Table of Contents - Quality Service Manual

1 engine Service MANUALIT able of engine on engine Geometry Turbocharger (VGT)..107 Exhaust Gas Recirculation (EGR) , Inlet, and Exhaust and High-pressure Oil Logic engine Compressor and Power Steering System Module 213 Oil Pan and Oil Suction Cover, Cooling System, and Related Head and Valve and Flywheel , Crankshaft, and and A - B - all safety instructions in the "Safety Information" section of this Manual before doing any all warnings, cautions, and notes. April 2011 Navistar, Inc. All rights reservedIIENGINE Service MANUALA ppendix C - Special Service all safety instructions in the "Safety Information" section of this Manual before doing any all warnings, cautions, and notes.

2 April 2011 Navistar, Inc. All rights reservedENGINE Service MANUAL1 ForewordNavistar, Inc. is committed to continuous researchand development to improve products and introducetechnological advances. Procedures, specifications,and parts defined in published technical serviceliterature may be Manualprovides a general sequenceof procedures for out-of-chassis engine overhaul(removal, inspection, and installation). For in-chassisservice of parts and assemblies, the sequence :Photo illustrations identify specific parts orassemblies that support text and procedures; otherareas in photo illustrations may not be vehicle manuals and Technical ServiceInformation (TSI)

3 Bulletins for additional Service Literature1171939R3 maxxforce DT,9,and10 EngineOperation and MaintenanceManualEGES-335-1 maxxforce DT,9,and10 EngineService ManualEGES-370-1 maxxforce DT,9,and10 EngineDiagnostic ManualEGED-375 maxxforce DT, 9, and 10 HardStart/ No Start Diagnostic FormEGED-380 maxxforce DT, 9, and 10 Performance Diagnostic FormEGED-385 maxxforce DT, 9, and 10 Electronic Control Systems FormTechnical Service Literature is revised periodicallyand mailed automatically to Revision Service subscribers. If a technical publication is ordered, thelatest revision will be :To order technical Service literature, contactyour Navistar all safety instructions in the "Safety Information" section of this Manual before doing any all warnings, cautions, and notes.

4 April 2011 Navistar, Inc. All rights reserved2 engine Service MANUALS ervice DiagnosisService diagnosis is an investigative procedure thatmust be followed tofind and correct an engineapplication problem or an engine the problem is engine application, see specificvehicle manuals for further diagnostic the problem is the engine , see specificEngineDiagnostic Manualfor further diagnostic for Effective Diagnosis Availability of gauges and diagnostic testequipment Availability of current information for engineapplication and engine systems Knowledge of the principles of operation forengine application and engine systems Knowledge to understand and do procedures indiagnostic and Service publicationsTechnical Service Literature required for EffectiveDiagnosis engine Service Manual engine Diagnostic Manual diagnostics Forms Electronic Control Systems diagnostics Forms

5 Service BulletinsEGES-335-2 Read all safety instructions in the "Safety Information" section of this Manual before doing any all warnings, cautions, and notes. April 2011 Navistar, Inc. All rights reservedENGINE Service MANUAL3 Safety InformationThis Manual provides general and specificserviceprocedures essential for reliable engine operation andyour safety. Since many variations in procedures,tools, and Service parts are involved, advice for allpossible safety conditions and hazards cannot safety instructions before doing any Service andtest procedures for the engine or vehicle.

6 See relatedapplication manuals for more for Safety Instructions, Warnings, Cautions,and Notes in this Manual can lead to injury, death ordamage to the engine or TERMINOLOGYT hree terms are used to stress your safety and safeoperation of the engine : Warning, Caution, andNoteWarning: A warning describes actions necessarytoprevent or eliminate conditions, hazards, and unsafepractices that can cause personal injuryor : A caution describes actions necessaryto prevent or eliminate conditions that can causedamage to the engine or : A note describes actions necessaryforcorrect,efficient engine INSTRUCTIONSV ehicle Make sure the vehicle is in neutral, theparkingbrake is set, and the wheels are blocked beforedoing any work or diagnostic procedures on theengine or area Keep work area clean, dry, and organized.

7 Keep tools and parts off thefloor. Make sure the work area is ventilated and well lit. Make sure afirst aid kit is equipment Use correct lifting devices. Use safety blocks and 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 prevention Make sure chargedfire extinguishers are in thework :Check the classification of eachfireextinguisher to ensure that the followingfire Type A Wood, paper, textiles, and rubbish2.

8 Type B Flammable liquids3. Type C Electrical equipmentBatteriesBatteries produce highlyflammable gas during andafter charging. Always disconnect the main negative batterycablefirst. Always connect the main negative battery cablelast. Avoid leaning over batteries. Protect your eyes. Do not expose batteries to openflames or sparks. Do not smoke in 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 all safety instructions in the "Safety Information" section of this Manual before doing any all warnings, cautions, and notes.

9 April 2011 Navistar, Inc. All rights reserved4 engine Service MANUALT ools Make sure all tools are in good condition. Make sure all standard electrical tools aregrounded. Check for frayed power cords before using under pressure Use extreme caution when working on systemsunder pressure. Follow approved procedures Do not overfill the fuel tank. Overfill creates afirehazard. Do not smoke in the work area. Do not refuel the tank when the engine is of tools, parts, and equipment Reinstall all safety guards, shields, and coversafter servicing the engine .

10 Make sure all tools, parts, and Service equipmentare removed from the engine and vehicle after allwork is all safety instructions in the "Safety Information" section of this Manual before doing any all warnings, cautions, and notes. April 2011 Navistar, Inc. All rights reservedENGINE SYSTEMS5 Table of ContentsEngine Serial Emission Accessory Mounted Component Management Management Air Cooler (CAC)..17 Exhaust Gas Recirculation (EGR) Geometry Turbocharger (VGT)..20 Aftertreatment (AFT) Management Oil Closed Loop Control Supply Supply System Lubrication Cooling System System Heater (optional).