prostar fuel system interferences - 12644 page 1 of 21 6% ...1. engine control module (ecm) 2. tie...

Title: ProStar Fuel System Interferences - 12644

Applies To: ProStar with 2010 EPA MaxxForce 11 & 13 Engines

Countries: CANADA, UNITED STATES

Document ID: IK1500067

Availability: Internal - Attachable Revision: 1 Major System: FUEL SYSTEMS Created: 8/1/2012 Current Language: English

Last Modified: 8/30/2012

Other Languages: NONE Author:

Lindsey Christopher

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Make repairs to correct interference with fuel system components to avoid fuel line contact wear. Release Date: March 2012 Supersedes: N/A Standard Repair Time: 1.4 Hours NOTE: This article identifies examples of interference that may exist between fuel system components and other engine and chassis components. Due to normal assembly variation it is impractical to document every possible interference condition, but critical areas around the high-pressure (fuel) pump-to-fuel rail tube assemblies and the six high-pressure (fuel) rail-to-injector tube assemblies should be given the highest focus. In consideration of the importance of eliminating abrasive contact with these fuel lines, this document first outlines a comprehensive re-routing procedure for all components in their area and then addresses interference of less critical issues involving other components. NOTE: All identified issues are located on the left (driver) side of the engine assembly. TOOLS REQUIRED

PARTS INFORMATION

REPAIR PROCEDURE

Proper PPE

Part # Description Qty. 3012753C2 TUBE HI PRESS RAIL TO INJCTR 1 13LMAX AS NEEDED

3006042C2 TUBE HI PRESS RAIL TO INJCTR 2 13LMAX AS NEEDED




3012758C2 FUEL LINE FUEL RAIL TO THE #6 INJECTOR AS NEEDED

71286 CABLE TIES NYLON 15-1/8" AS NEEDED

of 21IK1500067 - ProStar Fuel System Interferences - 12644

9/4/2012https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID...

SB-10045820-4146

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WARNING: To prevent personal injury or death, wear safety glasses with side shields.

NOTE: The below listed parts are needed only if high-pressure (fuel) rail-to-injector tube assembly wear is found. While making corrections identified in this article, carefully inspect each high-pressure (HP) rail-to-injector tube assembly. If wear is evident (Figure 1), replace the fuel tube assembly. Navistar HP Rail-to-Injector Tube Assembly Part Numbers: � Cylinder #1 � 3012753C2 � Cylinder #2 � 3006042C2 � Cylinder #3 � 3005678C2 � Cylinder #4 � 3005679C2 � Cylinder #5 � 3012757C2 � Cylinder #6 � 3012758C2 NOTE: The above part numbers may be either a C1 (original) or C2 (revised) suffix. The parts are interchangeable and the C2 suffix part is not required. Pre-work Vehicle Preparation: 1.Park vehicle on a flat surface inside shop. WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking brake, and block wheels before doing diagnostic or service procedures. 2. Shift transmission to park or neutral, set the parking brake, and chock wheels. WARNING: To prevent personal injury or death, remove ground cable from negative terminal of main batteries before disconnecting or connecting electrical components. Always connect ground cable last. 3. Remove the ground cable from the negative terminal of the main batteries.




4. Remove the air filter housing assembly (Figure 2, Item 1). 5. Remove the left inner fender splash panel (Figure 2, Item 3).

Interference Issues Affecting High-pressure (HP) Fuel Tube Assemblies:

1. Disconnect harness connectors from the ECM by rotating each connector lock lever and then pulling connector out of the ECM (Figure 3).

1. Air Filter Housing Assembly 2. Left Front Wheel 3. Left Inner Fender Splash Panel




2. Remove eight M6 x 30 bolts and remove the ECM from the ECM support (Figure 4).

1. Engine Control Module (ECM) 2. M6 x 30 Bolt (8)

1. Cold Start Solenoid (CSS) 2. Tie Strap Upper Connector Locations 3. Cold Start Relay (CSR)




3. Disconnect wiring harness connector from the CSR (Figure 5, Item 3). 4. Remove two M6 x 20 bolts securing the CSS to the ECM support (Figure 5, Item 1). 5. Cut tie straps off one lower and two upper tie strap locations (Figure 5, Items 2 and 5). 6. Remove three M8 x 40 bolts, six bracket insulators (three on each side of the ECM support), and remove the ECM support (Figure 5, Item 4).

4. M8 x 40 Bolt (3) with Bracket Insulators (6) 5. Tie Strap Lower Connector Location 6. ECM Support

1. High-pressure (HP) Pump-to-Rail Tube Assembly (2) 2. High-pressure Rail-to-Injector Tube Assembly (6)




7. Inspect the two HP pump-to-fuel rail tube assemblies and the six HP rail-to-injector tube assemblies (Figure 6) for contact wear. Figures 1 & 7 show typical contact wear found on HP fuel tube assemblies. WARNING: To prevent personal injury or death, the engine must be stationary for at least 5 minutes before doing any work on the high-pressure fuel system, to allow for system depressurization. 8. Remove all HP fuel tube assemblies that have contact wear. 9. Install new HP fuel tube assemblies and hand tighten each fitting nut. Using a crowfoot wrench, tighten each fuel tube fitting nut to 17 lb-ft (23 N-m), and then tighten each fitting nut an additional 60 degrees.

1. P-clamp securing the air compressor intake pipe




10.Cut and remove all tie straps securing the main engine wiring harness, from the front of the harness (adjacent to the ECM) to the P-clamp that secures the air compressor intake pipe (Figure 8). 11.Beginning at the P-clamp (Figure 8), carefully pull the main engine wiring harness outward and downward. When moving the harness, verify the locations of the alternator remote sense wire and block heater cord (round) (Figure 9). 12.Route the Alternator remote sense wire and block heater cord along the outside edge of the main engine wiring harness, to the maximum extent possible (Figure 9). It may be necessary to temporarily disconnect them to accomplish this.

1. Block heater cord. 2. Alternator remote sense wire (if equipped). 3. Main engine wiring harness.




13.Secure the main engine wiring harness, alternator remote sense wire, and block heater cord to the P-clamp that secures the air compressor intake pipe (Figures 8, 9, and 10), using one tie strap (Part # 289862C1). Verify components are clear of the HP fuel tube assemblies.

14.Cut and remove two tie straps that secure the secondary branch of the main engine wiring harness and pull it down, this will reduce the upward pull exerted on the main harness (Figure 11, Item 1).

1. Tie Strap (2) 2. Secondary branch of the main engine wiring harness (before relocation)

1. Tie strap attachment location 2. Secondary branch of the main engine wiring harness 3. P-clamp




15.With the secondary harness in its �pulled down� position, secure the harness using one tie strap (Part # 289862C1) (Figure 12, Item 1). 16.With the secondary harness pulled down, secure the secondary harness to the P-clamp adjacent to it, using one tie strap (Part # 289862C1) (Figure 12, Item 3 shows area before tie strap is installed).

17.Secure the relocated alternator remote sense wire and block heater cord to the main engine wiring harness using two tie straps (Part # 289862C1). Proceed with this action to the point where the round wire begins its turn up the side of the engine (Figure 13).

1. Alternator remote sense wire (if equipped)

2. Block Heater Cord 3. Tie Strap (2)

1. Branch harnesses (Before relocation)




18.Behind the fuel filter housing, re-route three branch harnesses UNDER the main engine wiring harness. Disconnect components these harnesses connect to as required. Figure 14 shows these branch harnesses BEFORE relocation. 19.Secure three branch harnesses to each other and the block heater cord (round) forming a single bundle, using three tie straps (Part # 289862C1). Verify the block heater cord is free of contact with any of the HP fuel tube assemblies. Place the three tie straps as follows: one to the left of the bundle; the second to the right, and the third approximately one inch above the group (Figure 15).

1. Block Heater Cord 2. Tie Strap (3)




20.Before reinstalling the ECM support, remove and discard the small gray wire tie holder from the left side of the support (Figure 16). 21.Position ECM support on the engine and install six bracket insulators and three M8 x 40 bolts (Figure 17, Item 4). Tighten bolts to 26 lb-ft (35 N-m). 22.Install CSS on ECM support and tighten two M6 x 20 bolts to 53 lb-in (6 N-m) (Figure 17, Item 1).

1. Cold Start Solenoid (CSS) 2. ECM Support 3. Cold Start Relay (CSR) 4. M8 x 40 Bolt (3) with bracket insulator (6)

1. Tie Straps in "X" configuration 2. Main vertical molded harness




23.Install two tie straps (part # 289862C1) around the main vertical molded harness that runs adjacent to the ECM support bracket. Install tie straps in an �X� configuration. This will pull the molded harness tightly against the ECM support bracket and away from the HP fuel tube assemblies (Figure 18, Item 1). 24.Install an additional tie strap around the vertical molded harness, but do not tighten until the ECM has been reinstalled (Figure 18, Item 3). 25.Position the ECM on the ECM support and install eight M6 x 30 bolts finger tight. Tighten bolts in a star pattern to 89 lb-in (10 N-m) (Figure 19).

3. Tie Strap (loose)

1. Engine Control Module (ECM) 2. M6 x 30 Bolt (8)




26.Tighten previously loose tie strap around the lower left ECM support bolt (Figure 20, Item 3).

1. Tie straps in "X" configuration 2. Main vertical molded harness 3. Tie Strap (tight)

1. Engine Control Module (ECM) 2. Tie strap upper connector locations 3. Engine injector harness connector (to ECM 16-pin E2 terminal) 4. ECM 58-pin C2 chassis terminal 5. ECM 58-pin C1 chassis terminal 6. Tie strap lower connector location 7. Engine sensor harness connector (to ECM 96-pin E1 terminal)




27.Align engine sensor harness connector with ECM E1 terminal and push connector straight in. Push down on lock lever to draw in and secure connector (Figure 21, Item 7). 28.Align engine injector harness connector with ECM E2 terminal and push connector straight in. Push down on lock lever to draw in and secure connector. Install connector clip (Figure 21, Item 3). 29.Connect chassis harness connector to ECM 58-pin C1 and C2 terminals. Lock connectors in place (Figure 21, Items 4 & 5). 30.Connect the wiring harness connector to the Cold Start Relay (CSR). 31.Install new tie straps to one lower and two upper tie strap locations (Figure 21, Items 2 & 6).

32.Carefully inspect the engine wiring harness and all HP fuel tube assemblies from the front of the engine to the rear. There should be proper clearance between the fuel tubes and all components (Figure 22).

Oil Level Sensor Connector Area This condition applies to units NOT equipped with an oil level sensor. The oil level sensor harness connector hangs unsupported, lying on top of HP fuel tube assemblies and against the crankcase. See Figure 23 for general location � image is looking up from the floor, at the left side frame rail.

1. High-pressure fuel tube assembly 2. Alternator remote sense wire (if equipped) 3. Proper harness-to fuel tube clearance




1. Reroute the connector harness inboard (toward the crankshaft centerline) of the fuel lines, until it is hanging free. 2. The harness can be left unsecured, or it can be secured through available hole in metal bracket (Figure 24), using one tie strap (Part # 289862C1).

Engine Cold Start Solenoid Area The Cold Start Solenoid (CSS) fuel supply hose may become kinked and cut off fuel flow (Figure 25).




1. Loosen banjo 6 bolt. (Figure 25, Item 2) 2. Rotate the fuel supply hose fitting from the 10 o�clock position (Figure 25) to the 8 o�clock position (Figure 26). 3. Tighten the banjo 6 bolt to 132 lb-in (15 N-m).

Fuel Filter-to-Primer Pump Area

1. CSS fuel supply hose kinked 2. Banjo 6 Bolt

1. CSS fuel supply hose NOT kinked 2. Banjo 6 Bolt




This condition will not be present in all units. Figure 27 shows the correct routing of the fuel filter supply hose attached, via a swivel saddle and wire tie, to the metal power steering line and NOT the oil dipstick tube. If the routing is correct, no further action is necessary.

Figure 28 shows the general area involved.




1. If the fuel hose is secured to the oil dipstick tube, remove and discard tie strap and swivel saddle guide (Figure 29, Item 2). This will relax stress in the hose and clearance will be resolved. The hose will require no further securing (Figure 30).

Fuel Filter Area This condition will be present only in vehicles equipped with Davco fuel filter/heater. Three fuel lines are tied together, with high potential for contact wear (Figure 31).

1. Contact Points 2. Tie Strap and Swivel Saddle 3. Metal Power Steering Line




1. Cut and discard the tie strap securing grey and black fuel lines to each other (Figure 31).

2. Using one swivel saddle guide (Part # 3666881C1) and one tie strap (Part # 289862C1), secure the two grey lines individually to the saddle guide, which will separate them from each other and the third line (Figure 32).

Post-work Vehicle Activities




1. Install the air filter housing assembly (Figure 33, Item 1). 2. Connect the battery ground cables to the negative terminal of the main batteries. 3. Start and idle the engine for 5 minutes, carefully inspecting the work area for concerns of any kind. Turn OFF the engine if any leaks or other concerns are found. 4. Install the left inner fender splash panel (Figure 33, Item 3). WARRANTY INFORMATION Warranty claim expense is to be charged to Warranty. Claims are to be submitted in the normal manner as Warranty Code 40, Group 12644. It is important that the coding be completed properly to assist in processing the warranty claim. Complete instructions will be found in the Warranty Policy Manual, Section 7.1.8. As with all claim submission, items acquired locally must be submitted in the .Other Charges. tab. The cost of any bulk items (bag of cable tie straps, roll of wire, barrel of oil, tube of silicone, etc.) should be prorated for the cost of the individual pieces/amount used during each repair.

1. Air Filter Housing Assembly 2. Left Front Wheel 3. Left Inner Fender Splash Panel




Copyright © 2012 Navistar, Inc.

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Warranty Claim Information

Group Noun Cause (C) Warranty Code Description Time (hrs)

12644 Blank 2 40 Fuel System Interferences 12644 As needed by SRT below

Standard Repair TimeOperation Number Description Time (hrs)A12T1- example Replae fuel lines as needed and other re-routing 1.4




prostar fuel system interferences - 12644 page 1 of 21 6% ...1. engine control module (ecm) 2. tie...

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