Page 1 DIAGNOSTIC/TROUBLESHOOTING MANUAL ® International DT 466, DT 570, and HT 570 DIESEL ENGINE EGES-270-1 © 2008 Navistar, Inc. Printed in the United States of America...
Page 3: Table Of Contents
Appendix D: Technical Service Information (TSI)..............649 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 4 DIAGNOSTIC/TROUBLESHOOTING MANUAL EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 5: Foreword
To order technical service literature, contact your International dealer. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 6: Service Diagnosis
Service Bulletins • Availability of current information for engine application and engine systems EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 7: Safety Information
Protect your eyes. • Do not wear rings, watches or other jewelry. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 8 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 9 Operation of Diamond Logic® Engine Brake in Braking Mode........56 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 10 1 ENGINE SYSTEMS EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 11: Engine Identification
U – United States 7 digit sufﬁx – Engine serial number sequence beginning with 2 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 12 Labels or identiﬁcation plates include information and speciﬁcations helpful to vehicle operators and technicians. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 13: Engine Description
Base rating shown. See Appendix A or B in this manual for additional ratings. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 14 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 15 A hydraulic power steering pump can be used with or without an air compressor. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 16: Engine Component Locations
EGR control valve Valve cover Secondary air heater supply Dearation port Breather assembly EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 17 12. Flat idler pulley assembly Front cover (front half) Water pump pulley EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 18 12. Engine Oil Temperature (EOT) (one) three wire connector sensor for the brake shut-off valve. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 19 11. Power steering pump 17. High-pressure oil pump Lifting eye 12. Oil pan assembly assembly EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 20 Water supply housing (Freon® 12. Coolant drain plug (underneath compressor bracket) location) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 21 EGR cooler return tube Rear engine mount bracket (2) assembly Flywheel housing EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 22: Engine Systems
EGR gases, and lubrication oil. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 23: Air Management System
11. Cylinder head 17. Exhaust Back Pressure (EBP) Intake manifold 12. Exhaust manifold sensor EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 24: Charge Air Cooler (Cac)
EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 25: Variable Geometry Turbocharger (Vgt)
An additional beneﬁt is lower emissions. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 26 When EBP demand decreases, the ECM decreases the duty cycle to the control module. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 27: Exhaust Gas Recirculation (Egr) System
Integrated Circuit (IC). The IC has three Hall effect position sensors to monitor valve movement. The EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 28: Exhaust System
CDPF, depending on application, and out the discharge pipe to the atmosphere. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 29: Fuel Management System
Injection Control Pressure (ICP) system • Lubrication system • Fuel supply system • Electronic control system EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 30: Injection Control Pressure (Icp) System Components And High-Pressure Oil Flow
Oil exhaust port (2) Fuel injector High-pressure oil hose Fuel inlet (4) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 31 IPR valve will operate from programmed default values. This is called Open Loop operation. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 32 No. 6 fuel injector in the high-pressure oil rail. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 33: Fuel Injectors
19. CLOSE coil Nozzle assembly 13. Edge ﬁlter 20. Spool valve (control valve) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 34 Low-pressure fuel ﬁlls the four ports and enters through the edge ﬁlter on its way to the chamber EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 35 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 36 High-pressure oil is deadheaded against the spool valve. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 37: Fuel Supply System
Transfer pump fuel supply pump 10. Fuel ﬁlter access cap EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 38: Fuel Flow Schematic
Primer pump assembly • Engine Fuel Pressure (EFP) sensor (optional) • Fuel ﬁltering element EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 39 Plug or EFP sensor (optional) 15. Water drain valve assembly 23. Stand pipe EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 40 ﬁlter housing. Another drain valve in the bottom of the housing drains strainer cavity. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 41: Engine Lubrication System
26. Air compressor (optional) Unﬁltered oil gallery 16. Oil pan assembly EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 42 Unﬁltered oil (under pressure) ﬂows through the header of the oil cooler. The oil is then internally EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 43 Connecting rod bearings are fed through drilled passages in the crankshaft from main journals to rod EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 44: Cooling System
EGR cooler return tube 15. Water inlet to front cover and assembly water pump EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 45 (back to front) to the thermostat. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 46 Coolant out to radiator Coolant ﬂow to heater port Coolant in from engine EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 47: Electronic Control System
A supplies 5 volts to engine sensors 4. Controls actuators • B supplies 5 volts to vehicle sensors EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 48 • Engine warning and protection modes EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 49: Injection Drive Module (Idm)
The IDM uses information from the ECM to determine the timing and quantity of fuel for each injector. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 50 OPEN coil, then the CLOSE coil. The low side EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 51: Engine And Vehicle Sensors
Crankshaft Position (CKP) 13. Engine Coolant Level (ECL) 20. Exhaust Back Pressure (EBP) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 52 The ECT is a backup, if the EOT is • out-of-range. The ECT sensor is installed in the water • EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 53 The sensor provides feedback to the ECM • Signal ground for closed loop control of the Variable Geometry EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 54 ﬁeld. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 55 (linear analog voltage) that indicates the operator’s demand for power. The APS is mounted in the accelerator pedal. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 56 ECM with a voltage when it is closed. A grounding switch grounds the circuit when EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 57: Diamond Logic® Engine Brake
• High durability one of three brake settings, depending on terrain and EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 58: Engine Brake Control
The high-pressure oil rail uses high-pressure oil from the injection control pressure system to open exhaust valves. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 59 A gallery. brake shut-off valve, mounted in the high-pressure oil EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 60: Operation Of Diamond Logic® Engine Brake In Braking Mode
• Operator input switches (On/Off) (power selection over. – Low, Med, High) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 61 Figure 49 Brake pressure relief valve in high-pressure oil rail Front of engine Brake pressure relief valve EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 62 1 ENGINE SYSTEMS EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 63 Radiator Shutter Enable (RSE)................64 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 64 2 ENGINE AND VEHICLE FEATURES EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 65 CAP is standard on trucks without an Idle Shutdown and can be retrieved using the EST. Timer (IST). EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 66 “EFP Sensor” in Section 7 (page percent power on demand. 406). EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 67 (228 °F), the red ENGINE lamp will be illuminated • High coolant temperature. and DTC 321 will be set. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 68 “RSE” in Section 7 (page 514). shutdown. The lamp will ﬂash for 30 seconds to warn EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 69 Using Cruise Switches..................97 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 70: Diagnostic Software Operation
3 DIAGNOSTIC SOFTWARE OPERATION EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 71: Diagnostic Trouble Code Detection
3 DIAGNOSTIC SOFTWARE OPERATION Diagnostic Trouble Code Detection Figure 53 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 72: Continuous Monitor
During normal engine operation, automatically performs several tests to detect faults. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 73: Diagnostic Trouble Codes
2. Turn the ignition switch to ON. (Do not crank the Failure Mode Indicator (FMI) engine.) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 74: Reading Dtcs
ﬂashes, a pause; and two amber ﬂashes and a pause indicate code 232. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 75: Diagnostic Tests
Electronic System Controller (ESC). Standard test does not have to be run again. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 76: Standard Test Using Cruise Switches
EST; MasterDiagnostics® software is required. The Standard test must be done before doing the Injector test. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 77: Continuous Monitor Test
2. Select Diagnostics from the menu bar. 3. Select Key-On Engine-Off Tests from the drop down menu. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 78: Output State Low Test
ﬁle window. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 79: Output State High Test
Figure 68 Output State Test Session Figure 67 Close session EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 80: Glow Plug/Inlet Air Heater Output State Test
1. Select D_OutputStateTest.ssn from the open actuator control or circuit operation. session ﬁle window. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 81: Key-On Engine-Running Tests
D_KOER_Standard.ssn from open Figure 73 Close session session ﬁle window. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 82: Continuous Monitor Test
Manifold Air Temperature (MAT) 6. Clear DTCs. • Manifold Absolute Pressure (MAP) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 83: Air Management Test
Air Management System are performing as EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 84 5. Correct problem causing active DTCs. 6. Clear DTCs. Figure 82 Close session EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 85 7. When ﬁnished with this test, select Session from menu bar, then Close. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 86 DTC 346 is set and the pressure is expected to increase. If EBP pressure test is cancelled. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 87: Vgt Test
40 seconds, the test will automatically end open the session. and the engine will return to normal operation. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 88 5. When ﬁnished with this test, select Session from menu bar, then Close. Figure 86 Close session EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 89: Injector Disable Tests
20 miles before the session. checking for misﬁre or rough idle. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 90 Overall engine operation is more stable. 4. Select Auto Run. Figure 91 Close session EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 91: Manual Test - Engine Cold
3. Select I6 Injector Disable Tests from drop down Figure 92 KOER IDT I6 session menu. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 92: Manual Test - Engine Hot
Automatic test (auto run feature) and the engine is hot. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 93 - this is the cut off value for fuel rate.) 14. Record cut off value on Diagnostic Form. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 94 If a suspect cylinder(s) is identiﬁed, do Relative Compression test to distinguish between an injector or mechanical problems. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 95: Relative Compression
Test data displayed in this test should be compared each cylinder. with data collected from the Injector Disable test. Example EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 96 Injector Disable test does, replace suspect injector(s). Figure 102 Relative Compression test EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 97: Reset Change Engine Oil Interval Message
EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 98 3 DIAGNOSTIC SOFTWARE OPERATION Figure 105 Select Parameter and Select Program EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 99 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 100 Program Count number has increased. then Close. Figure 108 Close session EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 101: Using Cruise Switches
5. Release both Cruise buttons. Figure 109 Switches for CRUISE ON and RESUME/ACCEL EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 102 3 DIAGNOSTIC SOFTWARE OPERATION EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 103 Low Power (Turbocharger Assembly and Actuator)...........139 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 104 4 ENGINE SYMPTOMS DIAGNOSTICS EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 105: Problems And Conditions
EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 106: Combustion Leaks To Coolant
If no, do step 3. Figure 111 Cylinder head cut-away with injector sleeve EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 107 8. Test the cylinder head with pressure test plate to validate the repair. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 108: Aerated Fuel
Fuel Source Supply to Fuel Pump” (page 106) in this section. Figure 113 Diagnostic coupling Valve Center section EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 109 Fuel/Oil Pressure Test Coupler to the Fuel Pressure Gauge. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 110: Alternate Fuel Source Supply To Fuel Pump
Source Supply to Fuel Pump” (page 106) in this section. Figure 119 Fuel test line EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 111: Alternate Fuel Source Supply To Fuel Filter Housing
Figure 121 Fuel ﬁlter inlet test line EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 112: Combustion Leaks To Fuel
4. Test for fuel aeration to validate the repair. Go to “Aerated Fuel Inspection” (page 105) in this section. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 113: Coolant In Lube Oil
8. Drain engine oil and remove the oil ﬁlter. • If no, do step 8. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 114: Engine Symptoms Diagnostics
Figure 125 Air compressor test setup 1. Drain coolant from the system. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 115: Front Cover Inspection
2. Test the cooling system again after any repair to validate the repair. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 116: Cylinder Head Leak Test
8. Test the cooling system again after any repair to validate the repair. Figure 128 Cylinder head (intake side) cup plugs EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 117: Ecm Reset / Idm Reset (Intermittent Engine Stumble)
Section 6 of this manual. • Intermittent open circuit • Failed battery power feed harness EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 118: Excessive Fuel Consumption
If all tests are passed, the engine is operating normally. • Fuel system leaks EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 119: Fuel In Coolant
3. Remove cap from deaeration tank and ﬁll with coolant to a level above the deaeration inlet line to tank. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 120 Shrader valve or a diagnostic coupling. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 121: Coolant Leak To Exhaust
8. Remove EGR cooler following the procedure in the Engine Service Manual. Figure 133 EGR cooler without cross-over tube EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 122 Figure 134 EGR cooler pressure test EGR cooler pressure test plates (2) Air pressure regulator EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 123: Coolant Over-Temperature
ﬁll cooling system. Test again for over-temperature condition. • EZ-Tech® interface cable EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 124: Temperature Sensor Validation Test
If any DTCs remain relating to coolant over-temp condition, correct DTC before continuing. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 125: Cooling System Operating Pressure Test
Figure 138 EGR coolant outlet port EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 126: Lube Oil In Coolant
NOTE: Replace O-ring with a new O-ring when installing the coolant drain plug. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 127 Engine Service Manual. If a leak is noticed, replace the oil cooler. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 128: Fuel In Lube Oil
If the engine is mechanically sound and the oil has been changed, diagnose for fuel in the oil with dye. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 129 NOTE: If the engine is equipped with a Shrader valve, use the Fuel Pressure Test Adapter. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 130 ﬂow from the pressure gauge clear hose. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 131 NOTE: If a set of injectors (six) must be replaced, contact International® Technical Services to start a case ﬁle. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 132: Low Oil Pressure
Engine Oil Pressure (EOP) value on the Electronic Service Tool (EST). • Shut-off valve EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 133: Oil Pressure Regulator Inspection
Go to “Oil and Crankcase Inspection” (page Oil pickup tube assembly 129) in this section. Gasket EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 134: Oil Pump Inspection
Figure 155 Old piston cooling tube Oil pump housing plate Inner gerotor Oil pump housing EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 135: Front Cover Inspection
Service Manual. Inspect the front cover and front cover gasket for damage. Repair or replace and test. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 136: Priming Fuel System
EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 137 Inline shut-off valve Clear test line Figure 161 Diagnostic coupling Valve Center section EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 138 DIESEL FUEL according to local regulations. Figure 164 Fuel/Oil Pressure Test Coupler EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 139: Rough Idle
Diagnostics form. The primary function of this test is to show the contributions of the individual EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 140 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 141: Smoke
• No Intake Air Heater (IAH) operation • Poor quality fuel EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 142 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 143: Low Power (Turbocharger Assembly And Actuator)
Check pre-cycle three times with at least three seconds of key-off time between tests. Linkage EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 144 4 ENGINE SYMPTOMS DIAGNOSTICS EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 145 15.5 – Relay Operation................200 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 146: Hard Start And No Start Diagnostics
5 HARD START AND NO START DIAGNOSTICS EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 147: Description
Diagnostic Form EGED-290-1 is available in 50 sheet pads. To order technical service literature, contact your International dealer. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 148: Test Procedures
Brake System (ABS) self-check for injector or cause hard start or no start). turbocharger pre-cycle. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 149 Failed actuator power ground circuit (will not cause hard start or no start) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 150: Engine Cranking
619) for speciﬁcations, and enter data in spec column for rpm and oil pressure on Diagnostic Form. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 151 Broken, missing, or loose piston cooling tubes • Missing, damaged, or worn bearing inserts EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 152: Diagnostic Trouble Codes
1. Enter the following information in the form • Complaint (for warranty) heading: • Technician EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 153: Entering Vehicle Information Using The Est
3. Select Engine Diagnostics, then International® Figure 171 EZ-Tech® interface cable MasterDiagnostics® II. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 154 4. Turn the ignition switch to ON. Figure 174 Open VIN+ session EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 155: Accessing Dtcs
Transmission: Manual/Auto • Ambient temperature Figure 175 DTC window • Coolant temperature EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 156: Reading Dtcs
Diagnostic Form and see Operational Voltage tables in Section 7 (page 283) for applicable sensor. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 157: Koeo Standard Test
7. Correct problem causing active DTCs. 8. Clear DTCs. Possible Causes • Failed electrical components or circuitry EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 158 — Later calibrations and current hardware levels do not support DTC 251. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 159: Koeo Injector Test
643) for DTCs. 5. Correct problem causing active DTCs. 6. Clear DTCs. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 160 Faulty wiring IDM main power relay • Injector wiring harness open or shorted EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 161: Est Data List
Batteries must be fully charged before doing the following steps. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 162 Blown inline fuse (in battery box) that supplies (injector oil gallery to brake oil gallery) voltage to the ECM EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 163: Monitoring Icp Using Vc Gasket Breakout Harness
“ICP Sensor” in Section 7 (page Pass-through connector for ICP sensor 457). EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 164 Pressure” (page 186). crank, continue to “Monitoring BCP using VC Gasket Breakout Harness” test EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 165: Monitoring Bcp Using Vc Gasket Breakout Harness
3. Connect VC Gasket Breakout Harness to pass-through connector and engine harness. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 166 NEG to black (signal ground). problem. 5. Record KOEO reading on Diagnostic Form. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 167: Monitoring Eop At Eot Sensor Port
Test hose connection to 0 - 160 psi gauge 0 - 160 psi gauge Test hose connection EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 168: Monitoring Engine Systems Using Breakout Box
5. Connect wiring harness connectors to breakout box headers X1, X2 and X3, X4. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 169 — POS X4–1 to NEG X3–6 (ECM PWR) — POS X4–2 to NEG X3–7 (ECM PWR) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 170: Fuel
“Safety Information” section of this manual. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 171 Shrader valve. Press end of coupling with a pocket screwdriver to relieve pressure. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 172 Failed seal for inlet ﬁtting in fuel ﬁlter housing • Water or contaminants in fuel tank EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 173 Debris in fuel tank • Cloudy fuel indicates unsuitable fuel grade for cold temperatures. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 174: Engine Systems
• Injector Driver Module (IDM) • Blockage in the air induction system EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 175: Engine Oil
Engine oil level will vary depending on temperature of engine. • Cylinder head porosity • Leaking injector EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 176: 10. Intake And Exhaust Restriction
Air ﬁlter restriction indicator or gauge 2. Record concerns on Diagnostic Form. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 177 Catalyzed Diesel Particulate Filter (CDPF) – if equipped • Collapsed air ﬁlter EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 178: 11. Main Power Relay To Ecm
Diagnostic Form tests are complete, do Voltage Measurement at ECM with Breakout Box. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 179: Voltage Measurement At Ecm With Breakout Box
Information” section of this manual. NOTE: Batteries must be fully charged before doing the following steps. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 180 If the voltage is above 7 V, continue with Hard Start and No Start Diagnostic tests. Figure 206 Breakout box EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 181: 12. Main Power Relay To Idm
Diagnostic Form tests are complete, check voltage at IDM connector. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 182 High-resistance or an open power feed circuit to the IDM or IDM main power relay. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 183: Voltage Measurement With Breakout Harness At Main Power Relay
12-pin connector and IDM connector. Figure 209 Relay Breakout Harness EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 184: 13. Fuel Pressure And Aerated Fuel
Center stem • 1 to 5 gallon bucket • Fuel/Oil Pressure Test Coupler EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 185 NOTE: If the engine is equipped with a Shrader valve, use the Fuel Pressure Test Adapter. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 186 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 187: Checking For Aerated Fuel Using Spare Fuel Line
Information” section of this manual. • Debris or rust in fuel strainer EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 188 Warranty will not cover the cost of the fuel test line. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 189: Operation Of Fuel Pump
2. Disconnect fuel line (suction side) from fuel ﬁlter between the ﬁlter housing and fuel tank. housing. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 190: 14. Low Icp System Pressure
• Spare VT 365 ICP sensor (Part No. -1845274C92 or equivalent) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 191 2. Connect Actuator Breakout Harness to IPR. Do not connect engine harness. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 192: Oil Reservoir Level
“Safety Information” section of this manual. Information” section of this manual. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 193 NOTE: Oil will spill from hose. Position the high-pressure oil hose so oil will not spill. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 194 (ICP connector). 7. Apply B+ volts and ground to the IPR valve. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 195: Under Valve Cover Leak Test
High-pressure hose Figure 234 ICP Test Kit ICP sensor adapter Fitting, 13/16-16 NPT EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 196 Use inline shut-off valve to control and contain bleed-off pressure mixture (air and oil). EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 197 ICP sensor (Figure 238) • O-ring for high-pressure oil rail (Figure 240) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 198: 14.5 - Ipr Function
High-pressure hose Figure 241 ICP Test Kit ICP sensor adapter Fitting 13/16-16 NPT EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 199 IPR valve is not energized. Figure 246 B+ on power distribution terminal EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 200 • If the IPR valve is energized, the air leak should stop. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 201: 15. Inlet Air Heater System
Standard Test does not have to be run again. 3. Select Diagnostics from the menu bar. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 202: 15.2 - Voltage At Element Terminal
Figure 253 Inlet Air Heater Output State Test Figure 251 Element terminal EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 203: 15.3 - Element Terminal Continuity
If the element has continuity, verify the previous Inlet Air Heater test. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 204: 15.4 - Wiring Harness Continuity And Resistance
“Safety Information” section of this manual. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 205 6. Select Diagnostics from the menu bar. 7. Select Key-On Engine-Off Tests from the drop down menu. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 206 Failed element • Failed ECM • ECM not programmed (inlet air heater) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 207 Brake Lash...................277 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 208: Performance Diagnostics
6 PERFORMANCE DIAGNOSTICS EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 209: Description
Diagnostic Form Information Figure 261 Diagnostic Form EGED-290-1 (Performance Diagnostics side) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 210 Diagnostic Form EGED-290–1 is available in 50 sheet pads. To order technical service literature, contact your International dealer. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 211: Test Procedures
1. Enter the following information in the form heading: • Technician • Date (for warranty) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 212: Entering Vehicle Information Using The Est
“Safety Information” section of this manual. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 213 2. Boot-up EST. 4. Turn the ignition switch to ON. Figure 267 International® launchpad EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 214 6 PERFORMANCE DIAGNOSTICS Figure 268 Open VIN+ session EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 215: Accessing Dtcs
Transmission: Manual/Auto • Ambient temperature Figure 269 DTC window • Coolant temperature EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 216: Reading Dtcs
Diagnostic Form and see Operational Voltage tables in Section 7 (page 283) for applicable sensor. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 217: Koeo Standard Test
7. Correct problem causing active DTCs. 8. Clear DTCs. Possible Causes • Failed electrical components or circuitry EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 218 — Later calibrations and current hardware levels do not support DTC 251. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 219: Koeo Injector Test
643) for DTCs. 5. Correct problem causing active DTCs. 6. Clear DTCs. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 220 Faulty wiring IDM main power relay • Injector wiring harness open or shorted EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 221: Engine Oil
Engine oil level will vary depending on temperature of engine. • Cylinder head porosity • Leaking injector EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 222: Fuel
“Safety Center stem Information” section of this manual. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 223 Shrader valve. Press end of coupling with a pocket screwdriver to relieve pressure. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 224 Failed seal for inlet ﬁtting in fuel ﬁlter housing • Water or contaminants in fuel tank EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 225 Debris in fuel tank • Cloudy fuel indicates unsuitable fuel grade for cold temperatures. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 226: Fuel Pressure And Aerated Fuel
Fuel/Oil Pressure Test Coupler Figure 284 Shrader valve assembly Valve Center stem EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 227 Shrader valve or a diagnostic coupling. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 228 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 229 9. Set the parking brake and apply service brake. can cause high-restriction and low fuel pressure. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 230: Checking For Aerated Fuel Using Spare Fuel Line
EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 231 Warranty will not cover the cost of the fuel test line. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 232: Operation Of Fuel Pump
2. Disconnect fuel line (suction side) from fuel ﬁlter between the ﬁlter housing and fuel tank. housing. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 233: Intake Restriction
EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 234 On engines recently repaired, rags or cap plugs may have been left in the intake system. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 235: Exhaust Restriction
Continue Performance Diagnostics. incorrect. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 236 Do Test 13 Air Management and Test 14 VGT Test. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 237: Monitoring Ebp Using Pressure Sensor Breakout Harness
EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 238: Koer Standard Test
NOTE: The KOER Standard test can only be range. done with the EST; MasterDiagnostics® software is required. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 239 5. From the KOER Diagnostics Menu, select Standard Test and select Run to start the test. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 240: 10. Injection Control Pressure
4. Run engine at low idle, monitor ICP, and record reading on Diagnostic Form. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 241 Checks” in Section 7. Collect and dispose of engine ﬂuids according to local regulations. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 242 ICP sensor, the ECM commands the IPR valve to reduce injection control pressure. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 243: Monitoring Icp Using Vc Gasket Breakout Harness
2. Disconnect engine harness connector from valve cover gasket for ICP sensor and do steps 3 to 10. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 244 “Monitoring BCP using VC Gasket Breakout Harness.” EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 245 IPR following procedures in Engine Service Manual and test again. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 246: Monitoring Bcp Using Vc Gasket Breakout Harness
BCP sensor and do steps 2 to 6. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 247 6. problem with the BCP sensor signal or the engine brake. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 248: 11. Injector Disable Test
Injector Disable Test 11 to distinguish between an injector or mechanical problem. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 249 I6 Injector Disable Test Results (Auto Run – Text View) Figure 317 Injector Disable Tests EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 250: Manual Test
EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 251 20 miles before checking for misﬁre or rough idle. Figure 321 Injector Disable Test EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 252: 12. Relative Compression
As the piston passes TDC, compression resistance Example dissipates and crankshaft speed increases. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 253 NOTE: If test results are identical to previous test results, the current test failed and the previous results were displayed. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 254 • Incorrect valve lash adjustment Possible Causes • Broken compression rings EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 255: 13. Air Management
2. Select Diagnostics from menu bar. 3. Select Key-On Engine-Running Tests from the drop down menu. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 256 5. Record DTCs on Diagnostic Form. “Diagnostic Trouble Codes” – Appendix C (page 643) for DTCs. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 257: 14. Vgt Test
2. Select Diagnostics from the menu bar. 3. Select Key-On Engine-Running Tests from the drop down menu. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 258 • Failed EGR control valve reduction to the EBP and MAP values. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 259: Torque Converter Stall (Automatic Only)
(If doing twice – wait 2 minutes between tests.) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 260: 16. Crankcase Pressure
5. Make sure all hoses are secure and not leaking. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 261 • If pressure is below speciﬁcation, repair or replace air compressor. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 262: Test Drive (Full Load, Rated Speed)
Performance Speciﬁcations” – Appendix B (page 619) for speciﬁcations and record on Diagnostic Form. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 263 Shrader valve or a diagnostic coupling. Figure 339 Shrader valve assembly Valve Center stem EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 264 Figure 342 Fuel Pressure Test Adapter EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 265 Boost Pres (MAP) and engine brake components. • Inject Ctrl Pres (ICP) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 266 Figure 345 Test hose assembly Inline shut-off valve ICP system test adapter Oil sample line EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 267 Logic® engine brake • Failed BCP sensor • Brake control pressure system leakage EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 268 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 269 Combustion gases leaking into fuel system • Inoperative fuel pressure regulator valve. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 270: Fuel Inlet Restriction
Figure 346 Fuel Test Fitting Figure 348 Fuel/oil test coupler with test line EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 271 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 272: Monitoring Boost Pressure Using Pressure Sensor Breakout Harness
Performance Speciﬁcations” – Appendix B (page 619) or Section 7 “Operational Voltages Checks” EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 273: Monitoring Icp Using Vc Gasket Breakout Harness
ICP sensor and complete steps 3 through 9. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 274 If problem is corrected, see “ICP Operational Voltage Checks” in Section 7. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 275 If ICP is still high or unstable, replace IPR following procedures in Engine Service Manual and retest. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 276: Monitoring Bcp Using Vc Gasket Breakout Harness
ﬂoor, and accelerate to rated speed at 100% load. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 277 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 278: 18. Valve Lash And Brake Lash
6 is at TDC compression, see and do steps 4, 5, and 6. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 279 Figure 358 Valve lash adjustments with piston 6 at TDC compression Figure 359 Valve lash adjustment EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 280 Recheck for light drag on feeler gauge. If drag is too tight or loose, repeat steps 4 and 5. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 281: Brake Lash
Worn actuator in Diamond Logic® engine brake Figure 362 Feeler gauge between the valve bridge and brake actuator EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 282 6 PERFORMANCE DIAGNOSTICS EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 283 Brake Switch Circuit..................347 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 284 EWPS (Engine Warning and Protection System)............440 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 285 VSS Pin-Point Diagnostics (Allison Transmissions).........549 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 286 WIF Pin-Point Diagnostics............... .552 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 287: Description
Diagnostic Trouble Codes (DTCs) • Diagnostic procedures for sensors and actuators and verify circuit functions EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 288: Electronic Control System Diagnostics Form
For detailed description of vehicle circuits, circuit numbers, or connector and fuse EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 289: Sensor And Actuator Locations
Figure 364 Sensor location – Front View Camshaft Position (CMP) sensor Engine Coolant Temperature (ECT) sensor EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 290 Engine Fuel Pressure (EFP) sensor location, see “Fuel Flow” in Section 1 (page 35). EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 291 Figure 366 Sensor location – Right View Exhaust Back Pressure (EBP) sensor Turbocharger control module EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 292: Vehicle Mounted Components
Barometric Absolute Pressure (BAP) sensor Accelerator Pedal Position and Idle Validation Connector (APS/IVS) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 293: Operational Diagnostics
If an active DTC remains after checking test ground. conditions, replace sensor. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 294: Pin-Point Diagnostics
1 k ohms, but the expected voltage for the other side of the actuator circuit will measure the EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 295: Connector Resistance Checks To Chassis Ground
500 ohms from the connector pin to battery battery cable last. ground. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 296: Harness Resistance Checks
5 ohms. See Circuit Diagnostics in this section for circuit speciﬁcations. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 297: Circuit Diagnostics
11. Cylinder head 17. Exhaust Back Pressure (EBP) Intake manifold 12. Exhaust manifold sensor EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 298: Ams Operation
The ECM uses the EBP sensor to continuously all vanes move to the same position. Unison ring EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 299 Engine Oil Temperature (EOT) sensor or Performance Diagnostics form. • Manifold Absolute Pressure (MAP) sensor EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 300 VGT power and ground circuits Do VGT Pin-Point Diagnostics. See “VGT Actuator” (page 524). EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 301 VGT power and ground circuits. Do VGT Pin-Point Diagnostics. See “VGT Actuator” (page 524). EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 302 EBP sensor bias low Check sensor signal voltage. See “EBP Sensor” (page 359). EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 303 VGT power or ground circuits Do VGT Pin-Point Diagnostics. See “VGT Actuator” (page 524). EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 304: Aps/Ivs (Accelerator Position Sensor And Idle Validation Switch)
ECM as redundant signal to verify the pedal idle position. • Fuel injector EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 305: Aps/Ivs Circuit Operation
APS/IVS assembly ignition switch is on, but when the ignition switch is EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 306 • When DTC 134 is active the amber ENGINE lamp is illuminated. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 307 Diagram Manual for circuit numbers, connector and fuse locations. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 308: Aps/Ivs Operational Diagnostics
3. Monitor APS signal voltage. Verify an active DTC for the APS/IVS circuit. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 309 ECM and IDM. See truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 310: Aps/Ivs Pin-Point Diagnostics
If < 1 kΩ with fuse removed, check for short to ground within wiring harness. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 311 ECM and IDM. See truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 312 DTC 134= APS and IVS disagree DTC 135= Idle validation switch circuit fault – 50% APS only EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 313: Ata Datalink (American Trucking Association)
Injection Driver Module (IDM) also allows for programming the ECM and IDM. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 314: Ata Circuit Operation
• Programming engine and vehicle features EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 315 ECM. The WTEC controller must be disconnected when programming the engine ECM. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 316: Ata Pin-Point Diagnostics
If > 5 Ω, check for an open circuit. The EST tool will not communicate. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 317 ATA Diagnostic Trouble Codes 231 ATA data communication link error – ATA wiring or connector EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 318: Bap Sensor (Barometric Absolute Pressure)
• ENGINE lamp (amber) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 319: Bap Circuit Operation
DTC 151 is set when the BAP signal is greater • Breakout Box than 4.95 V for more than 0.5 second. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 320: Bap Pin-Point Diagnostics
> 500 Ω If < 500 Ω , check for short to ground. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 321 DTC 152 = Signal voltage was < 1.0 V for more than 0.5 second EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 322: Bcp Sensor (Brake Control Pressure)
Electronic Control Module (ECM) analog voltage that indicates pressure. Engine Oil Temperature (EOT) sensor • EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 323 During engine brake operation, if the ECM lamp. recognizes that the BCP signal is greater than desired EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 324: Bcp Circuit Operation
• When DTC 127 is active the amber ENGINE lamp is illuminated. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 325 4.5 MPa (653 psi) for more • Terminal Test Adapter Kit than three seconds. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 326: Bcp Operational Diagnostics
3. Monitor BCP signal voltage. Verify an active DTC for the BCP circuit. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 327 7. Connect VC Gasket Breakout Harness to engine at all suspected problem locations. If circuit harness only. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 328 VC Gasket Breakout Harness to between ECM and UVC. Use a breakout box to measure EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 329 ECM and IDM. See truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 330 X2-11 (spec < 5 Ω) to check for open in the harness. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 331 ECM and IDM. See truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 332: Bcp Pin-Point Diagnostics (Ecm To Valve Cover Gasket Connector)
> 500 Ω If< 500 Ω , check for short to ground. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 333 0 psi (0 kPa) Maximum at engine cranking speed BCP Diagnostic Trouble Codes EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 334 DTC 547 = Brake control pressure was > 4.5 MPa (653 psi) for more than 3.0 seconds EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 335 . Disconnect negative battery cable. Disconnect harness from sensor. Use disconnected negative battery cable for ground test point.) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 336 ECM and IDM. See truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 337: Bcp Pin-Point Diagnostics (Ecm To Bcp Sensor- Valve Cover Removed)
DTC 547 = Brake control pressure was > 4.5 MPa (653 psi) for more than 3.0 seconds EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 338: Brake Shut-Off Valve
Brake shut-off valve • Engine brake switches • Variable Geometry Turbocharger (VGT) actuator EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 339 When brake gallery pressure reaches 1000 psi, the brake pressure relief valve opens, and oil drains back to sump. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 340: Brake Shut-Off Valve Circuit Operation
DTC will be set, and the amber ENGINE valve solenoid exists. lamp will be illuminated. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 341 4.5 MPa (653 psi) for more than 3 seconds. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 342: Brake Shut-Off Valve Pin-Point Diagnostics (Ecm To Valve Cover Gasket Connector)
Figure 398 Brake Shut-off Valve circuit diagram EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 343 If < 0.25 V, the concern is the valve cover gasket, UVC wiring, or Brake Shut-off Valve. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 344 Harness Resistance Checks (page 342). Figure 399 Brake Shut-off Valve circuit diagram EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 345 If < B+ with breakout box connected only to ECM, replace the ECM. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 346 > 1 kΩ If < 1 kΩ, check for short to ground. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 347 IDM. See truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 348: Removed)
Low and High Output State Tests. Measure across adapter and ground.) Test State/Point Setting/Spec Comment EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 349 Resistance Check – Brake Shut-off Valve (page 346). Figure 402 Brake Shut-off Valve circuit diagram EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 350 IDM. See truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 351: Brake Switch Circuit
The information is used to feature. disengage the Cruise control and Power Takeoff EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 352: Can Communications (Controller Area Network)
Drivetrain Datalink to the instrument panel. • WAIT TO START lamp EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 353: Can Pin-Point Diagnostics
Digital Multimeter (DMM) CAN Pin-Point Diagnostics Figure 405 CAN communication circuit diagram EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 354 If < 5 Ω, check for short between CAN+ and CAN –. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 355: Ckp Sensor (Crankshaft Position)
International® diesel engines. signal, the ECM calculates engine rpm and timing EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 356: Ckp Circuit Operation
DTCs are read using the EST or by counting the ﬂashes from the amber and red ENGINE lamp. • Breakout Box EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 357: Ckp Pin-Point Diagnostics
If < 500 Ω, check for short to ground. > 500 Ω EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 358 DTC 146 = CKP signal inactive (CMP signal active and ICP increased) DTC 147 = Incorrect CKP signal signature EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 359: Cmp Sensor (Camshaft Position)
International® diesel engines. sensor identiﬁes the position of the cam by locating EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 360: Cmp Circuit Operation
Digital Multimeter (DMM) ﬂashes from the amber and red ENGINE lamp. • Breakout Box EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 361: Cmp Pin-Point Diagnostics
> 1 kΩ If < 1 kΩ, check for short to ground. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 362 DTC 143 = Incorrect CMP signal signature DTC 145 = CMP signal inactive EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 363: Ebp Sensor (Exhaust Back Pressure)
ECM can control the VGT and EGR systems. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 364: Ebp Circuit Operation
• When DTC 341 is active the amber ENGINE lamp is illuminated. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 365: Ebp Operational Diagnostics
1. Using EST, open the D_ContinuousMonitor.ssn. Figure 414 Continuous Monitor Test EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 366 Connect engine harness to sensor. Use the EST to clear DTCs. If an active code remains after checking test conditions, replace the EBP sensor. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 367 ECM and IDM. See truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 368: Ebp Pin-Point Diagnostics
ECM and IDM. See truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 369 DTC 344 = Exhaust back pressure was > expected with key-on engine-off EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 370: Eci System (Engine Crank Inhibit)
The starter relay can also be controlled by an optional over crank thermocouple. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 371 When the transmission is in gear no power is available to the ECI relay. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 372: Eci Circuit Diagnostics
ECM will pull circuit up to 4 V to 5 V with switch ON and go to 0 V when the clutch is depressed or transmission is in neutral. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 373 Pull up voltage from ECM with key-on engine-off or running: transmission in gear or clutch up. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 374: Ecl Sensor (Engine Coolant Level)
The ECL switch is used in the plastic deaeration tank. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 375: Ecl Circuit Operation
ﬂashes from the amber and red ENGINE lamp. • Digital Multimeter (DMM) • Breakout Box EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 376: Ecl Pin-Point Diagnostics
DTC 236 = Signal voltage between 3.4 V and 4.3 V more than 2.0 seconds. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 377: Ecm / Idm Communications (Electronic Control Module / Injector Driver Module)
The ECM provides two output channels to aid the IDM with engine speed and position signals. The CKPO EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 378: Ecm / Idm Circuit Operation
ECM, IDM, and ENGINE lamp. EGR drive module. The ECM receives messages EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 379 DTC 552 is set when the CMPO transition occurs at the wrong CKPO tooth. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 380: Ecm / Idm Pin-Point Diagnostics
If < 11 V to 12 V, check for open or short to ground. Check IDM power relay. X2–12 to gnd Ground, no voltage expected EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 381 If disconnect of X3 corrected problem, replace IDM. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 382 IDM. If X3 is not connected to IDM, spec will be > 500 Ω. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 383 ECM X2–6 to X2–13 120 Ω If > spec, replace the ECM. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 384 DTC 553 = IDM CKPO signal inactive DTC 554 = IDM incorrect CKPO signal signature EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 385: Ecm Pwr (Electronic Control Module Power)
ECM main power relay. This closes the relay contacts and provides the ECM with necessary power. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 386: Ecm Pwr Circuit Operation
DTCs are read using the EST or by counting the ﬂashes from the amber and red ENGINE lamp. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 387 Terminal Test Adapter Kit the code to change from active to inactive status. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 388: Ecm Pwr Pin-Point Diagnostics
B+. See truck Chassis Electrical Circuit Diagram Manual for fuse and relay locations. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 389 See truck Chassis Electrical Circuit Diagram Manual for relay and fuse locations. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 390 Connect relay breakout harness and breakout box [X3 and X4] to chassis harness only.) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 391 IDM. See truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 392: Ecm Self Diagnostics (Electronic Control Module)
Enables diagnostic programming tools the ECM, the amber ENGINE lamp will be illuminated. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 393: Ecm Self Diagnostic Trouble Codes (Dtcs)
Check the EFRC and verify that it matches the ECM strategy level. Reprogram the ECM or change the EFRC as necessary. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 394 No start or run in ﬁeld defaults. Possible Causes: Internal ECM problem. Actions: Replace the ECM. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 395: Ect Sensor (Engine Coolant Temperature)
This causes the signal voltage to decrease. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 396 15% will be achieved as the ECT reaches approximately 110 °C (230 °F). EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 397: Ect Circuit Operation
DTC 114 can set due to a short to ground in the signal circuit or a failed ECT sensor. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 398: Ect Operational Diagnostics
7. Connect Temperature Sensor Breakout Harness to engine harness only. Figure 431 Continuous Monitor Test EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 399 Connect engine harness to sensor. Use the EST to clear DTCs. If an active code remains after checking test conditions, replace the ECT sensor. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 400: Ect Pin-Point Diagnostics
ECM and IDM. See truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 401 DTC 322 = See “Engine Warning and Protection System” (page 440). DTC 325 = See “Engine Warning and Protection System” (page 440). EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 402: Efan Control (Engine Fan Control)
Tech Services. deactivated. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 403: Fan Clutch Circuit Operation
EFAN control is disabled and the engine fan is on all the time. • Relay Breakout Harness EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 404: Fan Clutch Pin-Point Diagnostics
Do Output State Test - Voltage Checks at Fan Relay. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 405 If > 0.25 V, verify that ECM is programmed correctly. If ECM is programmed correctly, replace ECM. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 406 If > 5 Ω, check for harness open between fuse and relay terminal. See truck Chassis Electrical Circuit Diagram Manual for fuse information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 407: Fan Air Solenoid Circuit Operation
EFAN control is disabled and the engine fan is on • EZ-Tech® interface cable all the time. • Digital Multimeter (DMM) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 408: Fan Air Solenoid Pin-Point Diagnostics
If > 0.25 V, verify that ECM is programmed correctly. If ECM is programmed correctly, replace ECM. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 409 If > 5 Ω, check for harness open between fuse and fan solenoid. See truck Chassis Electrical Circuit Diagram Manual for fuse information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 410: Efp Sensor (Engine Fuel Pressure - Optional)
ﬁlter needs to be changed. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 411: Efp Circuit Operation
When DTC 136 is active the amber ENGINE lamp is not illuminated. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 412: Efp Operational Diagnostics
Repair if necessary. 7. Connect Pressure Sensor Breakout Harness to engine harness only. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 413 ECM and IDM. See truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 414: Efp Pin-Point Diagnostics
ECM and IDM. See truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 415 DTC 372 = Measured fuel pressure was greater than expected pressure by 103 kPa (15 psi) for more than 30 seconds. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 416 DTC 371 = Engine fuel pressure is above normal operating range DTC 372 = Engine fuel pressure is below normal operating range EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 417: Egr Actuator (Exhaust Gas Recirculation)
EGR actuator is located at the front of the engine on • Barometric Absolute Pressure (BAP) sensor the mixer duct. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 418: Egr Circuit Operation
ECM. EGR Circuit Operation Figure 442 EGR circuit diagram EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 419 EGR drive module to monitor position (EGR drive module Pin 9). EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 420 EGR drive module, the ECM sends 100 percent EGR position to the EST. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 421: Egr Pin-Point Diagnostics
13 Position sensor U shield 6 Motor W 6 Motor 14 Position sensor V EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 422 8 to gnd If not in spec, check for a short to voltage source. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 423 8 to Pin A (9260) > 1 kΩ If < 1 kΩ, short to ground exists. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 424 1 V to 4 V Digital signal. See “ECM / IDM Communications” (page 373). EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 425 16 to gnd If not in spec, check for a short to voltage source. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 426 15 to 16 > 1 kΩ If < 1 kΩ, short to ground exists. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 427 > 1 kΩ If < 1 kΩ, short to ground exists. (9260) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 428 16 to gnd > 1 kΩ If < 1 kΩ, short to ground exists. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 429 DTC 368 = ECM did not receive EGR drive module communication for more than one second. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 430: Eop Sensor (Engine Oil Pressure)
The EOP sensor is a variable capacitance sensor installed in the left side of the crankcase below and EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 431: Eop Circuit Operation
• When DTC 211 is active the amber ENGINE lamp is illuminated. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 432: Eop Operational Diagnostics
1. Using EST, open the D_ContinuousMonitor.ssn. • Breakout Box • Breakout Harness • Terminal Test Adapter Kit EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 433 7. Connect Pressure Sensor Breakout Harness to engine harness only. Figure 446 Continuous Monitor Test EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 434 ECM and IDM. See truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 435: Eop Pin-Point Diagnostics
> 500 Ω If < 500 Ω, check for short to ground. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 436 DTC 313 = See “Engine Warning and Protection System” (page 440). DTC 314 = See “Engine Warning and Protection System” (page 440). EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 437: Eot Sensor (Engine Oil Temperature)
Exhaust Gas Recirculation Position (EGR) pump assembly. The ECM supplies a 5 V reference EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 438: Eot Circuit Operation
700 rpm to below -10 °C (14 °F) at 750 rpm. EOT Circuit Operation Figure 449 EOT circuit diagram EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 439 100 °C (212 °F) for engine running conditions. determine the temperature of the oil. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 440: Eot Operational Diagnostics
Be careful to avoid rotating parts (belts and fan) and hot engine surfaces. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 441 Connect engine harness to sensor. Use the EST to clear DTCs. If an active code remains after checking test conditions, replace the EOT sensor. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 442: Eot Pin-Point Diagnostics
ECM and IDM. See truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 443 DTC 312 = Signal voltage was > 4.78 V for more than 0.35 second EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 444: Ewps (Engine Warning And Protection System)
• 3–way protection engine condition will be recorded by a logging feature EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 445: Ewps Operational Diagnostics
1 is used for the loss of engine oil pressure detection. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 446 (241 °F). When the temperature drops below 116 °C (241 °F) the DTC will become inactive. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 447 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 448: Iah System (Inlet Air Heater)
The ECM is programmed to energize the IAH elements through the IAH relays while monitoring EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 449: Iah Circuit Operation
When a fault is detected, a DTC will be set. IAH Diagnostic Trouble Codes (DTCs) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 450 Breakout Box • EZ-Tech® interface cable • Amp Clamp • Digital Multimeter (DMM) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 451: Iah Pin-Point Diagnostics
Run Glowplug / Inlet Air Heater Output State Test. For help, see “Inlet Air Heater Output State Test” in Section 3 (page 68).) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 452 If continuity is not present, check element for carbon build-up, corrosion, or open circuit. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 453 If > 0.25 V, and ECM is programmed correctly, replace the ECM. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 454 ECM and IDM. Refer to truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 455: Iat Sensor (Intake Air Temperature)
IAT sensor uses to produce an analog EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 456: Iat Circuit Operation
Terminal Test Adapter Kit the signal circuit or a failed IAT sensor. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 457: Iat Operational Diagnostics
3. Monitor IAT signal voltage. Verify an active DTC for the IAT circuit. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 458 Connect engine harness to sensor. Use the EST to clear DTCs. If an active code remains after checking test conditions, replace the IAT sensor. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 459: Iat Pin-Point Diagnostics
Harness Resistance Checks (Connect breakout box to engine harness [X1 only] and chassis harness [X4 only].) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 460 DTC 155 = Signal voltage was > 4.6 V for more than 0.35 second EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 461: Icp Sensor (Injection Control Pressure)
IDM uses to command the correct injector timing. injector connector. The ECM supplies a 5 V reference EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 462: Icp Circuit Operation
When DTC 125 is active the amber ENGINE lamp ﬂashes from the amber and red ENGINE lamps. is illuminated. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 463 When DTC 332 is active the amber ENGINE lamp is illuminated. Tools • EST with MasterDiagnostics® software EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 464: Icp Operational Diagnostics
7. Connect VC Gasket Breakout Harness to engine harness only. Figure 464 Continuous Monitor Test EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 465 VC Gasket Breakout Harness to between ECM and VC Gasket Breakout Harness EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 466 ECM and IDM. See truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 467 X1-6 to Pin 1 (spec < 5 Ω). ECM chassis ground (Pin A of EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 468 ECM and IDM. See truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 469: Icp Pin-Point Diagnostics (Ecm To Valve Cover Gasket Connector)
> 500 Ω If < 500 Ω, check for short to ground. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 470 IDM. See truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 471 DTC 124 = Signal voltage was < 0.039 V for more than 0.1 second EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 472 DTC 332 = Signal voltage was > 1.625 V, key-on engine-off 7.99 kPa (1160 psi) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 473: Icp Pin-Point Diagnostics (Ecm To Icp Sensor- Valve Cover Removed)
ﬁrst. Always connect the main negative battery cable last. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 474 ECM and IDM. See truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 475 DTC 332 = Signal voltage was > 1.625 V, key-on engine-off 7.99 kPa (1160 psi) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 476: Icp System (Injection Control Pressure)
EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 477 EZ-Tech® interface cable • EST with MasterDiagnostics® software • Digital Multimeter (DMM) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 478 See “Performance Diagnostics” – Section 6 (page 205). Do KOER Standard Test and Injection Control Pressure Test. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 479 When running test, wiggle wires on ICP sensor, IPR valve, and all (intermittent DTC detected). pass through connectors while engine is running. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 480 Test will verify major ICP system failure. See “Performance Diagnostics” – Section 6 (page 205). EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 481 Test will verify IPR valve circuit continuity. See “Hard Start and No Start Diagnostics” – Section 5 (page 143). EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 482 See “Hard Start and No Start Diagnostics” – Section 5 (page 143). Do IPR Pin-Point Diagnostics. See “IPR” (page 494). EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 483: Idm Pwr (Injection Driver Module Power)
This closes the relay contacts and provides the • Fuses IDM with necessary power. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 484: Idm Pwr Circuit Operation
DTCs are read using the EST or by counting the ﬂashes from the amber and red ENGINE lamp. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 485 DTC 534 can be set due to a poor connections between relay and batteries, poor connections EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 486: Idm Pwr Pin-Point Diagnostics
Continuous voltage. If previous test points are in spec and no voltage is present, replace relay. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 487 (–) and IDM pins. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 488 ﬁrst. Always connect the main negative battery cable last. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 489 < 5 Ω If > 5 Ω, check connection from IDM to relay. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 490 If < 900 Ω, check for short to ground within wiring harness. (9260) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 491 If > 5 Ω, see truck Chassis Electrical Circuit Diagram Manual for relay) circuit numbers, connector and fuse locations. Check connections in circuit. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 492 IDM. See truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 493: Inj Circuits (Injector Drive)
48 V DC at 20 A. The EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 494: Inj Pin-Point Diagnostics
DTC is active, replace the injector. lamp. NOTE: Only diagnose injectors with active DTCs. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 495 Disconnect injector and retest. If > 1 kΩ, the short is in the injector. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 496 Disconnect injector and retest. If > 1 kΩ, the short is in the injector. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 497 Disconnect injector and retest. If > 1 kΩ, the short is in the injector. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 498: Ipr (Injection Pressure Regulator)
• Electronic Control Module (ECM) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 499: Ipr Circuit Operation
DTCs are read using the EST or by counting the ﬂashes from the amber and red ENGINE lamp. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 500: Ipr Pin-Point Diagnostics
IDM. See truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 501: Ist System (Idle Shutdown Timer)
2 to 120 minutes. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 502 Ambient air temperature is below 16 °C (60 °F) or above 44 °C (110 °F). EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 503 This feature prevents engine shutdown due to cold ambient temperature. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 504: Map Sensor (Manifold Absolute Pressure)
• ENGINE lamp (amber) engine operating conditions. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 505: Map Circuit Operation
Digital Multimeter (DMM) DTC 122 • 3-Banana Plug Harness • 500 Ohm Resistor Harness EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 506 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS • Breakout Box • Terminal Test Adapter Kit • Breakout Harness EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 507: Map Operational Diagnostics
7. Connect Pressure Sensor Breakout Harness to engine harness only. Figure 485 Continuous Monitor Test EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 508 Connect engine harness to sensor. Use the EST to clear DTCs. If an active code remains after checking test conditions, replace the MAP sensor. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 509: Map Pin-Point Diagnostics
ECM and IDM. See truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 510 “DT 570 and HT 570 Performance Speciﬁcations – Appendix B (page 619) MAP Diagnostic Trouble Codes EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 511 DTC 123 = Detected boost signal voltage was > 115 kPa (17 psi) absolute at low idle. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 512: Mat Sensor (Manifold Air Temperature)
MAT sensor uses to produce an analog voltage that Trouble Code (DTC). EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 513: Mat Circuit Operation
Terminal Test Adapter Kit the signal circuit or a failed MAT sensor. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 514: Mat Operational Diagnostics
3. Monitor MAT signal voltage. Verify an active DTC for the MAT circuit. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 515 Connect engine harness to sensor. Use the EST to clear DTCs. If an active code remains after checking test conditions, replace the MAT sensor. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 516: Mat Pin-Point Diagnostics
2 (Green) to 1 100 °C (212 °F) 2.3 kΩ 0.93 V (Black) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 517 DTC 162 = Signal voltage was > 4.58 V for more than 0.35 second EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 518: Rse (Radiator Shutter Enable)
• Electronic System Controller (ESC) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 519: Rse Circuit Operation
ECT is greater than 87 °C (189 °F) (Note: ECT is customer programmable) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 520: Rse Pin-Point Diagnostics
• Digital Multimeter (DMM) RSE Pin-Point Diagnostics Figure 494 RSE circuit diagram EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 521 If > 5 Ω, check for harness open between fuse and fan solenoid. See truck Chassis Electrical Circuit Diagram Manual for fuse information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 522 DTC 256 = Output Circuit Check detected during KOEO Standard Test, indicates high or low resistance in circuit. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 523: Sccs (Speed Control Command Switches)
ECM. The minimum engine speed that the cruise control can be engaged is programmed in the ECM. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 524 Preset and Remote Variable. Operation of the speed selected speed range. control depends on which signal is enabled. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 525 Tools • EST with INTUNE and MasterDiagnostics® software EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 526: Tachometer Output Circuit
The frequency sent by the ECM is 1/5th of the actual engine rpm (12 pulses per engine revolution). EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 527: Tachometer Pin-Point Diagnostics
NOTE: The instrument cluster tachometer does not use these outputs. See truck Electrical System Troubleshooting Guide. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 528: Vgt Actuator (Variable Geometry Turbocharger)
Injection Pressure Regulator (IPR) • Camshaft Position (CMP) sensor • Manifold Absolute Pressure (MAP) sensor EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 529 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS • Manifold Air Temperature (MAT) sensor • ENGINE lamp (amber) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 530: Vgt Circuit Operation
A high duty cycle engine operating conditions. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 531 • Terminal Test Adapter Kit • 500 Ohm Resistor Harness EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 532: Vgt Pin-Point Diagnostics
If integrity of wiring is conﬁrmed to be in good condition, replace VGT actuator. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 533 Use the EST with MasterDiagnostics® software to view VGT duty cycle with key-on engine-off. When using the Fluke 88 DMM, measurement is typically within 2% of what MasterDiagnostics® reads. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 534 Resistor Harness between 3 and 2. Retest Output State Test - High. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 535 If integrity of wiring is conﬁrmed to be in good condition, replace VGT actuator. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 536 If < 0.25 V, diagnose engine wiring harness, do Harness Resistance Check – VGT Actuator to 12-Pin Connector (page 537). EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 537 If > 0.25 V, the concern is between 12-Pin Connector and battery ground terminal. See truck Chassis Electrical Circuit Diagram Manual. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 538 Toggling between the Low and High Output State Tests can be done during this test. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 539 Use the EST with MasterDiagnostics® software to view VGT duty cycle with key-on engine-off. When using the Fluke 88 DMM, measurement is typically within 2% of what MasterDiagnostics® reads. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 540 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS Figure 504 VGT circuit diagram EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 541 > 500 Ω If < 500 Ω, check for short to ground. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 542 ECM and IDM. Refer to truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 543: (Reference Voltage)
These values are processed by the ECM for engine • Water in Fuel (WIF) sensor (optional) operation. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 544: Circuit Operation
Manual for APS and BAP sensor circuit diagrams. Circuit Operation Figure 506 V circuit diagram EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 545 Repair as required. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 546: Pin-Point Diagnostics
2 to gnd >500 Ω WIF (optional) B to gnd >500 Ω EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 547 EFP (optional) < 5 Ω B to X1–14 WIF (optional) < 5 Ω EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 548: Vss (Vehicle Speed Sensor)
The VSS is on the left side of the transmission. The VSS reads the rotation of a 16 toothed gear and EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 549: Vss Circuit Operation (Manual And Allison Transmissions)
VSS circuit. Troubleshooting Guide and Allison maintenance and diagnostic manuals. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 550 VSS signal greater than 4365 Hz. • Electrical Circuit Diagrams (truck manual) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 551: Vss Pin-Point Diagnostics (Manual Transmissions)
> 500 Ω If < 500 Ω, check for short to ground. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 552 ECM and IDM. Refer to truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 553: Vss Pin-Point Diagnostics (Allison Transmissions)
Note: If circuit checks are within speciﬁcation and condition remains, see transmission manual for sensor inspection and adjustment. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 554 The Electronic Control Module (ECM) monitors the fuel ﬁlter header and alerts the operator when water EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 555 ﬂashes from the amber and red ENGINE lamp. • Breakout Box EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 556 > 1 kΩ If < 1 kΩ, check for short to chassis ground. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 557 ECM and IDM. Refer to truck Chassis Electrical Circuit Diagram Manual for complete chassis side ECM and IDM ground circuit information. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 558 7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 559 Voltmeter................... . .572 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 560 Troubleshooting....................578 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 561: Diagnostic Tools And Accessories
EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 562: Digital Multimeter (Fluke 88)
This ensures that the signal voltage measurement will not be affected by the voltmeter. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 563: 96-Pin Breakout Box - Dlc Ii
(ZTSE4483) • Temperature Sensor Breakout Harness (ZTSE4602) • Turbo Breakout Harness (ZTSE4659) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 564: 3-Banana Plug Harness
Injection Control Pressure (ICP) • Brake Control Pressure (BCP) Figure 523 ZTSE4662 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 565: 12-Pin Breakout Harness
APS/IVS Sensor Breakout Harness 500 Ohm Resistor Harness Figure 525 ZTSE4497 Figure 527 ZTSE4485 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 566: Pressure Sensor Breakout Harness
Intake Air Temperature (IAT) Figure 529 ZTSE4596 sensor. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 567: Temperature Sensor Breakout Harness
Turbo Breakout Harness monitor drive signals and position sensor signals. Figure 533 ZTSE4659 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 568: Terminal Test Adapter Kit
EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 569: Fuel Pressure Gauge
Shake the tube to eliminate any air bubbles. Installing, Reading, and Cleaning EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 570: Fuel Pressure Test Kit
Fuel/Oil Pressure Test Coupler Figure 540 ZTSE4526 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 571: Fuel Test Fitting
Figure 543 ZTSE4655 Fitting 13/16 - 16 NPT ICP sensor adapter EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 572: Inline Shut-Off Valve
The Charge Air Cooler (CAC) Test Kit is used to pressurize the charge air cooler and piping to check for leaks. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 573: Crankcase Pressure Test Adapter
ﬂuorescent yellow-green in color. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 574: Electronic Circuit Testing
To ﬁnd the current ﬂow, use the formula I = E ÷ R: EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 575: Using The Digital Multimeter
• Voltmeter control system. • Ohmmeter EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 576: Jumper Wires
What is the voltage reading? • What is the voltage drop across a load device? EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 577 (positive side) and connect the negative meter lead to a good vehicle ground. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 578: Ammeter
(I = E ÷ R). Therefore, increasing the voltage also EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 579: Ohmmeter
ﬂow in the circuit. Range selection and meter to a speciﬁcation. adjustment are not necessary with the DMM. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 580: Measuring Duty Cycle With Fluke 88
Duty Cycle function, and the trigger has a positive slope. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 581 Figure 561 FLUKE 88 in volts dc mode EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 582: Troubleshooting
Learn more that might give a clue to the nature and location of the problem. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 583 Abbreviations and Acronyms..................581 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 584 9 ABBREVIATIONS AND ACRONYMS EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 585: Abbreviations And Acronyms
EPA – Environmental Protection Agency N – Newton EPR – Engine Pressure Regulator EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 586 9 ABBREVIATIONS AND ACRONYMS NEG – Negative SCCS – Speed Control Command Switches NETS – Navistar Electronics Technical Support SID – Subsystem Identiﬁer N•m – Newton meter – Sulfur Dioxide NO – Nitrogen Oxide SYNC – Synchronization – Nitrogen Oxides TACH –...
Page 587 Terminology......................585 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 588 10 TERMINOLOGY EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 589: Terminology
(cavities) in the ﬂuid. ﬂuctuations resulting in a decrease of acoustic energy. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 590 (SAE J1004 SEP81) down the circuit being measured. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 591 EGR cooler or out the exhaust data communication. system. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 592 Utilized Next alternator and air compressor not charging. Generation Electronics (INTUNE) – EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 593 (SAE J1995 JUN90) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 594 ) – Sulfur dioxide is caused by intake air to charge air. oxidation of sulfur contained in fuel. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 595 Vehicle Retarder Enable/Engage – Output from the cab heat. ECM to a vehicle retarder. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 596 10 TERMINOLOGY EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 597 300 hp @ 2300 rpm (12NPX)................615 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 598 11 APPENDIX A: DT 466 PERFORMANCE SPECIFICATIONS 2004 MODEL YEAR EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 599: Dt 466 (Standard And High Torque - All Ratings)
(20 and 0 °F) 5W-40 synthetic or 0W-30 synthetic below -17 °C (0 °F) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 600: Appendix A: Dt 466 Performance Specifications 2004 Model Year
Below -17 °C (0 °F) use fuel heater Below -17 °C (0 °F) use oil pan heater EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 601: Dt 466 (Standard Torque)
138 kPa (20 psi) / 0.9 V after 10 second Minimum fuel pressure/voltage crank EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 602 2200 rpm or greater @ 5 seconds or less Lube oil temperature (oil gallery), maximum 118 °C (245 °F) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 603: Hp @ 2300 Rpm (12Npm)
138 kPa (20 psi) / 0.9 V after 10 second Minimum fuel pressure/voltage crank EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 604 2300 rpm or greater @ 5 seconds or less Lube oil temperature (oil gallery), maximum 118 °C (245 °F) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 605: Hp @ 2300 Rpm (12Npn)
138 kPa (20 psi) / 0.9 V after 10 second Minimum fuel pressure/voltage crank EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 606 2300 rpm or greater @ 5 seconds or less Lube oil temperature (oil gallery), maximum 118 °C (245 °F) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 607: Hp @ 2300 Rpm (12Npp)
138 kPa (20 psi) / 0.9 V after 10 second Minimum fuel pressure/voltage crank EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 608 2300 rpm or greater @ 5 seconds or less Lube oil temperature (oil gallery), maximum 118 °C (245 °F) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 609: Dt 466 (High Torque)
138 kPa (20 psi) / 0.9 V after 10 second Minimum fuel pressure/voltage crank EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 610 2300 rpm or greater @ 5 seconds or less Lube oil temperature (oil gallery), maximum 1187 °C (245 °F) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 611: Hp @ 2300 Rpm (12Nps)
138 kPa (20 psi) / 0.9 V after 10 second Minimum fuel pressure/voltage crank EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 612 1900 rpm or greater @ / 5 seconds or less Lube oil temperature (oil gallery), maximum 118 °C (245 °F) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 613: Hp @ 2300 Rpm (12Npt)
138 kPa (20 psi) / 0.9 V after 10 second Minimum fuel pressure/voltage crank EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 614 1900 rpm or greater @ 5 seconds or less Lube oil temperature (oil gallery), maximum 118 °C (245 °F) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 615: Hp @ 2300 Rpm (12Npu)
138 kPa (20 psi) / 0.9 V after 10 second Minimum fuel pressure/voltage crank EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 616 1700 rpm or greater @ 5 seconds or less Lube oil temperature (oil gallery), maximum 118 °C (245 °F) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 617: Hp @ 2300 Rpm (12Npv)
138 kPa (20 psi) / 0.9 V after 10 second Minimum fuel pressure/voltage crank EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 618 1700 rpm or greater @ 5 seconds or less Lube oil temperature (oil gallery), maximum 118 °C (245 °F) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 619: Hp @ 2300 Rpm (12Npx)
138 kPa (20 psi) / 0.9 V after 10 second Minimum fuel pressure/voltage crank EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 620 1700 rpm or greater @ 5 seconds or less Lube oil temperature (oil gallery), maximum 118 °C (245 °F) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 621 12NRZ (340 hp @ 2000 rpm)................639 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 622: Appendix B: Dt 570 And Ht 570 Performance Specifications 2004 Model Year
12 APPENDIX B: DT 570 AND HT 570 PERFORMANCE SPECIFICATIONS 2004 MODEL YEAR EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 623: Dt 570 And Ht 570 (All Ratings)
(20 and 0 °F) 5W-40 synthetic or 0W-30 synthetic below -17 °C (0 °F) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 624 Below -17 °C (0 °F) use fuel heater Below -17 °C (0 °F) use oil pan heater EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 625: Dt 570 (Standard Torque)
138 kPa (20 psi) / 0.9 V after 10 second Minimum fuel pressure/voltage crank EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 626 1700 rpm or greater @ 5 seconds or less Lube oil temperature (oil gallery), max. 118 °C (245 °F) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 627: 12Npz (310 Hp @ 2000 Rpm)
138 kPa (20 psi) / 0.9 V after 10 second Minimum fuel pressure/voltage crank EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 628 1700 rpm or greater @ 5 seconds or less Lube oil temperature (oil gallery), maximum 118 °C (245 °F) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 629: 12Nrb (330 Hp @ 2000 Rpm)
138 kPa (20 psi) / 0.9 V after 10 second Minimum fuel pressure/voltage crank EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 630 1700 rpm or greater @ 5 seconds or less Lube oil temperature (oil gallery), maximum 118 °C (245 °F) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 631: Ht 570 (High Torque)
138 kPa (20 psi) / 0.9 V after 10 second Minimum fuel pressure/voltage crank EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 632 1700 rpm or greater @ 5 seconds or less Lube oil temperature (oil gallery), maximum 118 °C (245 °F) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 633: 12Nrd (295 Hp @ 2000 Rpm)
138 kPa (20 psi) / 0.9 V after 10 second Minimum fuel pressure/voltage crank EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 634 1700 rpm or greater @ 5 seconds or less Lube oil temperature (oil gallery), maximum 118 °C (245 °F) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 635: 12Nre (310 Hp @ 2000 Rpm)
138 kPa (20 psi) / 0.9 V after 10 second Minimum fuel pressure/voltage crank EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 636 1700 rpm or greater @ 5 seconds or less Lube oil temperature (oil gallery), maximum 118 °C (245 °F) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 637: 12Nra 300 Hp @ 2000 Rpm
138 kPa (20 psi) / 0.9 V after 10 second Minimum fuel pressure/voltage crank EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 638 1700 rpm or greater @ 5 seconds or less Lube oil temperature (oil gallery), maximum 118 °C (245 °F) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 639: 12Nrg (310 Hp @ 2000 Rpm)
138 kPa (20 psi) / 0.9 V after 10 second Minimum fuel pressure/voltage crank EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 640 1700 rpm or greater @ 5 seconds or less Lube oil temperature (oil gallery), maximum 118 °C (245 °F) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 641: 12Nrh (330 Hp @ 2000 Rpm)
138 kPa (20 psi) / 0.9 V after 10 second Minimum fuel pressure/voltage crank EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 642 1700 rpm or greater @ 5 seconds or less Lube oil temperature (oil gallery), maximum 118 °C (245 °F) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 643: 12Nrz (340 Hp @ 2000 Rpm)
138 kPa (20 psi) / 0.9 V after 10 second Minimum fuel pressure/voltage crank EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 644 1700 rpm or greater @ 5 seconds or less Lube oil temperature (oil gallery), maximum 118 °C (245 °F) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 645 Diagnostic Trouble Code Index..................643 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 646 13 APPENDIX C: DIAGNOSTIC TROUBLE CODE INDEX EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 647: Appendix C: Diagnostic Trouble Code Index
** Indicates red ENGINE lamp on if the Engine Warning Protection System (EWPS) is enabled and a DTC is set. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 648 ** Indicates red ENGINE lamp on if the Engine Warning Protection System (EWPS) is enabled and a DTC is set. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 649 ** Indicates red ENGINE lamp on if the Engine Warning Protection System (EWPS) is enabled and a DTC is set. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 650 ** Indicates red ENGINE lamp on if the Engine Warning Protection System (EWPS) is enabled and a DTC is set. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 651 ** Indicates red ENGINE lamp on if the Engine Warning Protection System (EWPS) is enabled and a DTC is set. EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 652 13 APPENDIX C: DIAGNOSTIC TROUBLE CODE INDEX EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 653: Appendix D: Technical Service Information (Tsi)
Description......................651 EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 654 14 APPENDIX D: TECHNICAL SERVICE INFORMATION (TSI) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 655 Technical Service Information (TSI) letters are periodically published to inform service technicians of EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 656 14 APPENDIX D: TECHNICAL SERVICE INFORMATION (TSI) EGES-270-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © August 2008 Navistar, Inc.
Page 658 Printed in the United States of America...

This manual is also suitable for:

International dt 570 International ht 570

Navistar International DT 466 Diagnostic/Troubleshooting Manual

Diagnostic/Troubleshooting Manual I

Table of Contents

3 Diagnostic Software Operation 65

4 Engine Symptoms Diagnostics 99

Table of Contents

Description

Diagnostic Form Information

Test Procedures

1 Initial Ignition Switch on (Do Not Start)

2 Engine Cranking

3 Diagnostic Trouble Codes

4 KOEO Standard Test

5 KOEO Injector Test

6 EST Data List

7 Fuel

8 Engine Systems

9 Engine Oil

10 Intake and Exhaust Restriction

11 Main Power Relay to ECM

12 Main Power Relay to IDM

13 Fuel Pressure and Aerated Fuel

14 Low ICP System Pressure

15 Inlet Air Heater System

Table of Contents

Description

Diagnostic Form Information

Test Procedures

1 Diagnostic Trouble Codes

2 KOEO Standard Test

3 KOEO Injector Test

4 Engine Oil

5 Fuel

6 Fuel Pressure and Aerated Fuel

7 Intake Restriction

8 Exhaust Restriction

9 KOER Standard Test

10 Injection Control Pressure

11 Injector Disable Test

12 Relative Compression

13 Air Management

14 VGT Test

15 Torque Converter Stall (Automatic Only)

16 Crankcase Pressure

17 Test Drive (Full Load, Rated Speed)

18 Valve Lash and Brake Lash

Table of Contents

Description

Electronic Control System Diagnostics Form

Sensor and Actuator Locations

Diagnostic Procedures for Sensors and Actuators

Circuit Diagnostics

CAN Communications (Controller Area Network)

CKP Sensor (Crankshaft Position)

CMP Sensor (Camshaft Position)

EBP Sensor (Exhaust Back Pressure)

ECI System (Engine Crank Inhibit)

ECL Sensor (Engine Coolant Level)

ECM / IDM Communications (Electronic Control Module / Injector Driver Module)

ECM PWR (Electronic Control Module Power)

ECM Self Diagnostics (Electronic Control Module)

ECT Sensor (Engine Coolant Temperature)

EFAN Control (Engine Fan Control)

EFP Sensor (Engine Fuel Pressure - Optional)

EGR Actuator (Exhaust Gas Recirculation)

EOP Sensor (Engine Oil Pressure)

EOT Sensor (Engine Oil Temperature)

EWPS (Engine Warning and Protection System)

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Summary of Contents for Navistar International DT 466