Navistar N9 Diagnostic Manual Download

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Summary of Contents for N9

Page 1: ...N10 Engine Revision 6 SCR US Canada Mexico December 2014 DIAGNOSTIC MANUAL N9 and N10 Engine Navistar Inc 2701 Navistar Drive Lisle IL 60532 USA 2014 Navistar Inc All rights reserved All marks are tr...

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Page 3: ...on 3 Diagnostic Troubleshooting Procedures 7 Engine System Tests and Inspections 2091 Engine Specifications 2399 Diagnostic Tools and Accessories 2419 Component Locator 2461 Engine Systems Overview 24...

Page 4: ...II DIAGNOSTIC MANUAL...

Page 5: ...information and specifications for technicians to maintain Navistar diesel engines See vehicle manuals and Technical Service Information TSI bulletins for additional information Technical Service Lite...

Page 6: ...l for further diagnostic information Prerequisites for Effective Diagnosis Availability of gauges and diagnostic test equipment Availability of current information for engine application and engine sy...

Page 7: ...s 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 condit...

Page 8: ...y 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...

Page 9: ...res 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 Reinst...

Page 10: ...6 DIAGNOSTIC MANUAL...

Page 11: ...ngine Does Not Start Symptoms 49 2 1 Engine Cranks Fast Slow or Does Not Crank 49 2 2 Engine No Start Cold Ambient Temperature 53 2 3 Engine at Operating Temperature No Re Start 54 2 4 Engine Never St...

Page 12: ...re 1 Aftertreatment Fuel Temperature Sensor 226 AFT FP2 Aftertreatment Fuel Pressure 2 Sensor 257 AFT FPC Aftertreatment Fuel Pressure Control System 279 NH3 Aftertreatment Ammonia Sensor and Sensor M...

Page 13: ...aust Gas Recirculation 1074 EGT Sensor Exhaust Gas Temperature 1115 Engine 1132 EOP Sensor Engine Oil Pressure 1152 EOT Sensor Engine Oil Temperature 1163 ETP Engine Throttle Valve Position 1187 EWPS...

Page 14: ...10 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES...

Page 15: ...king 96 3 FLI page 1265 Fuel Level signal Out of Range HIGH 96 4 FLI page 1265 Fuel Level signal Out of Range LOW 96 19 FLI page 1265 Fuel Level not detected on J1939 100 1 EWPS page 1210 Engine Oil S...

Page 16: ...t number of data points 132 13 MAF page 1782 MAF Sensor Calibration Needed 132 14 MAF page 1782 MAF Sensor Calibration Failed 132 31 MAF page 1782 MAF Frequency out of range HIGH 158 15 ECM page 1000...

Page 17: ...page 1210 Engine stopped by IST 596 19 BODY page 428 Cruise Control Enable Switch not detected on J1939 597 2 BODY page 428 Brake switch or circuit fault 597 19 BODY page 428 Brake Switch not detecte...

Page 18: ...age 1365 Injector 5 Spool Motion Compensation Max Authority Reached 655 14 INJ page 1365 Injector 5 Fuel quantity timing error 656 4 INJ page 1365 Injector 6 open coil short circuit 656 5 INJ page 136...

Page 19: ...1328 31 Engine page 1132 Misfire Cylinder 6 1378 31 EWPS page 1210 Change Engine Oil Service Interval 1387 31 ECM page 1000 Altitude Reference Adder Fault 1569 31 DEFTLT page 746 SCR Tamperproof Warn...

Page 20: ...signal Out of Range HIGH 3031 4 DEFTLT page 746 DEFTT signal Out of Range LOW 3055 2 INJ page 1365 ICP IPR Adaptation In Range Fault 3061 31 CSER Exhaust warm up time fault 3216 4 NOX page 1827 NOxIN...

Page 21: ...signal erratic intermittent or incorrect 3361 3 DEF SP page 698 DEFSP signal Out of Range HIGH 3361 4 DEF SP page 698 DEFSP signal Out of Range LOW 3362 31 DEF SP page 698 DEF dosing unable to prime 3...

Page 22: ...INJ page 1365 Injector 1 close coil short circuit 3659 5 INJ page 1365 Injector 1 close coil open circuit 3660 4 INJ page 1365 Injector 2 close coil short circuit 3660 5 INJ page 1365 Injector 2 clos...

Page 23: ...ECBP above desired level 4287 1 ECBP page 972 ECBP below desired level 4287 3 ECBP page 972 ECBP signal Out of Range HIGH 4287 4 ECBP page 972 ECBP signal Out of Range LOW 4334 2 DEF AP page 591 DEFL...

Page 24: ...Ammonia page 338 NH3 operation fault 4377 19 Ammonia page 338 NH3 Sensor Module not detected on j1939 4380 2 Ammonia page 338 NH3 signal erratic intermittent or incorrect 4382 10 Ammonia page 338 NH3...

Page 25: ...too frequently 5456 2 AFTFIS page 226 AFTFIT signal erratic intermittent or incorrect 5456 3 AFTFIS page 226 AFTFT signal Out of Range HIGH 5456 4 AFTFIS page 226 AFTFT signal Out of Range LOW 5491 3...

Page 26: ...ater Out of Range LOW 5745 18 DEFSMH page 508 DEF Dosing Unit Heater below Warning Temperature 5746 3 DEF SMH Relay page 782 DEF Supply Module Heater Relay short to PWR 5746 4 DEF SMH Relay page 782 D...

Page 27: ...p 3 No Repair broken loose or corroded electrical system connections or components Charge batteries to 12 6 volts After repairs are complete retest for original problem Step 3 Inspect air intake syste...

Page 28: ...nt to specification If coolant is contaminated go to Coolant Contamination page 88 After repairs are complete retest for original problem Step 7 Verify Engine Control Module ECM communicates with Elec...

Page 29: ...page 30 4 0 Engine Running Engine Not Under Load Operational Checkout Procedure page 34 5 0 Engine Running Engine Under Load Operational Checkout Procedure page 36 6 0 Cooling System Operational Check...

Page 30: ...OUBLESHOOTING PROCEDURES 2 0 Engine Does Not Start Operational Checkout Procedure Overview The following steps direct technicians to systematically troubleshoot engine no start conditions and avoid un...

Page 31: ...ector s Step 3 Check for no start related Diagnostic Trouble Codes DTC Decision Yes Go to Fault Code Diagnostics for no start related SPN Using Electronic Service Tool EST with ServiceMaxx software ch...

Page 32: ...Go to 8 1 Low Fuel Delivery Pressure page 120 No ICP out of specification Go to SPN 164 FMI 0 Fault Code Diagnostics page 1287 No One or more engine temperature sensors not within 20 F 7 C of others...

Page 33: ...rt engine Does engine fail to start specifically during cold ambient temperatures Yes Go to 2 2 Engine No Start Cold Ambient Temperature page 53 No Go to Step 7 Step 7 Engine at operating temperature...

Page 34: ...P SPN 931 Electric Fuel Pump EFP SPN 164 Injection Control Pressure ICP SPN 679 Injection Pressure Regulator IPR SPN 636 Camshaft Position CMP SPN 637 Crankshaft Position CKP SPN 108 158 628 629 1136...

Page 35: ...of specification Go to 8 1 Low Fuel Delivery Pressure page 120 No ICP out of specification Go to SPN 164 FMI 0 Fault Code Diagnostics page 1287 No one or more engine temperature sensors Not within 20...

Page 36: ...Decomposition Tube Inspection Decomposition Reactor Tube Inspection page 2380 Step 5 Determine if engine will not start specifically during cold ambient temperatures Decision Attempt to start engine...

Page 37: ...TING PROCEDURES 33 Step 7 Determine if engine starts and then stalls Decision Attempt to start engine Does engine start and then stall Yes Go to 3 3 Engine Starts Then Stalls page 64 No Go to 2 4 Engi...

Page 38: ...heck DTC list for SPN 91 2623 Accelerator Pedal Position APP SPN 94 Fuel Delivery Pressure FDP SPN 931 Electronic Fuel Pump EFP SPN 164 3055 Injection Control Pressure ICP SPN 679 Injection Pressure R...

Page 39: ...rough or surge at idle No Go to Step 4 Step 4 Determine if engine is able to reach rated speed Decision Yes Go to Step 5 A Start engine B Increase engine rpm to rated speed and return to idle Is engi...

Page 40: ...list for SPN 91 2623 Accelerator Pedal Position APP SPN 94 Fuel Delivery Pressure FDP SPN 931 Electronic Fuel Pump EFP SPN 164 3055 Injection Control Pressure ICP SPN 679 Injection Pressure Regulator...

Page 41: ...n Decision Review engine running snapshot Does vehicle have low power or slow acceleration Yes Go to 5 1 Low Power Slow Acceleration page 74 No if equipped with Power Takeoff PTO Go to Step 5 NOTE No...

Page 42: ...38 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 6 0 Cooling System Operational Checkout Procedure...

Page 43: ...1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 39 7 0 Lube Oil System Operational Checkout Procedure...

Page 44: ...Vehicle Operational Checkout Procedure page 23 Step 2 Determine if engine has a fuel delivery problem Decision Perform Fuel Delivery Pressure FDP Test page 2273 Is fuel pressure between 60 and 100 psi...

Page 45: ...ne Compression Brake Switch SPN 4287 Engine Compression Brake Pressure ECBP Does EST DTC list have any of the above listed SPN Yes Go to Fault Code Diagnostics for appropriate SPN No Perform 0 to 60 M...

Page 46: ...Did you perform 1 0 Preliminary Vehicle Operational Checkout Procedure Yes Go to Step 2 page 42 No Go to 1 0 Preliminary Vehicle Operational Checkout Procedure page 23 Step 2 Determine if parked rege...

Page 47: ...y etc ECM ground circuit Low Battery Voltage Faulty ECM Test Procedure Step 1 Perform preliminary operational checkout procedure Decision Did you perform 1 0 Preliminary Vehicle Operational Checkout P...

Page 48: ...ermine if Engine Control Module ECM ground circuits are working properly Decision A Key Off B Connect Breakout Harness 00 00959 01 to ECM 76 pin gray chassis connector and ECM C Connect Breakout Harne...

Page 49: ...re voltage between battery positive and ECM PWR relay pin 85 Is voltage between pin 85 and battery positive within 0 5V of battery voltage Yes Go to Step 10 No Go to Step 8 Step 8 Determine if ECM MPR...

Page 50: ...een ECM and Diagnostic Connector are Open or have high resistance Decision A Key Off B Disconnect Batteries C Measure resistance between 9 pin Diagnostic Connector pin D and ECM pin C 62 CAN L D Measu...

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