Hard Start and No Start Diagnostics Technician Date ECM Calibration Torque Hours

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MaxxForce® 15 VIN Unit No. HP Rating Engine SN Miles

Beginning with 2011 Model Year Complaint Transmission: Manual Auto

WARNING  If sensor is out of specification, go to suspect sensor in Special Test Procedures Fuel Aeration and Restriction High Pressure Fuel System
Electronic Control Systems Diagnostics.
To prevent personal injury or death, read all safety
 Use ServiceMaxx™ software to run Actuator Test and Low Pressure Fuel System Aeration Test FRP Circuit Test
instructions in the Safety Information section of Engine
record position values at 5% and 95%. Note: See Figure 1 for Aeration Test Diagram.  Disconnect FRP sensor electrical connector and attempt
Diagnostics Manual EGES-515 before doing form procedures. Fuel System Priming  Remove Clean Fuel Tank Tool from LP fuel pump inlet. to start engine.
Notes: Look up the VIN on the ISIS® network for build date, Signal 5% 95% Note: Verify fuel level before priming.
 Connect Fuel Inlet Restriction/Aeration Tool between LP  If engine starts, diagnose FRP sensor circuits. Go to FRP
engine hp, engine serial number, ECM calibration, and EGR Valve Position  Pump fuel primer pump until fuel fills the system.
pump outlet and fuel supply line to secondary filter using Sensor in Electronic Control Systems Diagnostics.
transmission. Engine Throttle Position  If fuel does not pull from fuel tank, check for restricted or
fuel line coupler.  If engine does not start, reconnect FRP sensor and go to
open supply line.
 If signal is out of specification, go to suspect actuator in  Prime fuel system to remove air from lines.
See Hard Start and No Start Diagnostics in EGES-515 for  If supply line is not restricted or open, replace primer pump. High Pressure Pump Inlet Pressure Test.
Electronic Control Systems Diagnostics.  Crank engine while visually monitoring for fuel aeration.
additional information to do each test or procedure. Record
results on this form.  Monitor DPF status signal value. Fuel Delivery Pressure Test  If fuel is not aerated, go to Restriction Test. High Pressure Pump Inlet Pressure Test
DPF Status  With engine OFF, disconnect fuel supply line at LP fuel  If fuel is aerated, connect Clean Fuel Tank Tool to primary  Disconnect fuel supply to DSI valve assembly.
Do all checks in sequence unless otherwise stated. Doing a
 If DPF status is “Regen needed-critical level”, disconnect pump inlet and cap off supply line. filter inlet.  Use Fuel Line Coupler to connect Fuel Inlet
check or test out of sequence could cause incorrect results.
exhaust system upstream of Pre-DOC and attempt to start  Connect Clean Fuel Tank Tool to LP fuel pump inlet.  Prime fuel system to remove air from lines. Restriction/Aeration Tool to DSI fuel supply line.
See EGES-515 Appendix A for Performance Specifications engine.  Prime system by squeezing primer ball on Clean Fuel Tank  Crank engine while visually monitoring for fuel aeration.  Connect Fuel Block Off Tool to Fuel Inlet
and Electronic Control Systems Diagnostics for DTCs. and turn check valve.  If fuel is not aerated, repair open in supply line from Restriction/Aeration Tool.
1. Initial Key On Check 4. Check for DTCs  Crank engine while monitoring FDP. primary filter to fuel tank.  Connect Fuel Pressure Gauge to Fuel Inlet
 Check Integral Digital Display for WATER IN FUEL indicator.  Use ServiceMaxx™ software to record DTCs.  If fuel is aerated, repair open in LP fuel pump supply line or Restriction/Aeration Tool.
Signal Spec. Actual  Crank engine while monitoring Fuel Pressure gauge.
Comments Active and Pending Previously Active and Healing primary filter.
Fuel Delivery Pressure 30 psi
SPN/FMI SPN/FMI Gauge Reading Spec. Actual
 If WATER IN FUEL stays on, go to Fuel Quality Check.  If FDP drops below specification, go to Fuel Dead Head Restriction Test
Note: See Figure 2 for Restriction Test Diagram Inlet Pressure 70-130 psi
2. Visual Inspection Test.
 Check all fluid levels. Note: Fuel restriction specifications are within ± 2 in Hg for all  If gauge pressure is within specification, go to High
 If FDP stays within specification, go to Fuel Aeration and
 Inspect electrical connectors. readings. Pressure Fuel Return Flow Test.
Restriction Test.
 Inspect air filter minder. Gauge Reading Specification Actual  If gauge pressure is lower than specification, replace
 Inspect CAC.  Correct any active and pending DTCs. See Electronic Fuel Dead Head Test secondary fuel filter and retest. Go to High Pressure Fuel
Fuel restriction 4 in. Hg
 Inspect for visible exhaust damage. Control Systems Diagnostics.  Retain Clean Fuel Tank Tool connection to LP fuel pump Return Flow Test.
 Inspect primary fuel filter.  Evaluate previously active faults with high counts. inlet.  Connect Fuel Inlet Restriction/Aeration Tool to LP pump
Comments  Disconnect fuel line from LP fuel pump outlet and connect fuel supply line using Fuel Line Coupler. High Pressure Fuel Return Flow Test
5. Engine Cranking Fuel Inlet Restriction/Aeration tool.  Connect Fuel Inlet Restriction/Aeration Tool to LP pump  Disconnect fuel return tube assembly from injectors at left
Note: If, under normal operation, engine is subjected to  Use compu check fitting to connect Fuel Pressure Gauge inlet using Fuel Outlet Fitting. rear side of engine.
Fuel Level Check
temperatures below 10°C (50°F), go to Cold Start Assist to Fuel Inlet Restriction/Aeration Tool.  Connect Pressure Test Kit vacuum gauge to Fuel Inlet  Cap off male fitting of return line using Fuel Return Block
 Check instrument panel gauge and look into tank to
System. If engine is subjected to temperatures greater than  Connect Fuel Block Off Tool to Fuel Inlet Restriction/Aeration Tool. Off Fitting.
verify fuel level.
10°C (50°F), proceed with Engine Cranking Test. Restriction/Aeration Tool.  Prime fuel system to remove air from lines.  Connect High Pressure Return Line Tester to fuel injector
 If fuel gauge reads above empty, but tank is empty,
 Use ServiceMaxx™ software to open Hard Start No Start  Prime system by squeezing primer ball on Clean Fuel Tank  Crank engine while monitoring vacuum gauge. return line and route other end to diesel fuel container.
diagnose gauge.
session. and turn check valve.  If restriction is within specification, verify FDP sensor  Crank engine and monitor fuel return from test line.
 If fuel tank is empty, add fuel and prime system. See
 Press record and start cranking engine for a maximum of  Crank engine until fuel pressure stabilizes or up to a reading with gauge. If FDP is within specification, go to  If fuel is returning, go to Fuel Rail Pressure Leak Isolation.
Fuel System Priming in Hard Start and No Start
10 seconds. maximum of 20 seconds. High Pressure Fuel System Tests.  If no fuel is returning, go to next step.
Diagnostics.
Sensor Spec. Actual Gauge Specification Actual  If restriction is above specification and engine is equipped  Connect fuel return tube assembly at injectors.
Fuel Quality Check with Racor primary filter, go to Restriction Test Point 2.  Remove banjo bolt that connects fuel return line and fuel
Switched Battery (min) 10.5 V LP Fuel Pump Pressure 130-189 psi
 Route clear hose from fuel drain valve on filter housing  If restriction is above specification and engine is equipped rail.
to approved container. Open valve and fill. Engine Speed 130 rpm  If pressure is within specification, inspect engine mounted  Connect High Pressure Return Line Tester to fuel rail return
30 psi with Davco primary filter, go to Restriction Test Point 3.
 Check for water, waxing, icing, sediment, gasoline, or Fuel Delivery Pressure fuel filter and housing for defects or damage. If no defect port.
kerosene. Fuel Rail Pressure 3771 psi or damage is found, go to High Pressure Fuel System. Restriction Test Point 2  Crank engine and monitor fuel return from test line.
Comments TC1 Turbine Outlet Pressure <5 psi  If pressure is below specification, replace fuel pump. Refer Gauge Reading with  If fuel flows from test line, replace fuel rail pressure relief
DPF Differential Pressure 0 psi to Engine Service Manual for replacement procedure and Clean Fuel Tank Tool Spec. Actual valve.
 If fuel quality is questionable, correct problem. Take a
sample to verify fuel quality is satisfactory.  If SWBAT drops below specification, check cranking voltage perform HP Pump Fuel Pressure Test in Hard Start and No Fuel restriction 6 in. Hg  If fuel does not flow from test line, replace fuel pump. Refer
at batteries using DMM. If not okay, check batteries and Start diagnostics.  Connect Clean Fuel Tank Tool to primary filter inlet. to Engine Service Manual for replacement procedure and
3. EST Connection and Data Recording charging system, connect battery charger, and retest.  Prime fuel system to remove air from lines. perform HP Pump Fuel Return Pressure Test in Hard Start
 Use ServiceMaxx™ software to record KOEO pressure and  If no rpm signal is present, see CKP Sensor and CMP HP Pump Fuel Return Pressure Test  Crank engine while monitoring vacuum gauge. and No Start Diagnostics.
temperature values. Sensor in Electronic Control Systems Diagnostics. If Engine  Restore fuel system to normal operating condition and  If restriction is within specification, repair restriction in
Note: Ideally, allow the engine to cold soak for at least 2 hours Speed is below specification, check batteries and starting disconnect HP fuel pump return line. supply line between primary filter and fuel tank.
before recording results. system.  Use Fuel Line Coupler to connect HP fuel pump return line
 If FDP is below specification, go to Low Pressure Fuel  If restriction is above specification, repair or replace
to Fuel Inlet Restriction/Aeration Tool.
Sensor Spec. Actual System.  Connect Fuel Pressure Gauge to compu check fitting on primary filter and check fuel lines.
Air Inlet Temp -  If FDP is within specification but FRP is below specification, Fuel Aeration/Restriction Tool. Restriction Test Point 3
Engine Coolant Temp1 - go to High Pressure Fuel System.  Start engine and run at high idle while monitoring Fuel
Gauge Reading with
Engine Coolant Temp2 -  If TC1 Turbine Outlet Pressure is above specification, open Pressure Gauge.
exhaust just before Pre-DOC and try to start engine. If Clean Fuel Tank Tool Spec. Actual
Engine Oil Temp - Gauge Specification Actual
engine starts, see AFT System in Electronic Control Systems Fuel restriction 6 in. Hg
Fuel Rail Pressure 0 psi
Diagnostics. Fuel Pressure 13 psi  Connect Clean Fuel Tank Tool to primer pump inlet.
TC1 Turbine Outlet Pressure 0 psi
 If a problem is not found after completing all of the above test  If above specification, inspect fuel return line between HP  Prime fuel system to remove air from lines.
Fuel Delivery Pressure 0 psi steps, open a case file, attach Diagnostic results, and  Crank engine while monitoring vacuum gauge.
Pump and fuel tank for restriction.
Intake Manifold Pressure 0 psi ServiceMaxx™ recorded file. Call tech support.  If restriction is within specification, go to test point 2.
 If pressure is less than specification, no further action is
Barometric Pressure - required.  If restriction is above specification, repair or replace primer
DPF Differential Pressure 0 psi pump and check fuel lines. Retest with original fuel lines EGED-520 © 2011 Navistar, Inc.
installed to verify condition is corrected. All rights reserved
All marks are trademarks of their respective owners
Fuel Rail Pressure Leak Isolation Fuel Supply at Cold Start Fuel Solenoid
 Retain High Pressure Return Line Tester connection to (CSFS) Test Test
injector return line from previous test.  Disconnect fuel supply to CSFS. Point 1
 Disconnect number six injector fuel line and cap off rail  Use Cold Start Solenoid Test Adaptor Kit to connect Fuel Secondary
with High Pressure Rail Plug. Pressure Gauge to CSFS fuel supply line. Fuel Filter
 Crank engine while monitoring fuel leaking out of test line.  Crank engine while monitoring Fuel Pressure Gauge.
 If fuel is leaking out of test line, leave High Pressure Rail Signal Spec. Actual
Plug connected. Continue capping off one injector supply
Cold Start Assist Fuel Pressure 10 psi
port at a time until fuel rail builds starting pressure.
Replace injector tube and fuel pipe on any injector that is  If Cold Start Assist Fuel Pressure is below specification,
verify fuel line is not restricted. If fuel line is not restricted,
leaking sufficiently enough to not build pressure.
pressure regulator is faulty. Replace secondary fuel filter
 If fuel is not leaking out of test line and fuel rail builds Fuel Inlet
housing.
starting pressure, replace number six injector tube and Restriction/Aeration Low-Pressure
 If Cold Start Assist Fuel Pressure is within specification, go
fuel pipe. to Fuel Supply at CSI Test. Fuel Pump

Cold Start Assist System Fuel Supply at Cold Start Igniter (CSI) Test
Note: This test can only be run if ECT1 is below 10°C (50°F) , Fuel Supply from
Primer Primary Filter
Cold Start Assist System Test or ServiceMaxx™ software can run Cold Start Assist Pump
 Use ServiceMaxx™ software to open Hard Start No Start procedure.
session.  Use ServiceMaxx™ software to open Hard Start No Start Test
 If ECT1 is above 10°C (50°F), use ServiceMaxx™software Session. Point 2
to run Cold Start Assist procedure.  Reconnect fuel supply line to CSFS.
Figure 1
 If ECT1 is below 10°C (50°F), go to next step.  Disconnect fuel supply to CSI.
 Cycle Ignition switch and monitor Wait To Start Lamp.  Use Cold Start Solenoid Test Adaptor Kit to connect Fuel Test
 When Wait To Start Lamp stops flashing, crank engine Pressure Gauge to CSI fuel supply line.
Fuel Inlet
Restriction/Aeration Point 1
while monitoring IMT signal.  When Wait To Start Lamp stops flashing, crank engine
 If IMT does not increase approximately 3.8°C (10°F) during while monitoring Fuel Pressure Gauge.
Tool
engine crank, go to Cold Start Igniter Test. Gauge Spec. Actual
 If IMT increases approximately 3.8°C (10°F), Cold Start
Assist is working correctly. CSI Fuel Supply Pressure 10 psi
 If pressure is below specification, verify fuel line is not
Signal Before After
restricted. If fuel line is not restricted, see Cold Start Fuel
IMT Solenoid in Electronic Control System Diagnostics.
 If pressure is within specification, replace Cold Start Fuel
Cold Start Igniter Test Igniter.
 Use ServiceMaxx™ software to open 2010 BB Actuator
session.
Low Pressure
 Connect current clamp around CSI power circuit.
Fuel Pump Fuel
 Select Cold Start Igniter from Actuator drop-down menu.
Supply
 Press Start Test button and monitor current draw. Primer from
Specification Actual Pump Tank
Current Draw 20A
 If current draw is less than specification, see Cold Start Fuel
Igniter in Electronic Control Systems Diagnostics.
Test
Point 3
 If current draw is above specification, CSI is working
1 2 3 4 5 6
correctly. Go to Cold Start Fuel Solenoid Test.
Primary
Cold Start Fuel Solenoid Test Vacuum Gauge Fuel Filter Test
 Connect breakout harness between Cold Start Fuel Point 2
Solenoid and engine harness.
 Use ServiceMaxx™ software to open 2010 BB Actuator Figure 2
session.
 Select Cold Start Fuel Solenoid from Actuator drop-down
menu.
 Press Start Test button while using DMM to monitor
voltage change between pin 1 and pin 2.

Pin Actual Voltage

1 to 2
 If voltage does not change when running test, see Cold
Start Fuel Igniter in Electronic Control System Diagnostics.
 If voltage changes from approximately 0.3 V to 11.30 V
when commanded ON in ServiceMaxx™ software,
go to next test.

EGED-520 © 2011 Navistar, Inc.

All rights reserved
All marks are trademarks of their respective owners