Section 5 - Maintenance Schedule and Service Procedures

SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES
Maintenance Schedule
NOTE: No maintenance is required on the Doser Injector,
because it is not a serviceable component. Failed parts
should be replaced, not serviced. The Doser is warranted
under base mechanical and or emission warranty.
MaxxForce® DT, 9, 10 and N9, N10 Diesel Engines

Service operation interval - which ever comes first: miles/kilometers, months, years, hours, or liters/gallons of fuel
Service Interval Service Operation
See service procedures in this section for more information.
Before Engine Operation Check engine oil level.
Check coolant level.
Drain water separator.1
Inspect Charge Air Cooler (CAC).
Check for external leaks.
Check air restriction indicator.
Engine oil drain, engine oil filter and centrifuge Change engine oil and filter
filter change intervals based on engine family Change centrifuge filter. See Centrifuge Filter (page 77)
and fuel consumption. See Engine Oil and Filter
(page 72).
15,000 miles (24,140 km) Inspect belt, air intake piping, and clamps.
6 months, 550 hours Check coolant freeze point.
7949 liters (2,100 gallons) of fuel
Page 63
MaxxForce® DT, 9, 10 and N9, N10 Diesel Engines (cont.)

30,000 miles (48,300 km) Change fuel filter.
12 months, 1,100 hours Clean or change fuel strainer.
15,898 liters (4,200 gallons) of fuel
Annually Inspect electrical system.
120,000 miles (193,000 km) Inspect vibration damper.

5,000 hours Adjust engine valve lash.
Adjust engine brake lash (if equipped).
24 months Pressurize air induction system.
150,000 miles (240,000 km) Add Extended Life Coolant (ECL) Extender to ELC maintained systems.
30 months, 6,000 hours
180,000 - 200,000 miles Measure crankcase pressure.

(290,000 - 322,000 km) Inspect sequential turbochargers.
6,700 - 7,500 hours
Page 64
MaxxForce® DT, 9, 10 and N9, N10 Diesel Engines (cont.)

2
200,000 miles (322,000 km) Cleaning Diesel Particulate Filter (DPF)
30 months, 6,000 hours
200,000 miles (322,000 km) or 6,500 hours Diesel Exhaust Fluid (DEF) Supply Module Filter- Replace
300,000 miles (500,000 km) Service cooling system3.
5 years, 12,000 hours
1 Drain water separator Daily.

2 Reduced service interval required if allowed CI-4 engine lubrication oil is used. If using CI-4 oil, reduce DPF cleaning interval to 240,000 km
(150,000 miles) 22 months, or 4,500 hours.
3 For Extended Life Coolants (ELC). Coolant service intervals are more frequent with conventional coolants.
Page 65
Service Procedures
GOVERNMENT REGULATION: Engine fluids Figure 29 Oil level gauge (typical)

(oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and
other contaminated materials (e.g. filters, rags) in CAUTION: To prevent engine damage do the following:
accordance with applicable regulations. Recycle • Assure oil level readings are within the crosshatched
or dispose of engine fluids, filters, and other operating range on the oil level gauge.
contaminated materials according to applicable
regulations. • Do not overfill the engine with oil.
• Do not operate engine if oil level is above or below the
operating range.
WARNING: To prevent personal injury or death, shift 4. If oil level is below operating range, fill with recommended
transmission to park or neutral, set parking brake, and block oil for operating climate. The ADD mark indicates 2.8 liters
wheels before doing diagnostic or service procedures. (3 quarts US) of oil should be added. See Engine Oil Quality
and Service Categories(page 34).
OIL LEVEL
Service Interval: Before Engine Operation

1. Park vehicle on level ground.
NOTE: Do not check oil level if engine is running or

immediately after engine shutdown.
2. Shut down engine and wait 5 minutes.
3. Remove oil level gauge from fill tube.
Page 66
Service Procedures (cont.)

COOLANT LEVEL NOTE: Never add ELC to the expansion tank. Only add ELC
to the coolant tank.
1. Park vehicle on level ground, set the parking brake, and shut
GOVERNMENT REGULATION: Engine fluids down the engine.
(oil, fuel, and coolant) may be a hazard to human 2. Check coolant level in the opaque plastic coolant tank.
other contaminated materials (e.g. filters, rags) in • Coolant level should be at midpoint of ADD and MAX.
accordance with applicable regulations. Recycle • If coolant level is below the ADD mark, continue with
or dispose of engine fluids, filters, and other step 3.
regulations.
WARNING: To prevent personal injury or death, do the
following when removing the radiator cap or coolant tank
cap:
WARNING: To prevent personal injury or death, shift
• Allow the engine to cool for 15 minutes or more.
transmission to park or neutral, set parking brake, and block
wheels before doing diagnostic or service procedures. • Wrap a thick cloth around the radiator cap or coolant tank
cap.
• Loosen cap slowly a quarter to half turn to vent pressure.
Extended Life Coolant (ELC) 50/50 Premix is the standard
factory fill for the cooling system. ELC 50/50 Premix is • Pause for a moment until all pressure has escaped to avoid
used to replenish coolant loss and ensure that glycol / water being scalded by steam.
concentrations stay in balance. If a customer wishes to use a
• Continue to turn cap counterclockwise to remove.
conventional (non-OAT ELC) coolant, it should minimally meet
ASTM D6210, Standard Specification for fully - Formulated 3. Add ELC 50/50 Premix to the correct coolant level (midpoint
Glycol Base Engine Coolant for Heavy Duty Engines. of ADD and MAX).
4. Install and tighten coolant tank cap until the plastic cap clicks
or the metal caps runs up against the detent.
Page 67

WATER SEPARATOR
GOVERNMENT REGULATION: Engine fluids

other contaminated materials (e.g. filters, rags) in
accordance with applicable regulations. Recycle
or dispose of engine fluids, filters, and other
regulations.
WARNING: To prevent personal injury or death, do not Figure 30 Fuel filter header assembly
smoke and keep fuel away from flames and sparks. 1. Electric fuel pump
2. Fuel filter cover
WARNING: To prevent personal injury or death, store 3. Exhaust Gas Recirculation (EGR) valve
diesel fuel properly in an approved container designed for 4. Oil fill tube
and clearly marked DIESEL FUEL. 5. Water drain valve
1. If necessary, connect a hose to the end of the water drain

valve.
Page 68

WATER SEPARATOR (cont.)
2. Put a suitable container under water drain valve or drain CHARGE AIR COOLER (CAC)
hose.
3. Turn ignition switch to ON. This will start the electric fuel
pump. Do not start engine.
WARNING: To prevent personal injury or death, shut
NOTE: The water/fuel mixture will drain slowly and may take down engine, set parking brake, and block wheels before
up to a minute to attain pure fuel flow. inspecting the Charge Air Cooler.
4. Turn water drain valve to open and allow water/fuel mixture 1. Inspect Charge Air Cooler (CAC) core for debris, damaged,
to drain. Continue draining until only fuel is draining. and clogged external fins.
2. Before starting engine remove any debris blocking the core.
NOTE: Fuel will only drain from the water drain valve as long
as the electric fuel pump is running. The electric fuel pump
can run any where from 10 to 20 seconds. Do not turn the
ignition switch to OFF then ON again without waiting the 10
seconds. If the 10 seconds waiting period is not observed,
the electric fuel pump will not restart.
5. Fuel will only flow as long as the fuel pump is running. If
additional fuel pump run time is desired, turn the ignition
switch to OFF, wait 10 seconds then turn the ignition switch
to ON to continue draining water.
6. Once fuel-water draining is complete, close water drain
valve and turn the ignition switch to OFF.
7. Recycle or dispose of drained fluids properly according to
applicable regulations.
Page 69

EXTERNAL LEAKAGE AIR CLEANER RESTRICTION
Service Interval: Before Engine Operation Service Interval: Before Engine Operation
WARNING: To prevent personal injury or death, shut

down engine, set parking brake, and block wheels before
inspecting for external leakage.
1. Check for the following:
• Cracked hoses
• Loose clamps
• Coolant stains
• Oil stains
• Fuel stains
• Leakage at water pump (wetness from the weep hole is
normal)
2. Correct problems.
Figure 31 Air cleaner restriction indicator
Push reset button to check air restriction indicator. If the air

filter was not changed, the yellow indicator will return to the
Page 70

AIR CLEANER RESTRICTION (cont.)
same reading when the vehicle is driven under normal driving

conditions.
If the yellow position indicator has locked in the red zone, a
new air filter should be installed to prevent low engine power
or engine damage.
1. Remove restricted air filter element and discard.
CAUTION: To prevent engine damage, do not use compressed

air to clean filter housing.
2. Use a clean water-dampened cloth to clean inside of air filter
housing.
3. Inspect air filter housing for damage or distortion. Install new
housing if necessary.
4. Install a new air filter element.
5. Push reset button on air restriction indicator. The yellow
indicator will return to zero.
Page 71

ENGINE OIL AND FILTER MaxxForce® DT Diesel Engine With Less Than or Equal to
230 Horsepower (Without Centrifuge Filter)
WARNING: To prevent personal injury or death, wear Average Vehicle Speed
safety glasses and avoid moving components such as fans,
Fuel Economy (mpg) Less than or equal More than 30 mph
pulleys, and belts when taking an engine oil sample.
to 30 mph (48 kmpl) (48 kmpl)
Engine oil sampling can be utilized for the following:
Engine Oil Sampling - Optional 25,000 miles
More than 8.5 825 hours
(40,234 km)
1. Determine oil change interval based upon fuel
consumption and specific engine application. 4.5 to 8.5 700 hours See Figure 33
2. Catch contaminates which, if left unattended, may result 10,000 miles

Less than 4.5 600 hours
in engine failure. (16,093 km)
Service Interval (based upon fuel consumption and specific

MaxxForce® DT Diesel Engine With Less Than or Equal to
engine application):
230 Horsepower (With Centrifuge Filter)
See charts for specific engine family and service interval.
Average Vehicle Speed
CAUTION: To prevent engine damage, do not extend Fuel Economy (mpg) Less than or equal More than 30 mph
recommended oil change intervals. to 30 mph (48 kmpl) (48 kmpl)
30,000 miles (48,300
More than 8.5 1,000 hours
km)
4.5 to 8.5 800 hours See Figure 33
12,500 miles (20,117
km)
Page 72

ENGINE OIL AND FILTER (cont.)
MaxxForce® DT, 9, and 10 Diesel Engines With Greater

Than 230 Horsepower (Without Centrifuge Filter)
Fuel Economy (mpg) Less than or equal More than 30 mph
to 30 mph (48 kmpl) (48 kmpl)
20,000 miles (32,187
km)
6,000 miles (9,656
km)
MaxxForce® DT, 9, and 10 Diesel Engine With Greater Than

230 Horsepower (With Centrifuge Filter)
Fuel Economy Less than or equal More than 30 mph
(mpg) to 30 mph (48 kmpl) (48 kmpl)
25,000 miles (40,234
km)
4.5 to 8.5 650 hours See Figure 33 Figure 32 Drain intervals for MaxxForce® DT, 9, and 10
applications.
7,500 miles (12,070
km)
Page 73

N9 and N10 Diesel Engine

Fuel Economy Less than or equal More than 30 mph
(mpg) to 30 mph (48 kmpl) (48 kmpl)
27,500 miles (40,234
More than 8.0 –
km)
12,500 miles (20,117
km)
Figure 33 Drain intervals for N9 and N10 applications.
1. Park vehicle on level ground. Set parking brake and shift

transmission to park or neutral.
Page 74

2. Run engine until operating temperature is reached, then shut 4. Discard oil pan drain plug O-ring. Inspect the oil pan drain
down engine. plug. If it is free of defects, it can be reused. Replace if
necessary.
5. Using clean engine oil, lubricate a new oil pan drain plug
GOVERNMENT REGULATION: Engine fluids O-ring. Put O-ring onto the oil pan drain plug.
(oil, fuel, and coolant) may be a hazard to human 6. Install oil pan drain plug and tighten to 68 N·m (50 lbf·ft).
other contaminated materials (e.g. filters, rags) in 7. Recycle or dispose of oil according to applicable regulations.
regulations.
WARNING: To prevent personal injury or death, wear

protective clothing when draining hot oil.
WARNING: To prevent personal injury or death, do not

let engine fluids stay on your skin. Clean skin and nails
using hand cleaner and wash with soap and water. Wash or
discard clothing and rags contaminated with engine fluids.
3. Place a drain pan under the oil pan drain plug, remove oil
pan drain plug, and drain oil.
Page 75

10. Lubricate new oil filter gasket with clean engine oil.
CAUTION: To prevent engine damage, install the correct oil filter

for the engine application.
11. Install new oil filter.
• Standard oil filter (long)
• Front drive/steering axle oil filter (shorter)
CAUTION: To prevent engine damage, do not overtighten filter.

12. Hand tighten filter 2/3 to 1 full turn after gasket first contacts
oil filter header.
CAUTION: To prevent engine damage, do not overfill with oil.

13. Add engine oil with the correct oil viscosity and formulation.
Figure 34 Oil cooler module assembly API CJ-4 oil is recommended but CI-4 is allowable. Use of
CI-4 oils will reduce DPF cleaning interval, see Maintenance
1. Oil cooler housing Schedule (page 63). Add oil through the engine oil fill tube.
2. Oil cooler
3. Oil filter
8. Put drain pan under oil filter.

Figure 35 Oil level gauge (typical)
9. Remove old oil filter and recycle or dispose of according to
applicable regulations.
Page 76

14. Check oil level gauge. Oil level must be within the The centrifuge filter (if equipped) is located in one of the following
crosshatched operating range. positions:
15. Start engine and run at low idle. • On the right side of the engine compartment. It is
recommended to change the centrifuge filter every time the
16. Check reading on oil pressure gauge.
engine oil filter is changed. For safety information, refer to
• Minimum lube oil pressure is 15 psi (103 kPa) minimum the your Engine Operation and Maintenance Manual and
@ 700 rpm. Vehicle Operator Manual.
• If there is no gauge reading, shut engine down • In the engine compartment. It is recommended to change
immediately. Check for oil filter leaks. the centrifuge filter every time the engine oil and filter is
changed. See Engine Oil and Filter (page 72) for specific
• Let engine run until operating temperature is reached.
service intervals. For safety information, refer to the your
Check for leaks.
Engine Operation and Maintenance Manual and Vehicle
17. Shut down engine for 15 minutes. Operator Manual.
CAUTION: To prevent engine damage, do not overfill with oil.

18. Recheck oil level and add oil to bring oil level within the upper
half of the crosshatched operating range on oil level gauge. GOVERNMENT REGULATION: Engine fluids
CENTRIFUGE FILTER (IF EQUIPPED) health and the environment. Handle all fluids and
Service Interval (based upon fuel consumption and specific accordance with applicable regulations. Recycle
engine application): or dispose of engine fluids, filters, and other
regulations.
Page 77

CENTRIFUGE FILTER (IF EQUIPPED) (cont.)

protective clothing when draining hot oil.

1. Park the vehicle on level ground. Set the parking brake and
shift the transmission to park or neutral.
2. Before attempting to open the centrifuge oil filter, wait two
minutes to assure the rotor has stopped spinning.
NOTE: When separating the cover assembly from the body

assembly, it may be necessary to insert a coin or flat blade
screwdriver in to the gap to start the separation.
3. Turn the band clamp handle counter clockwise until the tee
bolt head can be disengaged. Remove band clamp.
4. Remove the cover and rotor assembly from the body Figure 36 Centrifuge filter assembly
assembly.
1. Cover assembly
2. Band clamp handle
3. Body assembly
4. Band clamp
Page 78

5. Remove and discard O-ring.

6. Remove the rotor and allow the oil to drain out of it before
discarding. Dispose of the rotor according to applicable
regulations.
7. Clean and inspect the cover assembly. Clean the O-ring
groove in the cover assembly and mating surface.
8. Inspect the bearings in the cover and body assemblies.
Make sure both assemblies are free of debris.
9. Lubricate a new O-ring with clean engine oil and insert in to
the groove of the cover assembly.
10. Insert a new rotor assembly into the cover assembly and
firmly press until it seats.
11. Insert the rotor inlet with the bearing in the body assembly.
Press the cover and body assemblies together.
12. Position the band clamp over the cover and body flanges.
Engage the tee bolt and turn the band clamp handle and
tighten securely.
Figure 37 Centrifuge rotor
13. Start the engine and check all connections for leaks.
1. O-ring
2. Rotor • If no leaks are observed, shutdown engine.
3. Body assembly
Page 79

• If leaks are observed, shutdown engine and correct

leaks. Start engine again and observe for leaks. If no
leaks are observed, shutdown engine.
RESETTING CHANGE ENGINE OIL SERVICE INTERVAL

MESSAGE
Reset the Service Interval Message (change engine oil) per the
following procedure:
1. If not already done, set the parking brake.
2. Turn ignition switch to ON.
3. Turn cruise ON.
4. Turn cruise OFF.
5. Turn cruise ON.
6. Very rapidly push the resume switch four times and then hold
down on the fifth time for four seconds.
7. The Change Oil message should clear.
8. The operation from the time the cruise is turned ON for
the second time to the fifth activation of the resume switch
must take place within six seconds. If you fail to reset the
message, repeat the process.
Page 80

BELT, AIR INTAKE PIPING AND CLAMPS Inspect condition of all drive belts. For any of the following
conditions install a new belt:
Service Interval: 15,000 miles (24,000 km), 6 months, or 550
hours • Excessive wear
• Missing material
• Grease or oil contamination
• Over three cracks per inch in a belt rib
Belt Removal
1. Attach a 1/2 inch drive breaker bar to square hole in auto
tensioner.
2. Pull the breaker bar clockwise and remove the belt from
the auto tensioner pulley and other pulleys.
3. Slowly release the breaker bar; the auto tensioner
Figure 38 Cracks in belt ribs automatically adjusts.
1. Belt in good condition 4. Remove the breaker bar.

2. Belt ready for replacement
3. Belt ribs
4. Cracks in belt
Page 81

BELT, AIR INTAKE PIPING AND CLAMPS (cont.)
Belt Installation
1. Attach a 1/2 inch drive breaker bar to square hole in auto
tensioner.
2. Pull the breaker bar clockwise and install the belt over
the auto tensioner pulley and other pulleys.
3. Slowly release the breaker bar; the auto tensioner
automatically adjusts.
4. Remove the breaker bar.
Air Intake Piping and Clamps
Inspect hoses, pipes, and clamps. For any of the following
conditions, install new parts:
• Loose hoses or clamps, tighten or replace as required.
• Ruptured hoses
• Cracked air cleaner housing
Figure 39 Square hole in auto tensioner
Page 82

COOLANT FREEZE POINT For vehicles operating in extremely cold climates, a coolant
mixture of 60% Concentrate and 40% water or 67% Concentrate
Service Interval: 15,000 miles (24,000 km), 6 months, or 550 and 33% water provide additional freeze protection as shown in
hours the table above. Mixtures having more than 67% Concentrate
ELC 50/50 Premix provides freeze protection to -36 °C (-34 °F) are not recommended due to the risk of additive fallout.
and maximum corrosion protection. If a customer wishes to use Check freeze point with a refractometer.
a conventional (non-OAT ELC) coolant, it should minimally meet
ASTM D6210, Standard Specification for fully - Formulated 1. Put drop of coolant on refractometer window.
Glycol Base Engine Coolant for Heavy Duty Engines. ELC 2. Look through eyepiece and focus.
50/50 Premix is used to replenish coolant loss and ensure that
glycol/water concentrations stay in balance. 3. Record freeze point.
ELC 50/50 Extender is added at the designated service interval. 4. Adjust coolant concentration as necessary to achieve
desired freeze point protection.
Freeze Point Protection Levels Concentrate (ethylene
glycol) and Water Mixtures FUEL FILTER
Concentrate and Water Freeze Point Protection Service Interval: 30,000 miles (43,300 km), 12 months, 1,100
Mixtures hours or 4200 gallons (15898 liters) of fuel
40% Concentrate and 60% -12 °F (-24.4 °C)
water
NOTE: Change fuel filter, if optional fuel filter lamp is
illuminated.
water NOTE: If fuel used has more than average impurities,
60% Concentrate and 40% -62 °F (-52.0 °C) shorter service intervals may be required.
water
water
Page 83

FUEL FILTER (cont.)
GOVERNMENT REGULATION: Engine fluids

regulations.
WARNING: To prevent personal injury or death, store

diesel fuel properly in an approved container designed for
and clearly marked DIESEL FUEL.
CAUTION: To prevent engine damage, do not add fuel to the

fuel filter housing; this can add contaminants to the fuel.
Figure 40 Fuel filter header assembly
1. Electric fuel pump
3. Exhaust Gas Recirculation (EGR) valve
4. Oil fill tube
5. Water drain valve
Page 84

FUEL FILTER (cont.)
1. Set parking brake and shift transmission to park or neutral. 4. Using a 23 mm wrench, loosen the fuel filter cover
counterclockwise three and one-half turns to expose the
vent hole below O-ring.
WARNING: To prevent personal injury or death,
make sure that the engine has cooled before removing 5. If necessary, attach a hose to the end of the water drain
components. valve.
2. Turn ignition switch to OFF and allow engine to cool before 6. Put a suitable container under the water drain valve.
removing components.
7. Open water drain valve and drain the fuel filter assembly.
8. Close water drain valve.
safety glasses with side shields. Limit compressed air 9. Recycle or dispose of fuel according to applicable
pressure to 207 kPa (30 psi). regulations.
CAUTION: To prevent engine damage, clean area around fuel

filter housing before removing fuel filter cover. This will protect
the open fuel filter housing from contaminants falling into the
housing. If contaminants do fall in, remove them and blow out
fuel filter housing with compressed air before installing a new
filter element. Contaminants reaching high-pressure fuel system
components may cause component failure.
3. Clean engine compartment components in the area of the
fuel filter housing using compressed air, before removing
the fuel filter cover. Also, wipe the fuel filter cover clean
to prevent contaminants from entering the fuel system.
Contaminants may cause engine failure.
Page 85

FUEL FILTER (cont.)
10. Continue turning the fuel filter cover until loose. Remove the
fuel filter cover and element from the fuel filter housing.
11. Remove the fuel filter cover from the fuel filter element by
holding the element vertically and pushing up on the cover.
The cover will snap off the fuel filter element. Dispose of the
fuel filter element according to applicable regulations.
12. Remove O-ring from the fuel filter cover. Discard O-ring.
13. Coat a new fuel filter O-ring for the fuel filter cover with clean
diesel fuel and install onto the fuel filter cover.
14. Attach fuel filter cover to the fuel filter element. Secure the
fuel filter cover to the fuel filter element by pushing the fuel
filter cover onto the fuel filter element. The fuel filter cover
will snap onto the fuel filter element.
15. Coat threads of fuel filter cover with clean diesel fuel.
16. Install a fuel filter element with cover into the fuel filter
Figure 41 Fuel filter removal and installation housing. Slowly lower the fuel filter element into the fuel
filter housing, until fuel filter cover is ready to be secured to
2. Exhaust Gas Recirculation (EGR) valve
the fuel filter housing.
3. Water drain valve 17. Secure the fuel filter cover and element to the fuel filter
4. Fuel pump (fuel strainer location) housing by turning the fuel filter cover clockwise until
5. Fuel filter element finger-tight.
6. Fuel filter cover O-ring
Page 86

FUEL FILTER (cont.)
CAUTION: To prevent engine damage, tighten fuel cover on fuel FUEL STRAINER
filter assembly.
Service Interval: 30,000 miles (43,300 km), 12 months, 1,100
18. Using a 23 mm wrench tighten fuel filter cover to 30 N·m (22 hours or 15898 liters (4200 gallons) of fuel
lbf·ft).
19. Depress clutch pedal if equipped. NOTE: If fuel used has more than average impurities,
shorter service intervals may be required.
20. Turn the ignition switch to ON for approximately 60 seconds,
allowing the fuel pump to prime the fuel system. See Priming NOTE: The fuel strainer is located under the electric fuel
the Fuel System (page 50). pump. The pump must be disconnected from the engine
21. Wait for the WAIT TO START lamp to stop illuminating. wiring harness and removed from the fuel filter housing for
Do not crank engine until the lamp is off. When the WAIT the fuel strainer to be cleaned or replaced. See following
TO START lamp goes off, turn ignition switch to START. If procedure.
the vehicle has push button starting, press and hold starter
button. WARNING: To prevent personal injury or death, do not
22. When the engine starts, release the ignition switch or starter smoke and keep fuel away from flames and sparks.
button. The ignition switch will return to ON and the engine
will continue to run. Check for leaks. Turn the ignition switch
to OFF.
Page 87

FUEL STRAINER (cont.)
1. Set parking brake and shift transmission to park or neutral.

2. Disconnect the wiring harness to the electric fuel pump by
pushing down on the tab of the wiring harness connector
and pulling away from the electric fuel pump.
Figure 42 Electric fuel pump and fuel strainer location

1. Electrical fuel pump wiring harness connector
2. Fuel filter cap
3. Fuel filter housing
Page 88

3. Remove three pump cover bolts. Do not discard bolts, these

will be reused when installing the fuel pump.
4. Using a flat blade screw driver gently pry up the fuel pump
from the fuel filter housing.
5. Once the fuel pump is loose, pull the fuel pump out of the
fuel filter housing.
6. Remove the fuel strainer and O-rings from the fuel pump.
Discard the O-rings.
7. Do one of the following:
• If fuel strainer is not damaged - clean fuel strainer,
coat two new O-rings with clean diesel fuel, and install
O-rings onto fuel pump.
• If strainer is damaged - coat two new O-rings with clean
diesel fuel, and install O-rings onto fuel pump. Install a
new fuel strainer onto the fuel pump.
8. Lower fuel pump assembly (with strainer) into the fuel filter
housing. Align the three bolt holes in the fuel pump cover
Figure 43 Fuel strainer with the bolt threads of the fuel filter housing. Place palm
1. Pump cover bolt (3) of hand on top of fuel pump and push down firmly. This will
2. Electric fuel pump seat the fuel pump into the fuel filter housing.
3. Fuel pump O-ring (2) 9. Secure the fuel pump to the fuel filter housing by installing
4. Fuel strainer and tightening the three pump cover bolts to 5 N·m (44 lbf·in).
5. Fuel filter housing
Page 89

10. Depress clutch pedal if equipped. ELECTRICAL SYSTEM

11. Turn ignition switch to ON for approximately 60 seconds Service Interval: Annually
allowing fuel pump to prime the fuel system.
1. Check wiring harness for cracks, rubbing, and loose
12. Start the engine and check for leaks. See Starting the connections.
Engine (page 50).
2. Check sensors for loose connections, corrosion or cracks.
13. Check for leaks. If leaks are found, shutdown the engine
and correct the problem. 3. Check battery cables for the following conditions:
14. Once leaks are fixed or no leaks are found, shutdown the • Broken insulation.
engine. • Rubbing or chaffing.
• Corroded or loose connections.
4. Repair items identified.
Electronics
Check for diagnostic fault codes and repair as required. After
repairs are made, clear fault codes and verify they do not
reappear. For correct procedures, see the applicable Engine
Diagnostic Manual or contact an authorized service provider.
Page 90

VIBRATION DAMPER ENGINE BRAKE LASH
Service Interval: 120,000 miles (193,000 km) or 5,000 hours Service Interval: 120,000 miles (193,000 km) or 5,000 hours
Have the vibration damper inspected by an authorized service • For inspection procedures, see the applicable Engine
provider for deterioration of rubber, dents, and runout. Service Manual.
• Have an authorized service provider adjust the valve lash at
ENGINE VALVE LASH
the correct service interval.
Service Interval: 120,000 miles (193,000 km) or 5,000 hours
INDUCTION SYSTEM
• For inspection procedures, see the applicable Engine
Service Manual. Service Interval: 24 months
• Have an authorized service provider adjust the valve lash at Pressure test the air induction system.
the correct service interval.
• For inspection procedures, see the applicable Engine
Diagnostic Manual.
• Have an authorized service provider pressure test the air
induction system.
Page 91

EXTENDED LIFE COOLANT (ELC) EXTENDER ELC Extender
Service Interval: 150,000 miles (240,000 km), 30 months or Cooling System Drain ELC Coolant Add ELC Extender
6,000 hours Capacity
22-30 liters (6-8 0.2 liter (0.5 quart 0.2 liter (0.5 quart
gallons) US) US)
following when removing the radiator cap or coolant tank 30-49 liters (8-13 0.5 liter (1.0 quart 0.5 liter (1.0 quart
cap: gallons) US) US)
• Allow the engine to cool for 15 minutes or more. 49-83 liters (13-22 0.7 liter (1.5 quart 0.7 liter (1.5 quart
gallons) US) US)
• Wrap a thick cloth around the radiator cap or coolant tank
cap.
NOTE: ELC 50/50 Premix is the standard factory fill for the
• Loosen cap slowly a quarter to half turn to vent pressure. cooling system. ELC 50/50 Premix is used to replenish
• Pause for a moment to avoid being scalded by steam. coolant loss and ensure that glycol/water concentrations
stay in balance. If a customer wishes to use a conventional
• Continue to turn cap counterclockwise to remove. (non OAT ELC) coolant, it should minimally meet ASTM
D6210, Standard Specification for fully - Formulated Glycol
1. Remove coolant tank cap. Base Engine Coolant for Heavy Duty Engines. Coolant
service intervals are more frequent with conventional
2. Confirm coolant system capacity. coolants.
3. According to Cooling System Capacity in the ELC Extender 4. Add the same volume of Extender to the cooling system.
table, drain the correct volume of coolant from the cooling
system. 5. Install and tighten the coolant tank cap until the plastic cap
clicks or the metal cap runs up against the detent.
Page 92

CRANKCASE PRESSURE CLEANING DIESEL PARTICULATE FILTER
Service Interval: 180,000 - 200,000 miles (290,000 - 322,000 For Engine Using CJ-4 Engine Oil
km) or 6,700 - 7,500 hours
Service Interval: 200,000 miles (322,000 km) 30 months or
• For inspection procedures, see theapplicableEngine 6,000 hours
Diagnostic Manual.
Clean DPF at designated service interval. The ECM will
• Have an authorized service provider measure the crankcase illuminate the MIL and generate an Ash Servicing Required
pressure at the correct service interval. message on the integral digital display at or if necessary before
the specified interval. Take vehicle to your Navistar certified
TURBOCHARGERS dealer for cleaning.
Service Interval: 180,000 - 200,000 miles (290,000 - 322,000 For Engines Using CI-4 Engine Oil
km) or 6,700 - 7,500 hours Service Interval: 150,000 miles (241,000 km) 22 months or
1. Clean, then remove the turbocharger compressor inlet 4,500 hours
connections for both turbochargers. Clean DPF at designated service interval. Take vehicle to an
2. Inspect the compressor wheels for the following: authorized service provider for cleaning.
• Dirt or corrosion
• Wheel rub damage
• Wheel blade damage (bent or broken tips)
3. Check condition of turbochargers. (Consult with an
authorized service provide if questionable.)
Page 93

SERVICE COOLING SYSTEM 1. Park vehicle on level ground. Set parking brake and shift
transmission to park or neutral.
Service Interval for Extended Life Coolant: 300,000 miles
(500,000 km ) or 12,000 hours 2. Place a drain pan under the radiator.
3. Remove coolant tank cap.
WARNING: To prevent personal injury or death, shift 4. Place coolant drain pan under radiator drain valve and open
transmission to park or neutral, set parking brake, and block radiator drain valve to drain coolant.
wheels before doing diagnostic or service procedures.
5. After radiator has drained, close the drain valve and move
the drain pan beneath the oil system module.

cap:
• Wrap a thick cloth around the radiator cap or coolant tank
cap.
• Loosen cap slowly a quarter to half turn to vent pressure.
• Pause for a moment to avoid being scalded by steam.
• Continue to turn cap counterclockwise to remove.
Figure 44 EGR coolant drain plug
Page 94

SERVICE COOLING SYSTEM (cont.)
6. If the Exhaust Gas Recirculation (EGR) cooler must be 8. After coolant has drained, install the coolant drain plug and
removed from the engine the coolant should be drained tighten to 28 N·m (18 lbf·ft).
before removal. See Engine Service Manual for the removal
and installation procedure.
Figure 45 Coolant drain plug for oil system module
7. Remove coolant drain plug from bottom of oil system

module.
Page 95

SERVICE COOLING SYSTEM (cont.)
NOTE: ELC 50/50 Premix is the standard factory fill for the 15. After engine reaches normal operating temperature and
cooling system. ELC 50/50 Premix is used to replenish the thermostat has opened, allow engine to run for 5 to 10
coolant loss and ensure that glycol/water concentrations minutes, then shut engine off.
stay in balance. If a customer wishes to use a conventional
16. Connect electrical connector at the Exhaust Gas
(non-OAT ELC) coolant, it should minimally meet ASTM
recirculation (EGR) valve. Clear any Diagnostic Trouble
D6210, Standard Specification for fully - Formulated Glycol
Codes (DTC) that may have occurred. See the Engine
Base Engine Coolant for Heavy Duty Engines.
Diagnostic Manual for further information.
9. Slowly fill cooling system with new ELC 50/50 Premix or
Concentrate and water mixture until coolant is at the mid
point between the ADD and FULL levels of the coolant tank.
10. Install and tighten the coolant tank cap until the plastic cap cap:
clicks or the metal cap runs up against the detent.
CAUTION: To prevent engine damage, disconnect electrical • Wrap a thick cloth around the radiator cap or coolant tank
connector at the EGR valve before running engine to purge air cap.
from cooling system. Failure to do so could cause failure of
EGR cooler. • Loosen cap slowly a quarter to half turn to vent pressure.
11. Disconnect electrical connector at the EGR valve. • Pause for a moment to avoid being scalded by steam.
12. Start the engine. • Continue to turn cap counterclockwise to remove.
13. Allow the engine to operate at a fast idle until the engine 17. If necessary, add coolant to the coolant tank to bring the level
reaches normal operating temperature. up to the COLD MAX mark.
14. As the engine warms up, make sure coolant is flowing
through coolant line – the coolant line will feel warm to the
touch.
Page 96
SECTION 6 – LONG TERM STORAGE
General Information • Check the battery charge and recharge if needed.

Disconnect the battery cables between batteries and
To maintain warranty coverage, engines intended to be taken between the batteries and vehicle. If freezing temperatures
out of service or stored 30 days or longer require the following are expected, remove batteries and store in an area with
procedures. these procedures are also recommended for temperature above freezing. If battery removal is not
engines outside of warranty to assure maximum engine life: required (warm climate) maintain the battery charge every
• Maintain a “Full” fuel tank with the addition of diesel fuel 30 days.
stabilizer to minimize microbial growth within the fuel • Test the cooling system, additive levels and coolant freeze
system. Run engine long enough to allow the fuel stabilizer protection. Coolant freeze protection must be set below the
to enter the entire fuel system. If the engine is utilized in a coldest anticipated temperature during storage.
mobile application drive vehicle to mix the stabilizer in the
fuel tank.
• Before storage replace engine fuel filter(s) and drain all
water separators of any water.
• Every 30 days or less, run engine until full operating
temperature has been maintained.
• Before storage, change the engine oil and filter with
the appropriate engine oil for conditions the engine will
experience during storage.
• Cover air intake ducts to prevent moisture and debris
intrusion during storage.
• Cover vertical exhaust stack.
Page 97
SECTION 6 – LONG TERM STORAGE
Page 98
SECTION 7 – SERVICE RECORDS
Maintenance Service Record
WARNING: To prevent personal injury or death, read

all safety instructions in the “Safety Information” section of
this manual.
WARNING: To prevent personal injury or death, shift

Save scheduled maintenance work orders and receipts for proof
of correct maintenance. Failure to maintain work orders and
receipts may affect your warranty coverage.
Page 99
Maintenance Service Record (cont.)

Date Service Month Service Hours Miles (km) Item Serviced
Page 100
Maintenance Service Record (cont.)

Date Service Month Service Hours Miles (km) Item Serviced
Page 101
Daily Care and Report Do the following before engine operation to prevent engine
failure.
WARNING: To prevent personal injury or death, read • Add coolant if necessary. Make sure filler cap seal is in good
all safety instructions in the “Safety Information” section of condition and the cap is installed tightly.
this manual. • Check air cleaner indicator with engine running. When the
yellow position indicator reaches and locks in the red zone,
WARNING: To prevent personal injury or death, shift a new air filter should be installed.
• Fill the fuel tank with correct fuel.
• Drain water from the fuel filter housing.
Check the following before engine operation to prevent engine
failure. Report all problems for immediate service. • Clean external surfaces of the engine, radiator, and
accessories.
• Oil level.
• Oil, air, fuel or coolant leaks.
• Cooling system hoses for leaks
• Coolant system level
• Excessive use of crankcase lubricating oil, coolant, battery
fluid or fuel.
• Unusual engine noise.
• Correct amount of electrolyte, if not a maintenance free
battery.
• Condition of electrical equipment
Page 102
Daily Care and Report (cont.)

Daily Care and Report
Model
Serial No.
Date Miles Fuel Lube Parts Labor Service Performed
Oil
Qty Cost Parts Cost Time Cost
Page 103
Daily Care and Report (cont.)

Daily Care and Report
Model
Serial No.
Date Miles Fuel Lube Parts Labor Service Performed
Oil
Qty Cost Parts Cost Time Cost
Page 104

Section 5 - Maintenance Schedule and Service Procedures

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SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

MaxxForce® DT, 9, 10 and N9, N10 Diesel Engines

MaxxForce® DT, 9, 10 and N9, N10 Diesel Engines (cont.)

Annually Inspect electrical system.

120,000 miles (193,000 km) Inspect vibration damper.

24 months Pressurize air induction system.

180,000 - 200,000 miles Measure crankcase pressure.

MaxxForce® DT, 9, 10 and N9, N10 Diesel Engines (cont.)

1 Drain water separator Daily.

GOVERNMENT REGULATION: Engine fluids Figure 29 Oil level gauge (typical)

Service Interval: Before Engine Operation

NOTE: Do not check oil level if engine is running or

Service Procedures (cont.)

Service Procedures (cont.)

Service Interval: Before Engine Operation

GOVERNMENT REGULATION: Engine fluids

1. If necessary, connect a hose to the end of the water drain

Service Procedures (cont.)

Service Procedures (cont.)

WARNING: To prevent personal injury or death, shut

Figure 31 Air cleaner restriction indicator

Push reset button to check air restriction indicator. If the air

Service Procedures (cont.)

same reading when the vehicle is driven under normal driving

CAUTION: To prevent engine damage, do not use compressed

Service Procedures (cont.)

2. Catch contaminates which, if left unattended, may result 10,000 miles

Service Interval (based upon fuel consumption and specific

Service Procedures (cont.)

MaxxForce® DT, 9, and 10 Diesel Engines With Greater

MaxxForce® DT, 9, and 10 Diesel Engine With Greater Than

Service Procedures (cont.)

N9 and N10 Diesel Engine

Figure 33 Drain intervals for N9 and N10 applications.

1. Park vehicle on level ground. Set parking brake and shift

Service Procedures (cont.)

WARNING: To prevent personal injury or death, wear

WARNING: To prevent personal injury or death, do not

Service Procedures (cont.)

CAUTION: To prevent engine damage, install the correct oil filter

CAUTION: To prevent engine damage, do not overtighten filter.

CAUTION: To prevent engine damage, do not overfill with oil.

8. Put drain pan under oil filter.

Service Procedures (cont.)

CAUTION: To prevent engine damage, do not overfill with oil.

Service Procedures (cont.)

WARNING: To prevent personal injury or death, wear

WARNING: To prevent personal injury or death, do not

NOTE: When separating the cover assembly from the body

Service Procedures (cont.)

5. Remove and discard O-ring.

Service Procedures (cont.)

• If leaks are observed, shutdown engine and correct

RESETTING CHANGE ENGINE OIL SERVICE INTERVAL

Service Procedures (cont.)

1. Belt in good condition 4. Remove the breaker bar.

Service Procedures (cont.)

Figure 39 Square hole in auto tensioner