2010-2015 Navistar Maxxforce 11 13 Diesel Engine Service & Repair Manual

© 2011 Navistar, Inc. All rights reserved. Printed in the United States of America SERVICE MANUAL MaxxForce® 11 and 13 DIESEL ENGINE Model Year 2010 and Up EGES-465-1 SERVICE MANUAL MaxxForce® 11 and 13 DIESEL ENGINE EGES-465-1 Model Year 2010 and Up

ENGINE SERVICE MANUAL I Table of Contents Foreword...................................................................................................................1 Service Diagnosis ........................................................................................................2 Safety Information........................................................................................................3 Engine Systems...........................................................................................................5 Mounting Engine on Stand............................................................................................53 Engine Electrical.........................................................................................................59 Cold Start Assist.......................................................................................................107 Aftertreatment System................................................................................................119 Exhaust Back Pressure Control.....................................................................................137 Turbochargers..........................................................................................................147 Air Compressor and Power Steering...............................................................................181 Fuel System.............................................................................................................195 Oil Cooler, Filter Housing and Crankcase Ventilation...........................................................235 Exhaust Gas Recirculation (EGR) System.........................................................................251 Air Intake Throttle Duct and Exhaust Manifold...................................................................271 Front Cover, Fan Drive, Cooling System and Related Components..........................................283 MaxxForce® Engine Brake by Jacobs.............................................................................315 Cylinder Head, Camshaft and Valve Train.........................................................................331 Flywheel and Flywheel Housing.....................................................................................363 Oil Pan and Oil Pickup Tube.........................................................................................381 Oil Pump and Timing Gears..........................................................................................393 Power Cylinders........................................................................................................409 Crankcase and Crankshaft...........................................................................................429 EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. ©2011 Navistar, Inc. All rights reserved

II ENGINE SERVICE MANUAL Abbreviations and Acronyms........................................................................................443 Terminology.............................................................................................................449 Appendix A – Speciﬁcations.........................................................................................461 Appendix B – Torques.................................................................................................467 Appendix C – Special Service Tools................................................................................487 EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. ©2011 Navistar, Inc. All rights reserved

ENGINE SERVICE MANUAL 1 Foreword Navistar, Inc. is committed to continuous research and development to improve products and introduce technological advances. Procedures, specifications, and parts defined in published technical service literature may be altered. This Engine Service Manual provides a general sequence of procedures for out-of-chassis engine overhaul (removal, inspection, and installation). For in-chassis service of parts and assemblies, the sequence may vary. NOTE: Photo illustrations identify specific parts or assemblies that support text and procedures; other areas in a photo illustration may not be exact. See vehicle manuals and Technical Service Information (TSI) bulletins for additional information. Technical Service Literature 1171972R3 MaxxForce® 11 and 13 Engine Operation and Maintenance Manual EGES 465 MaxxForce® 11 and 13 Engine Service Manual EGES 470 MaxxForce® 11 and 13 Engine Diagnostic Manual EGED 475 MaxxForce® 11 and 13 Hard Start and No Start and Performance Diagnostic Form EGED 500 MaxxForce® 11 and 13 Electric Control Systems Diagnostic Form Technical Service Literature is revised periodically and mailed automatically to “Revision Service” subscribers. If a technical publication is ordered, the latest revision will be supplied. To order technical service literature, contact your International dealer. All marks are trademarks of their respective owners. EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. ©2011 Navistar, Inc. All rights reserved

2 ENGINE SERVICE MANUAL Service Diagnosis Service diagnosis is an investigative procedure that must be followed to find and correct an engine application problem or an engine problem. If the problem is engine application, see specific vehicle manuals for further diagnostic information. If the problem is the engine, see specific Engine Diagnostic Manual for further diagnostic information. Prerequisites for Effective Diagnosis • Availability of gauges and diagnostic test equipment • Availability of current information for engine application and engine systems • Knowledge of the principles of operation for engine application and engine systems • Knowledge to understand and do procedures in diagnostic and service publications Technical Service Literature required for Effective Diagnosis • Engine Service Manual • Engine Diagnostic Manual • Diagnostics Forms • Electronic Control Systems Diagnostics Forms • Service Bulletins EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. ©2011 Navistar, Inc. All rights reserved

ENGINE SERVICE MANUAL 3 Safety Information This manual provides general and specific maintenance procedures essential for reliable engine operation and your safety. Since many variations in procedures, tools, and service parts are involved, advice for all possible safety conditions and hazards cannot be stated. Read safety instructions before doing any service and test procedures for the engine or vehicle. See related application manuals for more information. Disregard for Safety Instructions, Warnings, Cautions, and Notes in this manual can lead to injury, death or damage to the engine or vehicle. Safety Terminology Three terms are used to stress your safety and safe operation of the engine: Warning, Caution, and Note Warning: A warning describes actions necessary to prevent or eliminate conditions, hazards, and unsafe practices that can cause personal injury or death. Caution: A caution describes actions necessary to prevent or eliminate conditions that can cause damage to the engine or vehicle. Note: A note describes actions necessary for correct, efficient engine operation. Safety Instructions Work Area • Keep work area clean, dry, and organized. • Keep tools and parts off the floor. • Make sure the work area is ventilated and well lit. • Make sure a First Aid Kit is available. Safety Equipment • Use correct lifting devices. • Use safety blocks and stands. Protective Measures • Wear protective safety glasses and shoes. • Wear correct hearing protection. • Wear cotton work clothing. • Wear sleeved heat protective gloves. • Do not wear rings, watches or other jewelry. • Restrain long hair. Vehicle • Make sure the vehicle is in neutral, the parking brake is set, and the wheels are blocked before servicing engine. • Clear the area before starting the engine. Engine • The engine should be operated or serviced only by qualified individuals. • Provide necessary ventilation when operating engine in a closed area. • Keep combustible material away from engine exhaust system and exhaust manifolds. • Install all shields, guards, and access covers before operating engine. • Do not run engine with unprotected air inlets or exhaust openings. If unavoidable for service reasons, put protective screens over all openings before servicing engine. • Shut engine off and relieve all pressure in the system before removing panels, housing covers, and caps. • If an engine is not safe to operate, tag the engine and ignition key. Fire Prevention • Make sure charged fire extinguishers are in the work area. NOTE: Check the classification of each fire extinguisher to ensure that the following fire types can be extinguished. 1. Type A — Wood, paper, textiles, and rubbish 2. Type B — Flammable liquids 3. Type C — Electrical equipment Batteries • Always disconnect the main negative battery cable first. • Always connect the main negative battery cable last. • Avoid leaning over batteries. • Protect your eyes. EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. ©2011 Navistar, Inc. All rights reserved

4 ENGINE SERVICE MANUAL • Do not expose batteries to open flames or sparks. • Do not smoke in workplace. Compressed Air • Use an OSHA approved blow gun rated at 207 kPa (30 psi). • Limit shop air pressure to 207 kPa (30 psi). • Wear safety glasses or goggles. • Wear hearing protection. • Use shielding to protect others in the work area. • Do not direct compressed air at body or clothing. Tools • Make sure all tools are in good condition. • Make sure all standard electrical tools are grounded. • Check for frayed power cords before using power tools. Fluids Under Pressure • Use extreme caution when working on systems under pressure. • Follow approved procedures only. Fuel • Do not over fill the fuel tank. Over fill creates a fire hazard. • Do not smoke in the work area. • Do not refuel the tank when the engine is running. Removal of Tools, Parts, and Equipment • Reinstall all safety guards, shields, and covers after servicing the engine. • Make sure all tools, parts, and service equipment are removed from the engine and vehicle after all work is done. EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. ©2011 Navistar, Inc. All rights reserved

ENGINE SYSTEMS 5 Table of Contents Engine Identification.....................................................................................................7 Engine Serial Number..........................................................................................7 Engine Emission Label ........................................................................................7 Engine Accessory Labels and Identification Plates.......................................................8 Engine Specifications..........................................................................................8 Heavy Duty On Board Diagnostics (HD-OBD)...................................................10 Engine Description...................................................................................10 Optional Equipment..................................................................................11 Chassis Mounted Equipment.......................................................................11 Engine Component Locations...............................................................................12 Air Management System...............................................................................................16 Airflow...........................................................................................................17 Turbochargers..................................................................................................18 Air Control Valve (ACV).......................................................................................19 Boost Control...................................................................................................19 Low Pressure Charge Air Cooler (LPCAC)................................................................20 High Pressure Charge Air Cooler (HPCAC)...............................................................20 High Pressure Boost Pressure (HPBP) Sensor ..........................................................20 High Pressure Boost Temperature (HPBT) Sensor .....................................................20 Low Pressure Boost Pressure (LPBP) Sensor and Low Pressure Boost Temperature (LPBT) Sensor ......................................................................................................20 Exhaust Gas Recirculation (EGR) System................................................................21 Aftertreatment (AFT) System................................................................................24 Diesel Particulate Filter (DPF)......................................................................25 Diesel Oxidation Catalyst (DOC)...................................................................25 Aftertreatment (AFT) System Conditions and Responses....................................25 Downstream Fuel Injection.........................................................................26 Crankcase Oil Separator......................................................................................28 Fuel Management System.............................................................................................30 Fuel Flow........................................................................................................31 Low Pressure Fuel System...................................................................................32 High Pressure Fuel System..................................................................................34 Cold Start Assist System..............................................................................................35 Cold Start Assist System Components....................................................................35 Cold Start Assist System Operation........................................................................36 Oil Flow and Components.............................................................................................37 Engine Cooling System................................................................................................40 Cooling System Flow..........................................................................................40 Thermostat Operation.........................................................................................41 Coolant Control Valve (CCV) operation....................................................................42 EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. ©2011 Navistar, Inc. All rights reserved

6 ENGINE SYSTEMS Engine Brake System...................................................................................................43 Engine Brake Control System Components..............................................................43 Engine Brake System Operation............................................................................44 Electronic Control System.............................................................................................45 Electronic Control System Components..................................................................45 Operation and Function.............................................................................45 Reference Voltage (VREF)..........................................................................45 Signal Conditioner...................................................................................45 Microprocessor.......................................................................................45 Diagnostic Trouble Codes..........................................................................45 Microprocessor Memory............................................................................45 Actuator Control......................................................................................46 Actuators........................................................................................................46 Coolant Control Valve (CCV).......................................................................46 Exhaust Back Pressure Valve (EBPV) Control..................................................46 Exhaust Gas Recirculation (EGR) Valve .........................................................46 Air Control Valve (ACV).............................................................................46 Cold Start Relay (CSR)..............................................................................46 Cold Start Solenoid (CSS) Valve...................................................................47 Engine Throttle Valve (ETV)........................................................................47 Fuel Pressure Control Valve (FPCV)..............................................................47 Aftertreatment Fuel Doser (AFTFD)...............................................................47 Aftertreatment Shutoff Valve (AFTSV)............................................................47 Engine and Vehicle Sensors.................................................................................47 Thermistor Sensors..................................................................................47 Variable Capacitance Sensors.....................................................................49 Magnetic Pickup Sensors...........................................................................50 Potentiometer Sensors..............................................................................51 Switches...............................................................................................52 Additional Sensors............................................................................................52 Oxygen Sensor (O2S)................................................................................52 Humidity Sensor (HS)................................................................................52 EGES-465-1 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. ©2011 Navistar, Inc. All rights reserved

2010-2015 Navistar Maxxforce 11 13 Diesel Engine Service & Repair Manual

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