MaxxForce 5 Engine Update - · PDF fileWelcome to the International® 2007 MaxxForceTM 5 Engine Update Web Based Training Course. This ... ECM main power relay control,

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Study Guide M

axxForceTM 5 Engine Update

TMT-120710

MaxxForceTM 5 Engine UpdateStudy GuideTMT-120710

A NAV I STAR C O M PANY

©2007 International Truck and Engine Corporation4201 Winfield Road, Warrenville, IL 60555

All rights reserved.

No part of this publication may be duplicated or stored in an information retrieval system without the express written permission of

International Truck and Engine Corporation.

Introduction...................................................................... 32007.Engine.Updates..................................................... 5

Larger EGR Cooler .................................................................... 5

Single-Box Electronic Control Module ................................... 5

76-pin Engine Connector Inputs .................................... 6

76-pin Engine Connector Outputs ................................ 6

76-pin Chassis Connector Inputs ................................. 7

76-pin Chassis Connector Outputs .............................. 7

Engine Fuel Pressure Switch ................................................... 7

High Pressure Oil Pump ............................................................ 8

One-Piece High Pressure Oil Pump Adapter ....................... 8

Removal of High Pressure Oil Pump ...................................... 9

Removal of Branch Tube Adapter ........................................... 9

Branch Tube Adapter Installation ............................................ 9

Branch Tube Adaptor Leak Test .............................................11

Turbocharger Adapter Plate ....................................................12

Aftertreatment ............................................................................12

Intake Throttle Valve ..................................................................13

Fuel Injector ................................................................................14

EGR Valve...................................................................................14

Exhaust Back Pressure Sensor .............................................14

Engine Harness .........................................................................15

Intake Manifold ...........................................................................15

Glow Plug and Inlet Air Heater Relays .................................15

Conclusion...................................................................... 16

MaxxForceTM 5 Engine Update

Introduction

Welcome to the International® 2007 MaxxForceTM 5 Engine Update Web Based Training Course. This program is designed to provide updated information concerning the International® MaxxForceTM 5 engine.

To receive credit for completing this training course, you must take a post test on ISIS®/Education/Service/Online Testing.

Objectives

Upon.Completion.of.this..program,.you.will.be.able.to:

Identify.new.or.updated.components.on.the.2007.V6.engine

Identify.correct.procedures.use.on.new.07.components

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Introduction 1

NOTES

2 MaxxForceTM 5 Engine Update

2007 Engine Updates

For 2007 model Year, the V6 engine has been updated. Some components are new, some are relocated, and others are redesigned.

Larger.EGR.Cooler

The 2007 V6 engine recirculates more exhaust gases back through the intake manifold. The cooler still mounts under the intake manifold but must be larger to handle increased flow.

When the EGR valve is open, exhaust gases exit off the left-bank exhaust manifold, pass through the cooler and enter a passage in the intake manifold. Coolant flows from a port on the oil cooler cover and connects to the back of the cooler through a flexible tube. After traveling through the cooler, the coolant exits into a passage cast into the intake manifold. This passage directs the coolant to the front cover.

Single-Box.Electronic.Control.Module

The 2007 MaxxForce 5 engine uses a single box Electronic Control Module (ECM). The new ECM incorporates the barometric air pressure sensor as an

Module 1: 2007 Engine Updates 3

Module 1

“The 2007 V6 engine recirculates more exhaust gases back through the intake manifold.”

internal component.

The ECM has three connectors to allow for inputs and outputs. The three are identified as the 76 pin Engine connector, the 76-pin Chassis connector, and the 36-pin driver connector.

The Driver connector is only used for injector outputs and ICP sensor VREF, ground, and signal inputs. However, both the engine and the chassis connectors have a variety inputs and outputs.

76-pin Engine Connector Inputs

The inputs include the crankshaft position, camshaft position, engine oil temperature, engine coolant temperature, manifold air temperature, engine oil pressure switch position, exhaust back pressure, manifold absolute pressure (boost), intake throttle position, water-in-fuel detection, glow plug relay position, intake air heater relay position, EGR valve position (over CAN).

76-pin Engine Connector Outputs

The outputs include the EGR valve (over CAN), glow plug relay control, intake air heater relay control, injection pressure regulator valve control,

4 Module 1: General Information

“The Driver connector is only used for injector outputs and ICP sensor VREF, ground, and signal inputs.”

turbocharger control solenoid position control.

76-pin Chassis Connector Inputs

The inputs include the Afterteatment temperatures (three inputs), exhaust gas pressure differential, fuel pump relay position, e-fan, cruise control switch positions, A/C demand relay circuit position, intake air temperature, accelerator position, idle validation switch position, ignition switch position, CAN inputs, driveline disengagement switch position, injection pressure regulator power, fuel pressure switch position, brake switch and brake pressure switch position.

76-pin Chassis Connector Outputs

The outputs include the ATA communication, ECM main power relay control, fuel pump relay control, CAN outputs, A/C clutch relay control, engine crank inhibit.

Engine.Fuel.Pressure.Switch

The Engine Fuel Pressure Switch (EFPS) is used to detect a drop in fuel supply pressure below 30 +/- 5 psi. If low pressure is detected, a lamp in the instrument cluster will notify the operator that the vehicle requires service. Replacement of both fuel filters


“The Engine Fuel Pressure Switch (EFPS) is used to detect a drop in fuel supply pressure below 30 +/- 5 psi.”

at the proper interval is essential for maintaining the correct fuel pressure.

The switch is a one-wire input to the ECM. The ECM supplies a 5-volt signal to the switch. When the electric fuel pump builds pressure, the switch closes and the circuit is grounded. This shorts the voltage to ground and the ECM reads the circuit voltage as zero.

If fuel pressure drops below the switch point, the switch will open and the ECM will read the 5 volts on the circuit. The ECM will then signal the fuel pressure lamp in the instrument cluster.

High.Pressure.Oil.Pump

The V6 uses an updated larger capacity High Pressure Oil Pump. The pump is still gear driven and located at the rear of the engine.

One-Piece.High.Pressure.Oil.Pump.Adapter

The V6 now uses a One-Piece High Pressure Oil Pump Adapter for increased reliability of the Injection Control Pressure System.

6 Module 1: 2007 Engine Updates

“The V6 uses an updated larger capacity High Pressure Oil Pump”

Removal.of.High.Pressure.Oil.Pump

This replacement procedure must be followed anytime the branch tube adaptor is replaced on a 2007 model year V6 engine. In addition, this procedure should be used on all previous model year VT 275 and VT 365 engines when replacing the two piece branch tube adaptor with the one piece design.

To service the Branch tube adaptor, remove the high-pressure oil pump from the engine. Reference the appropriate service manual on ISIS for the correct service procedures.

Removal of the branch tube assembly and the rear cover are not required to perform this service procedure.

Removal.of.Branch.Tube.Adapter

Remove the branch tube adapter from the high-pressure oil pump assembly.

Branch.Tube.Adapter.Installation

Rotate the jam nut to the base of the branch tube adaptor. Install a


To.prevent.engine.damage,.match.new.O-rings.with.the.O-rings.removed..Several.O-rings.involved.in.this.procedure.are.similar.in.size,.but.will.not.seal.if.used.in.the.wrong.location.

WARNING!

To.prevent.engine.damage,.branch.tube.adaptor.must.be.installed.at.the.correct.depth.to.prevent.high-pressure.oil.leaks.

WARNING!

new branch tube adaptor O-ring and lubricate with clean engine oil. Next, thread the branch tube adapter into the high-pressure oil pump making sure the oil outlet hole is facing down. Do not tighten the jam nut at this time.

Check the adaptor installed depth by placing the Installation Depth Gauge (ZTSE4876-2) on the high-pressure oil pump. Now, rotate the adapter in or out of the pump housing until the adaptor holes align with the gauge holes.

Lubricate and install new O-rings in both the branch tube O-ring recess and in the high-pressure pump-inlet recess. Then, install the high-pressure pump and adapter assembly on the engine. Finger tighten the three bolts securing the high-pressure oil pump to the crankcase. Align the adaptor and branch tube holes and install the two bolts in the adapter finger tight. Torque the three bolts securing the high-pressure oil pump to specifications.

Remove the left branch tube bolt and thread the Anti-rotation Handle (ZTSE4876-1) into the assembly. Put a torque wrench with a 15/16 inch 12-point flare-nut crowfoot on the adapter nut. Use the handle to provide proper counter-torque while you torque the adaptor jam nut to specifications.


To.prevent.an.engine.no.start,.ensure.the.oil.supply.hole.in.the.branch.tube.adapter.is.facing.the.branch.tube.assembly.

WARNING!

.If.unable.to.align.the.adapter.holes.and.the.branch.tube.holes,.the.branch.tube.may.need.to.be.loosened.or.replaced..Before.loosening.the.branch.tube.assembly,.contact.Technical.Services.

WARNING!

Remove the handle and install the left bolt in the adaptor, then torque both bolts to specifications.

Branch.Tube.Adaptor.Leak.Test

There are two possible ways to leak test the branch tube connection before installing the high-pressure oil pump cover.

Method 1: If the engine is set for the low ICP system pressure test, perform a “Low ICP System Pressure” in the “Hard Start and No Start Diagnostics” section of the, International® V6 Diagnostics Manual on ISIS.

Method 2: If the engine is not set up for the low ICP system pressure test, leak test as follows:

Install the IPR valve into the high-pressure oil pump. Remove and discard the plug from the top of the high-pressure oil pump. Use the ICP system test adapter (ZTSE4594) to attach a shop air hose to the injection control pressure system.

Use an actuator breakout harness to apply B+ and ground to the IPR valve. With the IPR closed, apply shop air at 620 kPa (90 psi) maximum to the high-pressure oil pump. Then, Inspect the


adaptor connections for leakage.

After inspecting for leaks shut off shop air and then remove the actuator breakout harness and IPR valve. Disconnect shop air connection and the ICP system test adapter (ZTSE4594). Install a new plug. Torque the new plug to specifications.

Install the high-pressure oil pump cover, intake manifold and EGR cooler assembly, and dual turbocharger assembly. Reference the EGES-390, International® MaxxForce™ 5 Service Manual for correct service procedures.

Check the engine oil level and refill as required.

Turbocharger.Adapter.Plate

The turbocharger adapter plate is used to raise the turbocharger in order clear the larger EGR cooler.

Aftertreatment

The Aftertreatment portion of the exhaust system is mounted downstream of the turbocharger. The Diesel Oxidation Catalyst (DOC) and a Diesel Particulate Filter (DPF) reduce the amount of particulate matter allowed into the engine exhaust


“The turbocharger adapter plate is used to raise the turbocharger in order clear the larger EGR cooler.”

to comply with the 2007 emission standards. The ECM monitors the DOC’s and DPF’s soot levels, pressure sensor and temperature sensors.

Aftertreatment uses two methods to regenerate: Passive regeneration and active regeneration. Passive regeneration occurs as the engines exhaust temperature burns the soot under medium to heavy loads. Active regeneration occurs periodically when the soot levels are too high. During this process, a small mist of diesel fuel is injected into the exhaust stream, the mist travels through the exhaust pipe to wet the DOC’s pre-catalyst. This causes a chemical reaction which raises DPF temperatures to the level required to convert the soot into ash.

Intake.Throttle.Valve

The Intake Throttle valve is mounted on the inlet mixer duct on the front of the engine.

The Intake Throttle valve has a variable position throttle plate that the ECM can close to restrict intake air flow. The restricted air flow in combination with additional fuel injected into the cylinders reacts in the Diesel Oxidation Catalyst (DOC) to raise the temperature in the Diesel Particulate


“Aftertreatment uses two methods to regenerate: Passive regeneration and active regeneration.”

Filter (DPF) in order to burn the collected soot into the ash.

Fuel.Injector

The 2007 V6 fuel injector has internal design changes to make it more robust. The part number has also changed for 2007 Model Year.

EGR.Valve

The EGR valve is new for 2007. The valve is still located on the intake manifold at the front of the engine but is no longer controlled by a pulse width modulated circuit. The ECM now communicates to the new EGR valve over the engine CAN line. The drive module used on previous model years is now integrated into the valve.

Exhaust.Back.Pressure.Sensor

The 2007 V6 uses an Exhaust Back Pressure (EBP) Sensor in place of the Mass Air Flow (MAF) sensor on the previous model years. The EBP sensor is mounted on the left side of the engine to a tube that connects the sensor to the exhaust manifold. The EBP sensor measures the pressure in the exhaust before the turbocharger. EBP signals are used to determine the


“The 2007 V6 uses an Exhaust Back Pressure (EBP) Sensor in place of the Mass Air Flow (MAF) sensor on the previous model years.”

correct amount of fuel for injection.

Engine.Harness

The 2007 V6 Engine Harness is protected by an injected foam cover. The cover protects the harness and makes it more durable. The design is similar to the MaxxForce DT, 9, and 10. When working with the harness use care not to bend the foam more that 90° to avoid damage.

Intake.Manifold

The 2007 V6 has a redesigned intake manifold. Exhaust gases from the EGR cooler travel through a passage in the manifold to the EGR valve. Then, when the EGR valve is open, exhaust gases pass through the manifold to the intake elbow. The intake elbow then acts as a mixing chamber for exhaust and charge air.

Glow.Plug.and.Inlet.Air.Heater.Relays

The 2007 V6 uses glow plug and inlet-air-heater relays which share a common design with the 2007 V8 and I-6. Relay operation is similar to the previous model year engine. When the ECM determines the glow plugs should be


“The 2007 V6 Engine Harness is protected by an injected foam cover.”

on, battery voltage is supplied to pin-2 of the relay. The Intake Air Heater relay works in the same manner.

Conclusion

This concludes the International® MaxxforceTM 5 Engine Update WBT. The information and techniques presented here are pivotal when becoming a certified International® technician. You are now required to take a post-test via ISIS®/Education/Service/Online Testing.


NOTES

MaxxForceTM 5 Engine Update 15

NOTES


NOTES


NOTES


NOTES


Documents

MaxxForce 5 Engine Update - · PDF fileWelcome to the International® 2007 MaxxForceTM 5 Engine Update Web Based Training Course. This ... ECM main power relay control,