Navistar MaxxForce DT9/DT10 Engines OEM Service & Repair Manual

SERVICE MANUAL ENGINE SERVICE MANUAL EGES-335-2 April 2011 EGES-335-2 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. ©April 2011 Navistar, Inc. All rights reserved

ENGINE SERVICE MANUAL I Table of Contents Foreword...................................................................................................................1 Service Diagnosis ........................................................................................................2 Safety Information........................................................................................................3 Engine Systems...........................................................................................................5 Mounting Engine on Engine Stand...................................................................................55 Engine Electrical.........................................................................................................65 Variable Geometry Turbocharger (VGT)...........................................................................107 Exhaust Gas Recirculation (EGR) System.........................................................................119 Intake, Inlet, and Exhaust Manifolds................................................................................141 Fuel and High-pressure Oil Systems...............................................................................155 Diamond Logic® Engine Brake......................................................................................185 Air Compressor and Power Steering Pump.......................................................................201 Oil System Module Assembly....................................................................................... 213 Oil Pan and Oil Suction Tube........................................................................................231 Front Cover, Cooling System, and Related Components.......................................................243 Cylinder Head and Valve Train.......................................................................................291 Flywheel and Flywheel Housing.....................................................................................337 Power Cylinders........................................................................................................365 Crankcase, Crankshaft, and Camshaft.............................................................................403 Abbreviations and Acronyms........................................................................................443 Terminology.............................................................................................................449 Appendix A - Speciﬁcations.........................................................................................457 Appendix B - Torques.................................................................................................475 EGES-335-2 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. ©April 2011 Navistar, Inc. All rights reserved

II ENGINE SERVICE MANUAL Appendix C - Special Service Tools................................................................................487 EGES-335-2 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. ©April 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 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 photo illustrations may not be exact. See vehicle manuals and Technical Service Information (TSI) bulletins for additional information. Technical Service Literature 1171939R3 MaxxForce®DT, 9, and 10 Engine Operation and Maintenance Manual EGES-335-1 MaxxForce®DT, 9, and 10 Engine Service Manual EGES-370-1 MaxxForce®DT, 9, and 10 Engine Diagnostic Manual EGED-375 MaxxForce® DT, 9, and 10 Hard Start/ No Start Diagnostic Form EGED-380 MaxxForce® DT, 9, and 10 Performance Diagnostic Form EGED-385 MaxxForce® DT, 9, and 10 Electronic Control Systems 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. NOTE: To order technical service literature, contact your Navistar dealer. EGES-335-2 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. ©April 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-335-2 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. ©April 2011 Navistar, Inc. All rights reserved

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 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. 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. EGES-335-2 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. ©April 2011 Navistar, Inc. All rights reserved

4 ENGINE SERVICE MANUAL 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-335-2 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. ©April 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......................................................................................7 Engine Description..............................................................................................8 Standard Features.....................................................................................9 Optional Features....................................................................................10 Chassis Mounted Features.........................................................................10 Engine Component Locations...............................................................................11 Air Management System...............................................................................................16 Air Flow..........................................................................................................17 Air Management Components...............................................................................17 Charge Air Cooler (CAC)............................................................................17 Exhaust Gas Recirculation (EGR) System.......................................................18 Variable Geometry Turbocharger (VGT)..........................................................20 Aftertreatment (AFT) System.......................................................................22 Fuel Management System.............................................................................................23 ICP System......................................................................................................24 High-Pressure Oil Flow..............................................................................24 ICP Closed Loop System...........................................................................25 ICP Control System..................................................................................26 Fuel Injector...........................................................................................27 Fuel Supply System.....................................................................................................29 Fuel Supply System Flow....................................................................................30 Engine Lubrication System............................................................................................33 Oil Flow..........................................................................................................34 Engine Cooling System................................................................................................36 Cooling System Flow..........................................................................................37 Cooling System Components...............................................................................37 Coolant Heater (optional)...........................................................................37 Thermostat Operation...............................................................................38 Electronic Control System.............................................................................................39 Electronic Control System Components..................................................................39 Operation and Function.............................................................................39 Reference Voltage (VREF)..........................................................................40 Signal Conditioner...................................................................................40 Microprocessor.......................................................................................40 Microprocessor Memory............................................................................40 Actuator Control......................................................................................41 Actuators........................................................................................................41 EGES-335-2 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. ©April 2011 Navistar, Inc. All rights reserved

6 ENGINE SYSTEMS EGR Valve..............................................................................................41 IAH Relays.............................................................................................41 Intake Throttle Actuator and Position Sensor...................................................41 Engine and Vehicle Sensors.................................................................................42 Thermistor Sensors..................................................................................42 Variable Capacitance Sensors.....................................................................44 Magnetic Pickup Sensors...........................................................................45 Micro Strain Gauge (MSG) Sensors...............................................................46 Potentiometer.........................................................................................47 Switches...............................................................................................48 Intake Throttle Valve...........................................................................................49 Diamond Logic® Brake System.......................................................................................50 Brake Operation Modes.......................................................................................51 Exhaust Brake System........................................................................................51 Engine Brake System.........................................................................................52 EGES-335-2 Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures. Follow all warnings, cautions, and notes. ©April 2011 Navistar, Inc. All rights reserved

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Navistar MaxxForce DT9/DT10 Engines OEM Service & Repair Manual

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