Navistar Maxxforce 7 Engine Service & Repair Manual

ENGINE SERVICE MANUAL 0000002383 2010 MaxxForce ® 7 Revision 2 EPA 10 - US, Canada, Mexico February 2014 ENGINE SERVICE MANUAL 2010 MaxxForce ® 7 Navistar, Inc. 2701 Navistar Drive, Lisle, IL 60532 USA ©2014 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

ENGINE SERVICE MANUAL I TABLE OF CONTENTS Foreword...................................................................................................................1 Service Diagnosis ........................................................................................................2 Safety Information........................................................................................................3 Engine Systems...........................................................................................................5 Mounting Engine on Engine Stand...................................................................................45 Engine Electrical.........................................................................................................53 Exhaust Gas Recirculation (EGR) System.........................................................................113 Dual Turbocharger, Exhaust Manifolds, and Piping.............................................................141 Air Compressor and Power Steering Pump.......................................................................185 Fuel System.............................................................................................................207 Front Cover, Cooling System, and Related Components.......................................................263 Oil Cooler, Oil Pump, Oil Filter, and Oil Pan.......................................................................285 Cylinder Heads, Valve Covers, and Valve Train..................................................................309 Flywheel Assembly and Flywheel Housing.......................................................................367 Power Cylinders........................................................................................................395 Crankcase, Crankshaft, and Camshaft.............................................................................417 Abbreviations and Acronyms........................................................................................443 Terminology.............................................................................................................449 Appendix A – Speciﬁcations.........................................................................................461 Appendix B – Torques.................................................................................................469 Appendix C – Special Service Tools................................................................................479

II ENGINE SERVICE MANUAL

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 1171971R1 MaxxForce ® 7 Engine Operation and Maintenance Manual 0000002383 MaxxForce ® 7 (EPA 10) with HD-OBD Engine Service Manual 0000001681 MaxxForce ® 7 (EPA 10) with HD-OBD Engine Diagnostic Manual 0000003382 MaxxForce ® 7 (EPA 10) with HD-OBD Hard Start and No Start Diagnostic Form 0000003381 MaxxForce ® 7 (EPA 10) with HD-OBD Performance Diagnostic Form 0000003201 MaxxForce ® 7 (EPA 10) with HD-OBD Engine Wiring Schematic Form Technical Service Literature is revised periodically. 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.

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, diagnostic test equipment, and diagnostic software. • 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

ENGINE SERVICE MANUAL 3 Safety Information This manual provides general and specific service 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 Vehicle • Make sure the vehicle is in neutral, the parking brake is set, and the wheels are blocked before doing any work or diagnostic procedures on the engine or vehicle. 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 glasses and safety shoes. • Wear appropriate hearing protection. • Wear correct work clothing. • Do not wear rings, watches, or other jewelry. • Restrain long hair. 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 Batteries produce highly flammable gas during and after charging. • Always disconnect the main negative battery cable first. • Always connect the main negative battery cable last. • Avoid leaning over batteries. • Protect your eyes. • Do not expose batteries to open flames or sparks. • Do not smoke in workplace. Compressed air • Limit shop air pressure for blow gun to 207 kPa (30 psi). • Use approved equipment. • Do not direct air at body or clothing. • Wear safety glasses or goggles. • Wear hearing protection. • Use shielding to protect others in the work area. Tools • Make sure all tools are in good condition. • Make sure all standard electrical tools are grounded.

4 ENGINE SERVICE MANUAL • 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.

ENGINE SYSTEMS 5 Table of Contents Engine Identiﬁcation.....................................................................................................7 Engine Serial Number..........................................................................................7 Emission Label..................................................................................................7 Engine Accessories.............................................................................................7 Engine Description..............................................................................................8 Standard Features.....................................................................................9 Optional Features....................................................................................10 Thermal Management Valve (TMV)................................................................10 Chassis-mounted Features.........................................................................10 Engine Components...........................................................................................11 Air Management System...............................................................................................16 Air Management Components and Air Flow..............................................................16 Air Flow................................................................................................17 Charge Air Cooler (CAC).....................................................................................17 Charge Air Cooler Outlet Temperature (CACOT) Sensor...............................................17 Dual Turbocharger Assembly................................................................................19 High-pressure Turbocharger.......................................................................20 Turbocharger 1 Compressor Outlet Temperature (TC1COT) Sensor........................20 Thermal Management Valve (TMV) (optional)...................................................20 Low-pressure Turbocharger........................................................................20 Turbocharger 1 Wastegate Control (TC1WC) Solenoid........................................20 Exhaust Gas Recirculation (EGR) System................................................................21 EGR Flow..............................................................................................21 EGR Control Valve and Position Sensor.........................................................22 Engine Throttle Valve (ETV) and Position Sensor..............................................23 Aftertreatment (AFT) System................................................................................24 AFT Control System.................................................................................24 Sensors................................................................................................24 Diesel Oxidation Catalyst (DOC)...................................................................24 Diesel Particulate Filter (DPF)......................................................................24 AFT Conditions and Responses...................................................................24 Fuel System..............................................................................................................25 Fuel System Components....................................................................................25 High-pressure Fuel System..................................................................................26 High-pressure Fuel Pump (HPFP) Assembly....................................................26 Internal Transfer Pump (ITP).......................................................................26 Fuel Pressure Control Valve (FPCV)..............................................................26 Fuel Volume Control Valve (FVCV)................................................................27 Fuel Rail Pressure (FRP) Sensor..................................................................27 High-pressure Piezo Common Rail (HPCR) System...........................................27 Return Fuel System..................................................................................27 Low-pressure Fuel System...................................................................................29 Fuel Pump.............................................................................................29 Primary Fuel Filter....................................................................................29

6 ENGINE SYSTEMS Secondary Fuel Filter................................................................................29 Fuel Cooler............................................................................................29 Fault Detection/Management................................................................................29 Engine Lubrication System............................................................................................30 Lubrication System Components and Oil Flow..........................................................30 Cooling System..........................................................................................................32 Cooling System Components and Flow...................................................................32 Water Pump...........................................................................................32 Front Crankcase Cover Flow.......................................................................33 Thermostats...........................................................................................33 Deaeration Tank......................................................................................33 Radiator Shutters (220 Horsepower only).......................................................33 Fuel Coolant Valve (FCV)...........................................................................33 Engine Speed Position System.......................................................................................34 Electronic Control System.............................................................................................35 Electronic Control System Components..................................................................35 Operation and Function.............................................................................37 Reference Voltage (VREF)..........................................................................37 Signal Conditioner...................................................................................37 Microprocessor.......................................................................................37 Microprocessor Memory............................................................................37 Flash Memory.........................................................................................37 RAM.....................................................................................................37 Engine Fan Control (EFC)...........................................................................38 Inlet Air Heater (IAH).................................................................................38 Actuator Control......................................................................................38 Actuators........................................................................................................38 H-Bridge Circuit......................................................................................38 Exhaust Gas Recirculation (EGR) Valve and Control..........................................38 ETV and Engine Throttle Position Sensor.......................................................39 Engine and Vehicle Sensors.................................................................................39 Thermistor Sensors..................................................................................39 Variable Capacitance Sensors.....................................................................40 Micro Strain Gauge (MSG) Sensor................................................................40 Magnetic Pickup Sensors...........................................................................41 Potentiometer.........................................................................................41 Switches...............................................................................................42 Inlet Air Heater (IAH) System................................................................................43

Navistar Maxxforce 7 Engine Service & Repair Manual

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