallas asociadas....9372
Ciclo de conducci?n para determinar el estado de la falla....9372
Sensor de DOCOT (Temperatura de salida del catalizador de oxidaci?n diesel)....9375
Descripci?n general....9376
Herramientas necesarias....9376
SPN 4766 FMI 2 - La se?al de DOCOT no coincide con otros sensores de escape....9377
Informaci?n general de la falla....9377
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9377
Fallas relacionadas....9377
Ciclo de conducci?n para determinar el estado de la falla....9377
Posibles causas....9377
SPN 4766 FMI 3 - Se?al DOCOT fuera de rango ALTA....9380
Descripci?n general de la falla....9380
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9380
Ciclo de conducci?n para determinar el estado de la falla....9380
Posibles causas....9380
SPN 4766 FMI 4 - Se?al de DOCOT fuera de rango BAJA....9383
Descripci?n general de la falla....9383
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9383
Ciclo de conducci?n para determinar el estado de la falla....9383
Posibles causas....9383
Sensor de DPFDP (Presi?n diferencial del filtro de part?culas de diesel)....9385
Descripci?n general....9386
Herramientas necesarias....9387
SPN 3251 FMI 2 - Se?al de DPFDP err?tica, intermitente o incorrecta....9388
Descripci?n general de la falla....9388
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9388
Fallas relacionadas....9388
Ciclo de conducci?n para determinar el estado de la falla....9388
Posibles causas....9389
SPN 3251 FMI 3 - Se?al de DPFDP fuera de rango ALTA....9392
Descripci?n general de la falla....9392
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9392
Falla relacionada....9392
Ciclo de conducci?n para determinar el estado de la falla....9392
Posibles causas....9392
SPN 3251 FMI 4- Se?al de DPFDP fuera de rango BAJA....9394
Descripci?n general de la falla....9394
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9394
Fallas asociadas....9394
Ciclo de conducci?n para determinar el estado de la falla....9394
Posibles causas....9395
Sensor de DPFOT (Temperatura de salida del filtro de part?culas de diesel)....9397
Descripci?n general....9400
Herramientas necesarias....9400
SPN 3246 FMI 2 - La se?al de DPFOT no coincide con otros sensores de escape....9402
Informaci?n general de la falla....9402
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9402
Fallas relacionadas....9402
Ciclo de conducci?n para determinar el estado de la falla....9402
Posibles causas....9403
SPN 3246 FMI 3 - Se?al de DPFOT fuera de rango ALTA....9405
Descripci?n general de la falla....9405
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9405
Ciclo de conducci?n para determinar el estado de la falla....9405
Posibles causas....9405
SPN 3246 FMI 4 - Se?al de DPFOT fuera de rango BAJA....9408
Descripci?n general de la falla....9408
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9408
Ciclo de conducci?n para determinar el estado de la falla....9408
Posibles causas....9408
SPN 3246 FMI 20 -Se?al de DPFOT desviada ALTA....9410
Descripci?n general de la falla....9410
Reacci?n de la Luz indicadora de mal funcionamiento (MIL) ....9410
Fallas relacionadas....9410
Ciclo de conducci?n para determinar el estado de falla....9410
SPN 3246 FMI 21 - Se?al de DPFOT desviada BAJA....9417
Descripci?n general de la falla....9417
Reacci?n de la Luz indicadora de mal funcionamiento (MIL) ....9417
Fallas relacionadas....9417
Ciclo de conducci?n para determinar el estado de falla....9417
Sistema del DPF (Filtro de part?culas de diesel)....9423
Descripci?n general....9425
Herramientas necesarias....9425
SPN 3719 FMI 0- Carga de holl?n del DPF - M?xima (nivel 3/3)....9426
Descripci?n general de la falla....9426
Reacci?n de la Luz indicadora de mal funcionamiento (MIL) ....9426
Fallas relacionadas....9426
Ciclo de conducci?n para determinar el estado de la falla....9426
Circunstancias de la falla....9426
Posibles causas....9426
SPN 3719 FMI 15- Carga de holl?n del DPF - M?nima (nivel 1/3)....9430
Descripci?n general de la falla....9430
Reacci?n de la Luz indicadora de mal funcionamiento (MIL) ....9430
Fallas relacionadas....9430
Ciclo de conducci?n para determinar el estado de la falla....9430
Circunstancias de la falla....9430
Posibles causas....9430
SPN 3719 FMI 16- Carga de holl?n del DPF - Moderada (nivel 2/3)....9434
Descripci?n general de la falla....9434
Reacci?n de la luz indicadora de mal funcionamiento (MIL)....9434
Fallas relacionadas....9434
Ciclo de conducci?n para determinar el estado de la falla....9434
Circunstancias de la falla....9434
Posibles causas....9434
SPN 3720 FMI 0 - Carga de ceniza del DPF en el l?mite m?ximo....9438
Descripci?n general de la falla....9438
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9438
Fallas relacionadas....9438
Ciclo de conducci?n para determinar el estado de falla....9438
SPN 3936 FMI 10 - El modo de administraci?n t?rmica del DPF fall? al elevar la temperatura en el DOC como se esperaba....9444
Descripci?n general de la falla....9444
Reacci?n de la luz indicadora de mal funcionamiento (MIL)....9444
Fallas asociadas....9444
Ciclo de conducci?n para determinar el estado de falla....9444
SPN 3936 FMI 20 - Alta frecuencia de regeneraci?n....9449
Descripci?n general de la falla....9449
Reacci?n de la Luz indicadora de mal funcionamiento (MIL) ....9449
Fallas asociadas....9449
Ciclo de conducci?n para determinar el estado de falla....9449
EBPV (V?lvula de contrapresi?n de escape)....9456
Herramientas necesarias....9456
ECB1 (Freno de compresi?n del motor 1)....9459
Herramientas necesarias....9459
ECB2 (Freno de compresi?n del motor 2)....9462
Herramientas necesarias....9462
Interruptor de ECL (Nivel de refrigerante del motor)....9465
Herramientas necesarias....9465
Diagn?stico paso a paso con el software ServiceMaxx?....9465
Energ?a del ECM (M?dulo de control electr?nico)....9467
Herramientas necesarias....9467
Salida de energ?a del ECM (M?dulo de control electr?nico)....9470
Herramientas necesarias....9470
SPN 3597 FMI 4 ? Salida de alimentaci?n del ECM 1....9471
SPN 3598 FMI 4 ? Salida de alimentaci?n del ECM 2....9473
SPN 3599 FMI 4 ? Salida de alimentaci?n del ECM 3....9475
Autodiagn?stico del ECM (M?dulo de control del motor)....9477
Herramientas necesarias....9477
Procedimiento para volver a aprender del sensor de marcha....9479
Herramientas necesarias....9479
Funci?n....9479
ECS (Sistema de refrigerante del motor)....9480
Herramientas necesarias....9480
Descripci?n general....9481
Herramientas necesarias....9481
SPN 110 FMI 17- Sistema del refrigerante del motor debajo de la temperatura de monitoreo de OBD....9482
Descripci?n detallada de la falla....9482
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9482
Fallas relacionadas....9482
Circunstancias de la falla....9482
Ciclo de conducci?n para determinar el estado de la falla....9482
Posibles causas....9482
SPN 110 FMI 18- Sistema del refrigerante del motor debajo de la temperatura m?nima de circuito cerrado....9484
Descripci?n general de la falla....9484
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9484
Fallas relacionadas....9484
Circunstancias de la falla....9484
Ciclo de conducci?n para determinar el estado de la falla....9484
Posibles causas....9484
Verificaci?n de comparaci?n del sensor de enfriamiento con el software ServiceMaxx?....9486
Sensor de ECT1 (Temperatura del refrigerante del motor 1)....9487
Herramientas necesarias....9487
Diagn?stico paso a paso con el software ServiceMaxx?....9487
Sensor de ECT2 (Temperatura del refrigerante del motor 2)....9490
Descripci?n general....9492
Herramientas necesarias....9492
SPN 4076 FMI 2 Se?al de ECT2 err?tica, intermitente o incorrecta....9493
Descripci?n general de la falla....9493
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9493
Circunstancias de la falla....9493
Ciclo de conducci?n para determinar el estado de la falla....9493
Posibles causas....9494
Diagn?stico paso a paso con el software ServiceMaxx?....9496
EFC (Control del ventilador del motor) ? dos velocidades y variable....9498
Herramientas necesarias....9499
EFC de funci?n de dos velocidades....9499
EFC de funci?n variable....9499
EFC ? Funcionamiento del circuito del sensor de dos velocidades....9499
EFC ? Funcionamiento del circuito del sensor variable....9500
Sensor de EGRT (Temperatura de recirculaci?n de gas de escape)....9502
Herramientas necesarias....9502
Diagn?stico paso a paso con el software ServiceMaxx?....9504
V?lvula de EGR (Recirculaci?n del gas de escape)....9506
Herramientas necesarias....9507
Diagn?stico paso a paso con el software ServiceMaxx?....9507
Monitor del sistema de recirculaci?n del gas de escape (EGR)....9510
Herramientas necesarias....9510
SPN 3058 FMI 0 - El motor no entr? en el control de EGR de circuito abierto cuando se esperaba....9511
Descripci?n general de la falla....9511
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9511
Fallas relacionadas....9511
SPN 3058 FMI 10 - El motor no entr? en el control de EGR de circuito cerrado cuando se esperaba....9514
Descripci?n general de la falla....9514
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9514
Fallas relacionadas....9514
Sensor de EOL (Nivel de aceite del motor)....9517
Herramientas necesarias....9517
Diagn?stico paso a paso con el software ServiceMaxx?....9518
Sensor EOP (presi?n de aceite del motor)....9520
Herramientas necesarias....9520
Diagn?stico paso a paso con el software ServiceMaxx?....9521
Sensor EOT (temperatura de aceite del motor)....9523
Herramientas necesarias....9523
Diagn?stico paso a paso con el software ServiceMaxx?....9524
ETV (V?lvula del acelerador del motor)....9526
Herramientas necesarias....9527
Diagn?stico paso a paso con el software ServiceMaxx?....9529
SPN 51 FMI 10 - Desviaci?n de retroalimentaci?n del sensor de ETP durante la CSER....9532
Descripci?n general de la falla....9532
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9532
Fallas relacionadas....9532
Ciclo de conducci?n para determinar el estado de la falla....9532
EWPS (Sistema de advertencia y protecci?n del motor)....9534
Funci?n....9538
Par?metros programables del EWPS....9539
Herramientas necesarias....9539
SPN 110 FMI 0 - Sistema del refrigerante del motor por encima de la temperatura cr?tica....9541
Descripci?n general de la falla....9541
Reacci?n de la luz indicadora de mal funcionamiento (MIL)....9541
Fallas relacionadas....9541
Circunstancias de la falla....9541
Ciclo de conducci?n para determinar el estado de la falla....9541
Posibles causas....9541
SPN 110 FMI 11 - Registro del evento, temperatura caliente del refrigerante, extremo....9543
Descripci?n general de la falla....9543
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9543
Fallas relacionadas....9543
Circunstancias de la falla....9543
Ciclo de conducci?n para determinar el estado de la falla....9543
SPN 110 FMI 15 - Sistema de refrigerante del motor sobrepasa la temperatura de advertencia....9545
Descripci?n general de la falla....9545
Reacci?n de la luz indicadora de mal funcionamiento (MIL)....9545
Fallas relacionadas....9545
Ciclo de conducci?n para determinar el estado de la falla....9545
Posibles causas....9545
SPN 188 FMI 0 - La velocidad del motor no alcanz? la velocidad en vac?o deseada (demasiado alta)....9548
Descripci?n general de la falla....9548
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9548
Fallas relacionadas....9548
Ciclo de conducci?n para determinar el estado de la falla....9548
Posible causa:....9548
SPN 188 FMI 1 - La velocidad del motor no alcanz? la velocidad en vac?o deseada (demasiado baja)....9551
Descripci?n general de la falla....9551
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9551
Fallas relacionadas....9551
Ciclo de conducci?n para determinar el estado de la falla....9551
Posibles causas....9551
SPN 190 - FMI 0 - Nivel m?s severo de exceso de velocidad del motor....9554
Descripci?n general de la falla....9554
Reacci?n de la luz indicadora de mal funcionamiento (MIL)....9554
Antes de iniciar el diagn?stico:....9554
SPN 2588 FMI 0 - Velocidad excesiva del veh?culo 1, registro del evento, extremo....9556
Descripci?n general de la falla....9556
Reacci?n de la luz indicadora de mal funcionamiento (MIL)....9556
Fallas relacionadas....9556
Circunstancias de la falla....9556
Ciclo de conducci?n para determinar el estado de la falla....9556
Posibles causas....9556
SPN 2588 FMI 15 - Velocidad excesiva del veh?culo 1, registro del evento, no extremo....9557
Descripci?n general de la falla....9557
Reacci?n de la luz indicadora de mal funcionamiento (MIL)....9557
Fallas relacionadas....9557
Circunstancias de la falla....9557
Ciclo de conducci?n para determinar el estado de la falla....9557
Posibles causas....9557
SPN 2589 FMI 0 - Velocidad excesiva del veh?culo 2, registro del evento, extremo....9558
Descripci?n general de la falla....9558
Reacci?n de la luz indicadora de mal funcionamiento (MIL)....9558
Fallas relacionadas....9558
Circunstancias de la falla....9558
Ciclo de conducci?n para determinar el estado de la falla....9558
Posibles causas....9558
SPN 2589 FMI 15 - Velocidad excesiva del veh?culo 2, registro del evento, no extremo....9559
Descripci?n general de la falla....9559
Reacci?n de la luz indicadora de mal funcionamiento (MIL)....9559
Fallas relacionadas....9559
Circunstancias de la falla....9559
Ciclo de conducci?n para determinar el estado de la falla....9559
Posibles causas....9559
SPN 5395 FMI 0 - El motor no puede lograr el par de torsi?n a ralent? deseado (demasiado alto)....9560
Descripci?n general de la falla....9560
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9560
Fallas relacionadas....9560
Ciclo de conducci?n para determinar el estado de la falla....9560
Posibles causas....9560
SPN 5395 FMI 1 - El motor no puede lograr el par de torsi?n a ralent? deseado (demasiado bajo)....9562
Descripci?n general de la falla....9562
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9562
Fallas relacionadas....9562
Ciclo de conducci?n para determinar el estado de la falla....9562
Sensor de la FDP (Presi?n de suministro de combustible)....9565
Herramientas necesarias....9565
SPN 94 FMI 0 - La presi?n de distribuci?n de combustible supera el punto cr?tico....9567
Descripci?n general de la falla....9567
Reacci?n de la Luz indicadora de mal funcionamiento (MIL) ....9567
Ciclo de conducci?n para determinar el estado de la falla....9567
Posibles causas....9567
Diagn?stico paso a paso con el software ServiceMaxx?....9570
FPCV (V?lvula de control de la presi?n del combustible)....9572
Herramientas necesarias....9572
Diagn?stico paso a paso con el software ServiceMaxx?....9573
Sensor de la FRP (Presi?n del riel de combustible)....9575
Descripci?n general....9576
Herramientas necesarias....9576
Diagn?stico paso a paso con el software ServiceMaxx?....9577
SPN 157 - FMI 20 desviaci?n ELEVADA de la se?al de FRP....9580
Descripci?n general de la falla....9580
Reacci?n de la Luz indicadora de mal funcionamiento (MIL) ....9580
Fallas relacionadas....9580
Ciclo de conducci?n....9580
SPN 157 - FMI 21 desviaci?n BAJA de la se?al del FRP....9582
Descripci?n general de la falla....9582
Reacci?n de la Luz indicadora de mal funcionamiento (MIL) ....9582
Fallas relacionadas....9582
Ciclo de conducci?n....9582
Sistema de la FRP (Presi?n del riel de combustible)....9585
Descripci?n general....9588
Herramientas necesarias....9588
Diagn?stico paso a paso con el software ServiceMaxx?....9589
SPN 3055 FMI 0 - FRP excede el m?ximo....9590
Descripci?n general....9590
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9590
Fallas relacionadas....9590
Ciclo de conducci?n para determinar el estado de la falla....9590
Posibles causas....9590
SPN 3055 FMI 1 - presi?n del combustible baja al arrancar....9592
Descripci?n general de la falla....9592
Reacci?n de la luz indicadora de mal funcionamiento (MIL)....9592
Fallas relacionadas....9592
Circunstancias de la falla....9592
Ciclo de conducci?n para determinar el estado de la falla....9592
Posibles causas....9592
SPN 3055 FMI 15 - FRP por debajo del m?nimo con la orden m?xima....9597
Descripci?n general de la falla....9597
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9597
Fallas relacionadas....9597
Ciclo de conducci?n para determinar el estado de la falla....9597
Posibles causas....9597
SPN 3055 FMI 17 - FRP por encima del m?ximo con la orden de m?nima....9602
Descripci?n general de la falla....9602
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9602
Fallas relacionadas....9602
Ciclo de conducci?n para determinar el estado de la falla....9602
Posibles causas....9602
Supervisor de freno dif?cil....9605
Descripci?n general....9605
Herramientas necesarias....9605
Diagn?stico paso a paso con el software ServiceMaxx?....9605
HS (Sensor de humedad)/IAT (Sensor de temperatura del aire de entrada)....9606
Herramientas necesarias....9607
Diagn?stico paso a paso con el software ServiceMaxx?....9607
IMP (Presi?n del m?ltiple de admisi?n)....9611
Descripci?n general....9612
Herramientas necesarias....9612
Diagn?stico paso a paso con el software ServiceMaxx?....9614
SPN 102 - FMI 10 IMP - Respuesta lenta de sobrealimentaci?n....9617
Reacci?n de la Luz indicadora de mal funcionamiento (MIL) ....9617
Fallas asociadas....9617
Ciclo de conducci?n....9617
Sensor de la IMT (Temperatura del distribuidor de admisi?n)....9623
Herramientas necesarias....9623
Diagn?stico paso a paso con el software ServiceMaxx?....9624
Circuitos del INJ (Inyector)....9627
Descripci?n general....9634
Herramientas necesarias....9634
SPN 651 FMI 4- Cortocircuito del inyector 1....9636
Descripci?n general de la falla....9636
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9636
Ciclo de conducci?n para determinar el estado de la falla....9636
Posibles causas....9636
SPN 651 FMI 5- Carga/circuito abierto del inyector 1....9641
Descripci?n general de la falla....9641
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9641
Ciclo de conducci?n para determinar el estado de la falla....9641
Posibles causas....9641
SPN 652 FMI 4- Cortocircuito del inyector 2....9646
Descripci?n general de la falla....9646
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9646
Ciclo de conducci?n para determinar el estado de la falla....9646
Posibles causas....9646
SPN 652 FMI 5- Carga/circuito abierto del inyector 2....9651
Descripci?n general de la falla....9651
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9651
Ciclo de conducci?n para determinar el estado de la falla....9651
Posibles causas....9651
SPN 653 FMI 4- Cortocircuito del inyector 3....9656
Descripci?n general de la falla....9656
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9656
Ciclo de conducci?n para determinar el estado de la falla....9656
Posibles causas....9656
SPN 653 FMI 5- Carga/circuito abierto del inyector 3....9661
Descripci?n general de la falla....9661
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9661
Ciclo de conducci?n para determinar el estado de la falla....9661
Posibles causas....9661
SPN 654 FMI 4- Cortocircuito del inyector 4....9666
Descripci?n general de la falla....9666
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9666
Ciclo de conducci?n para determinar el estado de la falla....9666
Posibles causas....9666
SPN 654 FMI 5- Carga/circuito abierto del inyector 4....9671
Descripci?n general de la falla....9671
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9671
Ciclo de conducci?n para determinar el estado de la falla....9671
Posibles causas....9671
SPN 655 FMI 4- Cortocircuito del inyector 5....9676
Descripci?n general de la falla....9676
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9676
Ciclo de conducci?n para determinar el estado de la falla....9676
Posibles causas....9676
SPN 655 FMI 5- Carga/circuito abierto del inyector 5....9681
Descripci?n general de la falla....9681
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9681
Ciclo de conducci?n para determinar el estado de la falla....9681
Posibles causas....9681
SPN 656 FMI 4- Cortocircuito del inyector 6....9686
Descripci?n general de la falla....9686
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9686
Ciclo de conducci?n para determinar el estado de la falla....9686
Posibles causas....9686
SPN 656 FMI 5- Carga/circuito abierto del inyector 6....9691
Descripci?n general de la falla....9691
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9691
Ciclo de conducci?n para determinar el estado de la falla....9691
Posibles causas....9691
SPN 2797 FMI 11 - Cortocircuito del grupo de control del inyector 1 (INJ 1, 3, 5)....9696
Descripci?n general de la falla....9696
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9696
Fallas relacionadas....9696
Ciclo de conducci?n para determinar el estado de la falla....9696
Posibles causas....9697
SPN 2798 FMI 11 - Cortocircuito del grupo de control del inyector 2 (INJ 2, 4, 6)....9708
Descripci?n general de la falla....9708
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9708
Fallas relacionadas....9708
Ciclo de conducci?n para determinar el estado de la falla....9708
Posibles causas....9709
IST (Temporizador de apagado del ralent?) Sistema (Ralent? bajo limpio)....9719
IST (Ralent? bajo limpio)....9719
IST (Temporizador de apagado del ralent?) Sistema (Federal - opcional)....9720
IST (Federal - opcional) Funcionamiento del circuito del sensor....9720
Comunicaciones del enlace de datos J1939....9721
Herramientas necesarias....9721
Diagn?stico paso a paso con el software ServiceMaxx?....9723
Sensor del MAF (Flujo de aire masivo)....9724
Funci?n....9724
MIL (Luz indicadora de mal funcionamiento)....9725
Descripci?n general....9725
Herramientas necesarias....9725
O2S (Sensor de ox?geno)....9727
Descripci?n general....9729
Herramientas necesarias....9730
Diagn?stico paso a paso con el software ServiceMaxx?....9731
SPN 724 FMI 20 ? Adaptaci?n de O 2S por encima del l?mite m?ximo....9734
Descripci?n general....9734
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9734
Ciclo de conducci?n para determinar el estado de la falla....9734
Posibles causas....9734
SPN 724 FMI 21 ? Adaptaci?n de O2S por debajo del l?mite menor....9737
SPN 3223 FMI 0 - Temperatura del calefactor de O 2S por encima de la m?xima....9738
Descripci?n general de la falla....9738
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9738
Ciclo de conducci?n para determinar el estado de falla....9738
SPN 3223 FMI 5 ? Carga/circuito abierto del calefactor de O 2S....9740
Descripci?n general de la falla....9740
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9740
Fallas relacionadas....9740
Ciclo de conducci?n para determinar el estado de la falla....9740
Posibles causas....9740
Identificaci?n de la falla del sistema de O2S....9743
RAPP (Posici?n remota del pedal del acelerador)....9744
Descripci?n general....9744
Herramientas necesarias....9744
Mensajes de intervalos de servicio....9746
Funcionamiento de los mensajes de intervalo de servicio....9746
Reloj SART (Tiempo real aut?nomo)....9747
Herramientas necesarias....9747
Sensor TC1TOP (Presi?n de salida de la turbina 1 del turbocargador)....9749
Herramientas necesarias....9749
Diagn?stico paso a paso con el software ServiceMaxx?....9750
TC1WC (Control de la compuerta de descarga del turbocargador 1)....9753
Herramientas necesarias....9753
TC2WC (Control de la compuerta de descarga del turbocargador 2)....9756
Herramientas necesarias....9756
TC2CIS (Sensor de entrada del compresor 2 del turbocargador)....9759
Descripci?n general....9761
Herramientas necesarias....9761
SPN 1173 FMI 2 - Se?al de TC2CIT err?tica, intermitente o incorrecta....9762
Descripci?n general de la falla....9762
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9762
Fallas relacionadas....9762
Ciclo de conducci?n para determinar el estado de la falla....9762
Posibles causas....9763
SPN 1173 FMI 3 - Se?al de TC2CIT fuera de rango ALTO....9765
Descripci?n general de la falla....9765
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9765
Ciclo de conducci?n para determinar el estado de la falla....9765
Posibles causas....9765
SPN 1173 FMI 4 - Se?al de TC2CIT fuera de rango BAJO....9768
Descripci?n general de la falla....9768
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9768
Ciclo de conducci?n para determinar el estado de la falla....9768
Posibles causas....9768
SPN 1173 FMI 16 - Se?al de TC2CIT por encima de lo deseado (CAC entre etapas bajo enfriamiento)....9770
Descripci?n general de la falla....9770
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9770
Fallas relacionadas....9770
Ciclo de conducci?n para determinar el estado de la falla....9770
Posibles causas....9770
SPN 1177 FMI 2 - Se?al de TC2CIP err?tica, intermitente o incorrecta....9773
Descripci?n general de la falla....9773
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9773
Fallas relacionadas....9773
Ciclo de conducci?n para determinar el estado de la falla....9773
Posibles causas....9773
SPN 1177 FMI 3 - Se?al de TC2CIP fuera de rango ALTO....9776
Descripci?n general de la falla....9776
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9776
Ciclo de conducci?n para determinar el estado de la falla....9776
Posibles causas....9776
SPN 1177 FMI 4 - Se?al de TC2CIP fuera de rango BAJO....9779
Descripci?n general de la falla....9779
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9779
Ciclo de conducci?n para determinar el estado de la falla....9779
Posibles causas....9779
Sensor TOSS/VSS (Sensor de velocidad del veh?culo/velocidad del eje de salida de la transmisi?n)....9781
Descripci?n general....9783
Herramientas necesarias....9783
Diagn?stico paso a paso con el software ServiceMaxx?....9784
SPN 191 FMI 1 TOSS/VSS no se detect? con el veh?culo en movimiento....9786
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9786
Ciclo de conducci?n para determinar el estado de falla....9786
SPN 191 FMI 2 Se?al del TOSS/VSS err?tica, intermitente o incorrecta....9790
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9790
Ciclo de conducci?n para determinar el estado de falla....9790
SPN 191 FMI 3 Se?al del TOSS/VSS fuera de rango ALTO....9793
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9793
Ciclo de conducci?n para determinar el estado de falla....9793
SPN 191 FMI 4 Se?al del TOSS/VSS fuera de rango BAJO....9796
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9796
Ciclo de conducci?n para determinar el estado de falla....9796
SPN 191 FMI 16 Lectura del TOSS/VSS m?s alta que el l?mite....9799
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9799
Ciclo de conducci?n para determinar el estado de falla....9799
VREF (Referencia de voltaje)....9802
Herramientas necesarias....9804
Sensor de WIF (agua en el combustible)....9811
Herramientas necesarias....9811
Diagn?stico paso a paso con el software ServiceMaxx?....9812
WIFL (Luz de agua en el combustible)....9814
Descripci?n general....9814
Herramientas necesarias....9814
SPN 97 - FMI 3 - Cortocircuito a la ALIMENTACI?N de la WIFL....9815
SPN 97 - FMI 4 - Cortocircuito a TIERRA de la WIFL....9817
SPN 97 - FMI 5 - Carga/circuito abierto de la WIFL....9819
WTSL (Luz de esperar para arrancar)....9821
Descripci?n general....9821
Herramientas necesarias....9822
SPN 1081 - FMI 3 - Cortocircuito a la ALIMENTACI?N del circuito de la WTSL....9823
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9823
SPN 1081 - FMI 4 - Cortocircuito a TIERRA del circuito de la WTSL....9825
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9825
SPN 1081 - FMI 5- Carga/circuito abierto de la WTSL....9827
Reacci?n de la Luz indicadora de mal funcionamiento (MIL)....9827
Ubicaciones del sensor y activador....9829
Componentes instalados del motor....9829
Sistema de AFT....9831
Ubicaciones del freno de compresi?n del motor....9831
Componentes instalados en el veh?culo....9832
Sensor de temperatura del aire ambiente....9833
Contenido....9835
Herramientas el?ctricas....9837
Caja de conexiones de 180 pasadores....9837
Arn?s de conectores tipo banana 3....9838
Arn?s de resistencia de 500 ohmios....9838
Kit de prueba de terminales del motor electr?nico....9839
Kit de la sonda de prueba de terminal de abertura grande....9839
Mult?metro digital (DMM)....9840
EXP-1000 HD de Midtronics....9841
EZ-Tech? Herramienta electr?nica de servicio (EST)....9842
Software ServiceMaxx?....9842
Cable de interfaz (RP1210B cumple con ser compatible con J1939 y J1708)....9842
MaxxForce? 11 y kit de herramientas del motor 13....9843
Arn?s de conexi?n 4485A (APP)....9844
Arn?s de conexi?n 4602 (AFTFSV)....9844
Arn?s de conexiones 4735A (O2S)....9845
Arn?s de conexi?n 4760A (DOCIT, DOCOT, DPFOT y EGRT)....9845
Arn?s de conexiones 4761A (DPFDP)....9846
Arn?s de conexiones 4827 (IAHFS, ECT1, ECT2, EOL y EOT)....9846
Arn?s de conexi?n 4828 (AFTFD y FPCV)....9847
Arn?s de conexi?n 4829 (FRP)....9847
Arn?s de conexiones 4830 (AFTFIS, HS/IAT y TC2CIS)....9848
Arn?s de conexi?n 4844 (EFAN)....9848
Arn?s de conexi?n 4850 (IMP)....9849
Arn?s de conexi?n 4870 (CMV)....9849
Arn?s de conexi?n 4871 (AAT y CFV)....9850
Arn?s de conexi?n 4881 (FDP)....9850
Arn?s de conexi?n 4882 (EOP)....9851
Arn?s de conexi?n 4883 (IMT)....9851
Arn?s de conexiones 4885 (IAHR)....9852
Arn?s de conexi?n 4951 (CCOSS)....9852
Arn?s de conexi?n 4993 (CACOT)....9853
Arn?s de conexi?n 6002 (WIF)....9853
Arn?s de conexi?n 6003 (EBPV, TC1TOP, TC1WC y TC2WC)....9853
Arn?s de conexi?n 6004 (ECB)....9854
Arn?s de conexi?n 6016 (v?lvula de ETV y EGR)....9854
Arn?s de conexi?n 6021 (CKP y CMP)....9855
Arn?s de conexi?n 6027 (AFTFP2)....9856
Herramientas mec?nicas....9857
Kit de tapa de aire, tapa del combustible y tap?n....9857
Herramienta de liberaci?n de la tuber?a del refrigerante del compresor de aire....9857
Protector de entrada de aire....9858
Herramienta para prueba de emisiones....9859
Herramienta de fuente limpia de combustible....9859
Kit del adaptador de prueba del solenoide del calefactor del aire de admisi?n....9861
Man?metro digital....9862
Kit de prueba para la detecci?n de fugas en el enfriador de EGR....9863
Medidor de juego libre (0.50mm)....9863
Medidor de juego libre (0.80mm)....9864
Herramienta de bloqueo del combustible....9864
Copas de inyectores de combustible....9865
Herramienta de aireaci?n y restricci?n de la entrada de combustible....9865
Acoplador de la tuber?a de combustible....9866
Herramienta de desconexi?n de la tuber?a de combustible de 11.8 mm....9866
Herramienta de desconexi?n de la tuber?a de combustible de 16 mm....9867
Medidor de presi?n de combustible....9867
Tapones del riel de alta presi?n....9868
Probador de la tuber?a de retorno de alta presi?n....9868
Kit de prueba de presi?n....9869
Kit de prueba de presi?n del radiador....9869
Man?metro Slack Tube?....9871
Kit de detecci?n de fugas de UV....9872
Contenido....9873
Abreviaciones y acr?nimos....9875
Contenido....9883
T?rminos....9885
Contenido....9897
Todas las clasificaciones....9899
MaxxForce? 11 (10.5 L)....9905
330 hp a 1700 r. p. m...9905
370 hp a 1700 r. p. m...9906
390 hp a 1700 r. p. m...9907
MaxxForce? 13 (12.4 L)....9908
410 hp a 1700 r. p. m...9908
430 hp a 1700 r. p. m...9909
450 hp a 1700 rpm (Transmisi?n autom?tica Allison)....9910
450 hp a 1700 rpm (Transmisi?n manual)....9911
475 hp a 1700 r. p. m...9912
Contenido....9913
Valores de se?al....9915
Contenido....9923
Descripci?n....9925
tables....8771
Literatura de servicio t?cnico....8771
Motores MaxxForce? 11 y 13 diesel....8781
Especificaciones del solenoide del freno de motor....8914
Requerimientos de presi?n de aceite del freno de motor....8917
Flujo normal de retorno del combustible con la cantidad de inyectores conectados....9012
Ejemplo....9048
Ejemplo....9049
Ejemplo....9050
Ejemplo....9051
Condiciones de entrada para un Regen de rodamiento....9166
Condiciones de entrada para un Regen de estacionamiento....9167
Revisiones de comparaci?n del sensor....9169
Prueba de restricci?n de escape....9169
Revise los inhibidores de Regen de rodamiento....9171
Revise los inhibidores de Regen estacionado....9172
Revisiones de Regen estacionado....9174
Revisi?n de voltaje del conector ? AFTFD desconectado....9184
Verificaci?n de voltaje operacional....9185
Revisi?n de resistencia del actuador....9185
Verifique la resistencia del arn?s....9185
Revisi?n del circuito del sensor....9198
Diagn?stico paso a paso sin el software ServiceMaxx?....9199
Verifique la resistencia del arn?s....9199
Revisi?n del circuito del sensor....9202
Diagn?stico paso a paso sin el software ServiceMaxx?....9202
Verifique la resistencia del arn?s....9203
SPN 102 FMI 16 ? Sobrerefuerzo de presi?n del m?ltiple de admisi?n....9213
SPN 102 FMI 18 ? Refuerzo inferior de presi?n del m?ltiple de admisi?n....9214
Se?al de SPN 1173 FMI 16 ? TC2CIT sobre lo deseado (CAC de inter etapas bajo enfriamiento)....9214
SPN 2659 FMI 21 ? EGR bajo se ha detectado velocidad baja....9215
Revisi?n del circuito del sensor....9221
Diagn?stico paso a paso sin el software ServiceMaxx?....9222
Verifique la resistencia del arn?s....9222
Verificaci?n de voltaje operacional....9223
SPN 2630 FMI 2 ? La se?al CACOT no concuerda con los otros sensores....9227
Verifique el circuito del sensor con el software ServiceMaxx?....9228
Verificaci?n del voltaje del conector sin el software ServiceMaxx?....9228
Verifique la resistencia del arn?s....9228
Revisi?n de la resistencia del sensor....9234
Revisi?n del voltaje del conector sin el software ServiceMaxx?....9234
Verifique la resistencia del arn?s....9234
Par?metros programables....9235
Revisiones del interruptor....9236
Revisi?n de voltaje del conector....9237
Verificaci?n de voltaje operacional....9238
Revisi?n de resistencia del actuador....9238
Verifique la resistencia del arn?s....9238
Revisi?n de voltaje del conector....9268
Verificaci?n de voltaje operacional....9268
Revisi?n de resistencia del actuador....9268
Verifique la resistencia del arn?s....9269
SPN 626 FMI 18 ? falla del calefactor del aire de entrada: falta de calor en el m?ltiple de admisi?n....9275
Revisi?n de voltaje en IAHFI - Prueba del actuador....9275
Revisi?n de consumo de amperaje - prueba del activador....9276
Revisiones de voltaje en el conector del relevador....9276
Revisiones de voltaje en el relevador - Prueba del activador....9277
Revisi?n de la resistencia de IAHFI....9279
Verifique la resistencia del arn?s....9279
Verificaci?n de voltaje del conector ? IAHFS desconectado....9281
Verificaci?n de voltaje operacional....9281
Revisi?n de resistencia del actuador....9281
Verifique la resistencia del arn?s....9282
Revisi?n de voltaje del conector ? EBPV desconectada....9457
Verificaci?n de voltaje operacional....9457
Revisi?n de resistencia del actuador....9457
Verifique la resistencia del arn?s....9458
Revise el voltaje del conector ? ECB1 desconectado....9460
Verificaci?n de voltaje operacional....9460
Revisi?n de resistencia del actuador....9460
Verifique la resistencia del arn?s....9461
Revise el voltaje del conector ? ECB2 desconectado....9463
Verificaci?n de voltaje operacional....9463
Revisi?n de resistencia del actuador....9463
Verifique la resistencia del arn?s....9464
SPN 111 FMI 1 ? Nivel bajo del refrigerante del motor....9466
Revisi?n de voltaje del conector....9466
Verifique la resistencia del arn?s....9466
SPN 158 FMI 15- Voltaje del ECM demasiado ALTO....9468
SPN 158 FMI 17- Voltaje del ECM demasiado BAJO....9468
Verificaciones de voltaje en el ECM....9469
Revisi?n de voltaje....9471
Verifique la resistencia del arn?s....9472
Revisi?n de voltaje....9473
Verifique la resistencia del arn?s....9474
Revisi?n de voltaje....9475
Verifique la resistencia del arn?s....9475
SPN 108 FMI 3- Se?al BARO fuera de rango ALTA....9477
SPN 108 FMI 4 - Se?al BARO fuera de rango BAJA....9478
SPN 628 FMI 12 - Error de memoria del ECM....9478
SPN 629 FMI 2- Error del ECM- monitoreo nivel 2....9478
SPN 629 FMI 8 - Falla del temporizador de motor apagado....9478
SPN 629 FMI 12 - Error del chip interno del ECM....9478
SPN 629 FMI 14 - Componente interno del ECM....9478
SPN 1110 FMI 31 ? El ECM detecta abastecimiento de combustible sin demanda....9479
Verifique el circuito del sensor con el software ServiceMaxx?....9488
Verificaci?n del voltaje del conector sin el software ServiceMaxx?....9488
Verifique la resistencia del arn?s....9489
SPN 4076 FMI 16 ? la se?al de la ECT2 no concuerda con otros sensores (inmersi?n en fr?o)....9496
Verifique el circuito del sensor con el software ServiceMaxx?....9497
Verificaci?n del voltaje del conector sin el software ServiceMaxx?....9497
Verifique la resistencia del arn?s....9497
Revisi?n de voltaje en el conector EFC de una o dos velocidades - Prueba del activador....9500
Verifique la resistencia del arn?s....9501
SPN 412 FMI 2 ? la se?al de la EGRT no concuerda con otros sensores....9504
Verifique el circuito del sensor con el software ServiceMaxx?....9505
Verificaci?n del voltaje del conector sin el software ServiceMaxx?....9505
Verifique la resistencia del arn?s....9505
SPN 27 FMI 7 ? EGRP no coincide con la posici?n comandada....9508
Revisi?n de voltaje del conector ? V?lvula del EGR desconectada....9508
Verificaci?n de voltaje operacional....9509
Verifique la resistencia del arn?s....9509
Verifique el circuito del sensor con el software ServiceMaxx?....9518
Verificaci?n del voltaje del conector sin el software ServiceMaxx?....9519
Verifique la resistencia del arn?s....9519
Revisi?n del circuito del sensor....9521
Revisi?n de voltaje del conector....9522
Verifique la resistencia del arn?s....9522
Verifique el circuito del sensor con el software ServiceMaxx?....9524
Diagn?stico paso a paso sin el software ServiceMaxx?....9525
Verifique la resistencia del arn?s....9525
Revisi?n del voltaje del conector ? ETV desconectada....9529
Verificaci?n de voltaje operacional....9530
Verifique la resistencia del arn?s....9531
Verifique el circuito del sensor con el software ServiceMaxx?....9570
Verificaci?n del voltaje del conector sin el software ServiceMaxx?....9571
Verifique la resistencia del arn?s....9571
Revisi?n del voltaje del conector ? FPCV desconectada....9573
Verificaci?n de voltaje operacional....9573
Verifique la resistencia del arn?s....9574
Verifique el circuito del sensor con el software ServiceMaxx?....9578
Verificaci?n del voltaje del conector sin el software ServiceMaxx?....9579
Verifique la resistencia del arn?s....9579
SPN 157 FMI 0 - Falla de apertura de la v?lvula de alivio de la FRP....9589
SPN 157 FMI 14 - Falla de la v?lvula de alivio de la FRP....9589
SPN 1810 FMI 0 - Monitor de frenado fuerte, registro de evento, extremo....9605
SPN 1810 FMI 15- Monitoreo de frenado fuerte, registro de evento, no extremo....9605
SPN 172 FMI 2 ? La se?al de IAT no coincide con la de otros sensores....9608
Verifique el circuito del sensor con el software ServiceMaxx?....9609
Verificaci?n del voltaje del conector sin el software ServiceMaxx?....9609
Verifique la resistencia del arn?s....9610
Verifique el circuito del sensor con el software ServiceMaxx?....9615
Verificaci?n del voltaje del conector sin el software ServiceMaxx?....9615
Verifique la resistencia del arn?s....9616
Verificaci?n de comparaci?n del sensor de enfriamiento con el software ServiceMaxx?....9625
SPN 105 FMI 2 ? La se?al de la IMT no concuerda con la de otros sensores....9625
SPN 105 FMI 18 ? La se?al de la IMT no responde como se espera ....9625
Verifique el circuito del sensor con el software ServiceMaxx?....9625
Verificaci?n del voltaje del conector sin el software ServiceMaxx?....9626
Verifique la resistencia del arn?s....9626
Revisi?n del voltaje del conector de diagn?stico del veh?culo....9722
Revisi?n de comunicaci?n con EST....9722
Verifique la resistencia del arn?s....9723
SPN 1590 FMI 19 - Control crucero adaptable sin detectar en J1939....9723
Revisi?n del voltaje del conector de MIL sin el software ServiceMaxx?....9726
Verifique la resistencia del arn?s....9726
Verificaci?n del voltaje del conector sin el software ServiceMaxx?....9732
Verifique la resistencia del arn?s....9733
SPN 3223 FMI 1? Temperatura del calefactor de O 2S por debajo del m?nimo....9743
SPN 3223 FMI 17 ? temperatura del calefactor de O2S por debajo del m?nimo en ALIMENTACI?N baja de la bater?a....9743
Verifique el circuito del sensor con el software ServiceMaxx?....9745
Verifique la resistencia del arn?s....9745
Revisi?n de voltaje del conector....9747
Verifique la resistencia del arn?s....9748
La se?al de SPN 5541 FMI 2 ? TC1TOP no concuerda con la del BARO....9750
Verifique el circuito del sensor con el software ServiceMaxx?....9751
Verificaci?n del voltaje del conector sin el software ServiceMaxx?....9751
Verifique la resistencia del arn?s....9752
Revisi?n del voltaje del conector ? TC2WC desconectado....9754
Verificaci?n de voltaje operacional....9754
Revisi?n de resistencia del actuador....9754
Verifique la resistencia del arn?s....9755
Revisi?n del voltaje del conector ? TC2WC desconectado....9757
Verificaci?n de voltaje operacional....9757
Revisi?n de resistencia del actuador....9757
Verifique la resistencia del arn?s....9758
SPN 84 FMI 2 - Falla anti-alteraci?n de la velocidad del veh?culo....9784
Revisi?n del voltaje del conector de TOSS/VSS sin el software ServiceMaxx?....9784
Revise la continuidad del sensor TOSS/VSS sin el software ServiceMaxx?....9785
Verifique la resistencia del arn?s....9785
Revisi?n del funcionamiento del TOSS/VSS sin el software ServiceMaxx?....9785
Revisiones de voltaje para SPN 3509 FMI 14 ? VREF1....9805
Revisi?n de la resistencia del arn?s de SPN 3509 FMI 14 ? VREF1....9805
Revisiones de voltaje para SPN 3510 FMI 14 ? VREF2....9806
Revisi?n de la resistencia del arn?s de SPN 3510 FMI 14 ? VREF2....9806
Revisiones de voltaje para SPN 3511 FMI 14 ? VREF3....9807
Revisi?n de la resistencia del arn?s de SPN 3511 FMI 14 ? VREF3....9807
Revisiones de voltaje para SPN 3512 FMI 14 ? VREF4....9808
Revisi?n de la resistencia del arn?s de SPN 3512 FMI 14 ? VREF4....9808
Revisiones de voltaje para SPN 3513 FMI 14 ? VREF5....9809
Revisi?n de la resistencia del arn?s de SPN 3513 FMI 14 ? VREF5....9809
Revisiones de voltaje para SPN 3514 FMI 14 ? VREF6....9810
Revisi?n de la resistencia del arn?s de SPN 3514 FMI 14 ? VREF6....9810
Revisi?n de voltaje....9812
Verifique la resistencia del conector a TIERRA....9813
Verifique la resistencia del arn?s....9813
Llave en contacto y motor apagado (Key-On Engine-Off)....9899
Giro del motor....9899
Ralent? bajo, sin carga, temperatura de funcionamiento del motor estabilizada....9900
Ralent? alto, sin carga, temperatura de funcionamiento del motor estabilizada....9901
Carga completa, velocidad nominal en un dinam?metro, temperatura de funcionamiento del motor estabilizada....9901
Especificaciones del componente....9902
Estado de salida del activador....9903
Sistema del calentador de aire de admisi?n....9904
Presi?n del c?rter....9904
Extensi?n de varilla de EBPV....9904
Extensi?n de varilla de TC2WC....9904
1171898R5 - Engine Operation and Maintenance Manual MaxxForce 11 and 13 Diesel Engines....9928
1172042R1 - Engine Operation and Maintenance Manual MaxxForce 15 Diesel Engine....10017
EGED-430-2 - Engine Wiring Diagram Maxxforce 11 and 13 2008 Model Year....10136
EGED-435 - Maxxforc ETM 11 and 13 2008 Model Year Signal Values (All values with the breakout box installed on the ECM, EIM, ACM, and harness)....10138
EGED-435 Side 1....10138
EGED-435 Side 2....10139
EGED-475-3 - Hard Start and No Start Diagnostics MaxxForce 11 & 13 Beginning with 2010 Model Year....10140
EGED-520-2 - Hard Start and No Start Diagnostics MaxxForce 15 Beginning with 2011 Model Year....10153
EGED-525-1 - Engine Wiring Diagram Form Maxxforce 15 Beginning with 2011 Model Year....10165
EGED-530-3 - Performance Diagnostics MaxxForce 11 & 13 EPA 2010....10167
EGED-535-2 - Performance Diagnostics MaxxForce 15 Beginning with 2011 Model Year....10183
EGES-415 - MaxxForce 11 and 13 Service Manual....10197
EGES415a....10197
EGES415b....10301
EGES415c....10385
EGES415d....10481
EGES415e....10567
EGES-415-2 - MaxxForce 11 and 13 Engine Service Manual (2009-05)....10685
EGES4152a....10685
EGES4152b....10791
EGES4152c....10877
EGES4152d....10973
EGES4152e....11057
EGES-415-2 - MaxxForce 11 and 13 Engine Service Manual (2011)....11175
EGES-420 - MaxxForce 11 and 13 Engine Diagnostic_Troubleshooting manual....11665
EGES-420 PDF Index....11665
EGES420a....11666
EGES420b....11858
EGES420c....12106
EGES-420-2 - MaxxForce 11 and 13 Engine Diagnostic_Troubleshooting manual....12178
Diagnostic Trouble Code....12178
EGES-420-2 PDF Index....12185
EGES4202a....12186
EGES4202b....12376
EGES4202c....12624
EGES-465-2 - MaxxForce 11 and 13 Engine Service Manual (2011)....12696
EGES-470-1 - MaxxForce 11 and 13 Engine Diagnostic_Troubleshooting Manual (2011)....13206
EGES-470-1 - MaxxForce 11 and 13 Engine Electronic Control Systems Diagnostics....13666
EGES-510-2 - MaxxForce 15 Diesel Engine Service Manual Model Year 2011 and Up....13892
EGES-511 - Manuel d'entretien Et De R?paration MaxxForce 15 Moteur diesel Ann?e mod?le 2011 et plus....14467
EGES-512 - Manual de Servicio MaxxForce 15 Motor Diesel Modelo del a?o 2011 y m?s recientes....15081
EGES-515 - MaxxForce 15 Engine Electronic Control Systems Diagnostics....15715
EGES-515-1 - MaxxForce 15 Engine Diagnostic_Troubleshooting Manual....15727
Maxxforce 11 & Maxxforce 13 Model Year 2009 Features, Descriptions, & Unique Repair Procedures....16179
