Hard Start and No Start Diagnostics

MaxxForce® 15
Beginning with 2011 Model Year

EGED-520-2
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Note: This form must be completed before calling for technical assistance.
Technician: Date: Rated Power:

Software Identification: Total Miles: Engine On Time:

Vehicle Identification Number:

Engine Serial Number:

EDC Customer Unit Number:

Transmission Type (select one):

 Manual  Automatic

Complaint:

Note: If hard start condition is the result of a previous repair, validate previous repair.

WARNING
To prevent personal injury or death, read all safety instructions in the Safety Information section of EGES-515-1 Engine
Diagnostics Manual before doing form procedures.

Notes: Look up the VIN on the ISIS® network for build date, engine hp, engine serial number, ECM calibration, and
transmission.

See Hard Start and No Start Diagnostics in EGES-515-1 for additional information to do each test or procedure. Record
results on this form.

Do all checks in sequence unless otherwise stated. Doing a check or test out of sequence could cause incorrect results.

See EGES-515-1 Appendix A for Performance Specifications and Electronic Control Systems Diagnostics for DTCs.

Page 2 of 12 EGED-520-2 © 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
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Required Test Procedures

Do required test procedures in sequence. Doing a required test out of sequence can cause incorrect results.

1. Initial Key ON Check

 Check Integral Digital Display for WATER IN FUEL indicator.

Does WATER IN FUEL indicator stay on?  Yes  No

l If WATER IN FUEL indicator stays on, go to Fuel Quality Check (page 4).

2. Visual Inspection
 Check all fluid levels.
 Inspect electrical connectors.
 Inspect air filter minder.
 Inspect Charge Air Cooler (CAC) system.
 Inspect for visible exhaust damage.

Is engine oil level within specification?  Yes  No

Is engine coolant level within specification?  Yes  No

Are power and ground connections good?  Yes  No

Is air filter clean?  Yes  No

Is exhaust system in good condition?  Yes  No

Comments:

Fuel Level
 With vehicle parked on level ground, check instrument panel fuel gauge and look into fuel tank to verify fuel level.

Is there fuel in the fuel tank?  Yes  No

Comments:

l If fuel gauge reads above empty, but fuel tank is empty, diagnose fuel gauge.
l If fuel tank is empty, add fuel and prime fuel system. See Fuel System Priming (page 6).

Davco® Fuel Filter Inspection

 Visually inspect Davco® chassis-mounted fuel filter. See Davco® Fuel Filter Inspection in EGES-515-1 Hard Start and
No Start Diagnostics.
Comments:

EGED-520-2 © 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 3 of 12
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Fuel Quality Check

 Route clean hose from fuel drain valve on filter housing to approved, clear container. Open valve and fill.
 Check for water, waxing, icing, sediment, gasoline, or kerosene.
Comments:

l If fuel quality is questionable, correct problem. Take a sample to verify fuel quality is satisfactory.

3. Electronic Service Tool (EST) Connection and Data Recording

 Use ServiceMaxx™ software to record Key ON Engine OFF (KOEO) pressure and temperature values.
Note: Ideally, allow the engine to cold soak for at least 2 hours before recording results.
Sensor Specification Actual
Air Inlet Temp -

Engine Coolant Temp1 -

Engine Coolant Temp2 -

Engine Oil Temp -

Fuel Rail Pressure 0 psi

TC1 Turbine Outlet Pressure 0 psi

Fuel Delivery Pressure 0 psi

Intake Manifold Pressure 0 psi

Barometric Pressure -

DPF Differential Pressure 0 psi

l If sensor is out of specification, go to suspect sensor in EGES-515-1 Electronic Control Systems Diagnostics.

 Use ServiceMaxx™ software to run Actuator Test and record position values at 5% and 95%.
Signal 5% 95%
EGR Valve Position

Engine Throttle Position

l If signal is out of specification, go to suspect actuator in EGES-515-1 Electronic Control Systems Diagnostics.

 Monitor Diesel Particulate Filter (DPF) status signal value.

DPF Status

l If DPF status is Regen needed-critical level, disconnect exhaust system upstream of Pre-Diesel Oxidation Catalyst
(PDOC) and attempt to start engine. If engine starts, go to AFT System in EGES-515-1 Electronic Control Systems
Diagnostics. If engine does not start, continue Hard Start and No Start diagnostic procedures.

Page 4 of 12 EGED-520-2 © 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
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4. Check for Diagnostic Trouble Codes (DTCs)

 Use ServiceMaxx™ software to record DTCs.
Active and Pending SPN/FMI Counts Previously Active and Healing SPN/FMI Counts

l Correct any active and pending DTCs. See EGES-515-1 Electronic Control Systems Diagnostics.
l Investigate previously active DTCs with high counts.

5. Engine Cranking
Tools
•Digital Multimeter (DMM)
Note: If, under normal operation, engine is subjected to temperatures below 50°F (10°C), go to Cold Start Assist
System (page 11). If engine is subjected to temperatures greater than 50°F (10°C), proceed with Engine Cranking test.
 Use ServiceMaxx™ software to open Hard Start No Start session.
 Press record and start cranking engine for a maximum of 10 seconds.
Sensor Specification Actual
Switched Battery (SWBAT) (min) 10.5 V

Engine Speed (RPM) 130 rpm

Fuel Delivery Pressure (FDP) 30 psi

Fuel Rail Pressure (FRP) 3771 psi

TC1 Turbine Outlet Pressure (TC1OP) < 5 psi

DPF Differential Pressure (DPFDP) 0 psi

l If SWBAT drops below specification or Engine Speed is below specification, check cranking voltage at batteries using
DMM. If not okay, check batteries and charging system, connect battery charger, and retest.
l If Engine Speed remains at 0.00 rpm with engine rotating, see CKP and CMP in EGES-515-1 Electronic Control
Systems Diagnostics.
l If Engine Speed is below specification, check batteries and starting system.
l If FDP or FRP is below specification, go to Low-pressure Fuel System (page 6).
l If TC1TOP is above specification, open exhaust just before Pre-DOC and try to start engine. If
engine starts, see AFT System in EGES-515-1 Electronic Control Systems Diagnostics.
l If a problem is not found after completing all of the above test steps, open a case file, attach Diagnostic results, and
ServiceMaxx™ recorded file.

EGED-520-2 © 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 5 of 12
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Special Test Procedures

Low-pressure Fuel System

Fuel System Priming

Note: Verify fuel level before priming.
 Pump fuel primer pump until fuel fills the system.
l If fuel does not pull from fuel tank, go to Fuel Aeration Test (page 8).
l If supply line is not restricted or open, replace primer pump assembly.

Fuel Delivery Pressure (FDP) Test

Tools
•15-637-01 - Clean Fuel Source Tool
•ZTSE4409 - Pressure Test Kit
•ZTSE4891 - Air Cap, Fuel Cap, and Plug Kit
•ZTSE6091 - Manual Oil Pressure Test Tool
Note: Ensure fuel lines are clear of debris before disconnecting fuel lines.
 Remove FDP sensor and install Manual Oil Pressure Test Tool ZTSE6091.
 Connect Pressure Test Kit ZTSE4409 to Manual Oil Pressure Test Tool ZTSE6091.
 Crank engine while monitoring Pressure Test Kit ZTSE4409.
Signal Specification Actual
Fuel Delivery Pressure 30 psi

 Compare current FDP readings to FDP readings from Engine Cranking Test.
l If current FDP reading does not closely resemble previous FDP reading, go to FDP Sensor in EGES-515-1 Electronic
Control Systems Diagnostics.
l If FDP stays consistent, continue to next step.
 With engine OFF, disconnect fuel supply line at low-pressure fuel pump inlet.
 Use Air Cap, Fuel Cap, and Plug Kit ZTSE4891 to cap disconnected fuel supply line.
 Connect Clean Fuel Source Tool 15-637-01 to low-pressure fuel pump inlet.
 Use Clean Fuel Source Tool to prime fuel system.
 Crank engine while using ServiceMaxx™ software to monitor Fuel Delivery Pressure signal..
Signal Specification Actual
Fuel Delivery Pressure 30 psi

l If FDP drops below specification, go to Fuel Dead Head Test (page 7).
l If FDP stays within specification, go to Fuel Aeration Test (page 8).

Page 6 of 12 EGED-520-2 © 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
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Fuel Dead Head Test

Tools
•Compucheck fitting
•15-637-01 - Clean Fuel Source Tool
•ZTSE4409 - Pressure Test Kit
•ZTSE4886 - Fuel Inlet Restriction / Aeration Tool
•ZTSE4905 - Fuel Block Off Tool
 Retain Clean Fuel Source Tool 15-637-01 connection to low-pressure fuel pump inlet.
 Disconnect fuel line from low-pressure fuel pump outlet and connect Fuel Inlet Restriction / Aeration Tool ZTSE4886.
 Use compucheck fitting to connect Pressure Test Kit ZTSE4409 to Fuel Inlet Restriction / Aeration Tool ZTSE4886.
 Connect Fuel Block Off Tool ZTSE4905 to Fuel Inlet Restriction / Aeration Tool ZTSE4886.
 Use Clean Fuel Source Tool 15-637-01 to prime fuel system.
 Crank engine until fuel pressure stabilizes or up to a maximum of 20 seconds.
Gauge Specification Actual
LP Fuel Pump Pressure 130 to 189 psi

l If pressure is within or above specification, inspect engine-mounted fuel filter and housing for defects or damage. If no
defect or damage is found, go to High-pressure Fuel System (page 10).
l If pressure is below specification, replace fuel pump. Refer to Engine Service Manual for replacement procedure and
perform HP Pump Fuel Return Pressure Test.

HP Pump Fuel Return Pressure Test

Tools
•Compucheck fitting
•ZTSE4409 - Pressure Test Kit
•ZTSE4681 - Fuel Pressure Gauge
•ZTSE4886 - Fuel Inlet Restriction / Aeration Tool
•ZTSE4906 - Fuel Line Coupler
Note: Before performing this test, ensure new fuel pump is the correct replacement part.
 Restore fuel system to normal operating condition and disconnect high-pressure fuel pump return line.
 Use Fuel Line Coupler ZTSE4906 to connect high-pressure fuel pump return line to Fuel Inlet Restriction / Aeration Tool
ZTSE4886.
 Use compucheck fitting to connect Fuel Pressure Gauge ZTSE4681 to Fuel Aeration / Restriction Tool ZTSE4886.
 Start engine and run at high idle while monitoring Pressure Test Kit ZTSE4409.
Gauge Specification Actual
Fuel Pressure 13 psi

l If pressure is above specification, inspect fuel return line between high-pressure fuel pump and fuel tank for restriction.
l If pressure is less than specification, no further action is required.

EGED-520-2 © 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 7 of 12
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Fuel Aeration Test

Aeration Test Point 1

Tools
•ZTSE4886 - Fuel Inlet Restriction / Aeration Tool
•ZTSE4906 - Fuel Line Coupler
Note: See Figure 1 for fuel aeration test diagram.
 Remove Clean Fuel Source Tool 15-637-01 from low-pressure fuel pump inlet.
 Use Fuel Line Coupler ZTSE4906 to connect Fuel Inlet Restriction / Aeration Tool ZTSE4886 between fuel supply
line to engine-mounted fuel filter and low-pressure fuel pump outlet.
 Prime fuel system to remove air from lines.
 Crank engine while visually monitoring for fuel aeration.

Is fuel aerated?  Yes  No

l If fuel is not aerated, go to Fuel Restriction Test (page 9).

l If fuel is aerated, continue to Aeration Test Point 2.

Aeration Test Point 2

Tools
•15-637-01 - Clean Fuel Source Tool
•ZTSE6124 - Fuel Outlet Fitting
 Use Fuel Outlet Fitting ZTSE6124 to connect Clean Fuel Source Tool 15-637-01 to chassis-mounted filter inlet (Test
Point 2)
 Prime fuel system to remove air from lines.
 Crank engine while visually monitoring for fuel aeration.

Is fuel aerated?  Yes  No

l If fuel is not aerated, repair open in supply line from chassis-mounted fuel filter to fuel tank.
l If fuel is aerated, repair open in low-pressure fuel pump supply line or chassis-mounted fuel filter.

Page 8 of 12 EGED-520-2 © 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
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Fuel Restriction Test

Restriction Test Point 1

Tools
•ZTSE4409 - Pressure Test Kit
•ZTSE4886 - Fuel Inlet Restriction / Aeration Tool
•ZTSE4906 - Fuel Line Coupler
•ZTSE6124 - Fuel Outlet Fitting
Note: See Figure 2 for fuel restriction test diagram.
 Use Fuel Line Coupler ZTSE4906 to connect Fuel Inlet Restriction / Aeration Tool ZTSE4886 to low-pressure fuel
pump supply line.
 Use Fuel Outlet Fitting ZTSE6124 to connect Fuel Inlet Restriction / Aeration Tool ZTSE4886 to low-pressure fuel pump
inlet.
 Use compucheck fitting to connect Pressure Test Kit ZTSE4409 vacuum gauge to Fuel Inlet Restriction / Aeration Tool
ZTSE4886.
 Prime fuel system to remove air from lines.
 Crank engine while monitoring Pressure Test Kit ZTSE4409 vacuum gauge.
Gauge Reading Specification Actual
Fuel restriction 19 in. Hg (max.)

l If restriction is within specification, go to High-pressure Fuel System (page 10).

l If restriction is above specification and engine is equipped with Racor® chassis-mounted fuel filter, go to Restriction Test
Point 2 (page 10).
l If restriction is above specification and engine is equipped with Davco® chassis-mounted fuel filter, go to Restriction
Test Point 3 (page 10).

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Restriction Test Point 2

Tools
•15-637-01 - Clean Fuel Source Tool
•ZTSE4409 - Pressure Test Kit
 Connect Clean Fuel Source Tool 15-637-01 to chassis-mounted fuel filter inlet.
 Prime fuel system to remove air from lines.
 Crank engine while monitoring Pressure Test Kit ZTSE4409 vacuum gauge.
Gauge Reading Specification Actual
Fuel restriction 19 in. Hg (max.)

l If restriction is within specification, repair restriction in supply line between chassis-mounted fuel filter and fuel tank.
l If restriction is above specification, repair or replace chassis-mounted fuel filter and check fuel lines.

Restriction Test Point 3

Tools
•15-637-01 - Clean Fuel Source Tool
•ZTSE4409 - Pressure Test Kit
 Connect Clean Fuel Source Tool 15-637-01 to primer pump inlet.
 Prime fuel system to remove air from lines.
 Crank engine while monitoring Pressure Test Kit ZTSE4409 vacuum gauge.
Gauge Reading Specification Actual
Fuel restriction 19 in. Hg (max.)

l If restriction is within specification, go to Restriction Test Point 2.

l If restriction is above specification, repair or replace primer pump and check fuel lines. Retest with original fuel lines
installed to verify condition is corrected.

High-pressure Fuel System

Fuel Rail Pressure (FRP) Circuit Test

 Disconnect the FRP sensor electrical connector and attempt to start engine.
l If engine starts, diagnose FRP sensor circuits. Go to FRP Sensor in EGES-515-1 Electronic Control Systems
Diagnostics.
l If engine does not start, reconnect FRP sensor and go to High-pressure Pump Inlet Pressure Test.

High-pressure Pump Inlet Pressure Test

Tools
•ZTSE4409 - Pressure Test Kit
•ZTSE4886 - Fuel Inlet Restriction / Aeration Tool
•ZTSE4905 - Fuel Block Off Tool
•ZTSE4906 - Fuel Line Coupler
 Disconnect fuel supply to Down Stream Injection (DSI) valve assembly.
 Use Fuel Line Coupler ZTSE4906 to connect Fuel Inlet Restriction / Aeration Tool ZTSE4886 to DSI fuel supply line.
 Connect Fuel Block Off Tool ZTSE4905 to Fuel Inlet Restriction / Aeration Tool ZTSE4886.
 Connect Pressure Test Kit ZTSE4409 to Fuel Inlet Restriction / Aeration Tool ZTSE4886.
 Crank engine while monitoring Pressure Test Kit ZTSE4409.
Gauge Reading Specification Actual
Inlet Pressure 30 psi

l If gauge pressure is within specification, go to High-pressure Fuel Return Flow Test (page 11).
l If gauge pressure is lower than specification, replace secondary fuel filter and retest. Go to High-pressure Fuel Return
Flow Test (page 11).

Page 10 of 12 EGED-520-2 © 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
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High-pressure Fuel Return Flow Test

Tools
•Diesel fuel container
•ZTSE4887-2 - High Pressure Return Line Tester
•ZTSE6094-1 - Fuel Pressure Return Connector
 Disconnect fuel return tube assembly from injectors at left rear side of engine.
 Cap off fuel return line using tube fitting cap.
 Connect fuel return tube assembly to Fuel Pressure Return Connector ZTSE6094-1.
 Connect clean plastic hose to Fuel Pressure Return Connector ZTSE6094-1 and route other end to diesel fuel
container.
 Crank engine and monitor fuel return from clean plastic hose.
l If fuel is flowing from clean plastic hose, go to Fuel Rail Pressure (FRP) Leak Isolation.
l If no fuel is flowing, go to next step.
 Reconnect fuel return tube assembly.
 Remove banjo bolt that connects fuel return line and fuel rail.
 Use 90 degree elbow with swivel to connect High Pressure Return Line Tester ZTSE4887-2 to fuel rail. Route other end
of High Pressure Return Line Tester ZTSE4887-2 to diesel fuel container.
 Crank engine and monitor fuel return from High Pressure Return Line Tester ZTSE4887-2.
l If fuel flows from High Pressure Return Line Tester ZTSE4887-2, replace fuel rail pressure relief valve. Refer to Engine
Service Manual for replacement procedure.
l If fuel does not flow from High Pressure Return Line Tester ZTSE4887-2, replace fuel pump. Refer to Engine Service
Manual for replacement procedure and perform HP Pump Fuel Return Pressure Test (page 7).

Fuel Rail Pressure (FRP) Leak Isolation

Tools
•ZTSE4887-2 - High Pressure Return Line Tester
•ZTSE6098 - High Pressure Rail Plug
 Retain High Pressure Return Line Tester ZTSE4887-2 connection to injector return line from previous test.
 Disconnect number six injector fuel line and cap off rail with High Pressure Rail Plug ZTSE6098.
 Crank engine while monitoring fuel leaking out of test line.
l If fuel is leaking out of test line, leave High Pressure Rail Plug ZTSE6098 connected. Continue capping off one injector
supply port at a time until fuel rail builds starting pressure. Replace injector tube and fuel pipe on any injector that is
leaking sufficiently enough to not build pressure.
l If fuel is not leaking out of test line, and fuel rail builds starting pressure, replace number six injector tube and fuel pipe.

Cold Start Assist System

Cold Start Assist System Test

 Use ServiceMaxx™ software to open Hard Start No Start session.
l If ECT1 is above 50°F (10°C), use ServiceMaxx™software to run Cold Start Assist procedure.
l If ECT1 is below 50°F (10°C), go to next step.
 Cycle ignition switch and monitor Wait To Start Lamp.
 When Wait To Start Lamp begins flashing, crank engine while monitoring IMT signal.
l If Intake Manifold Temperature does not increase approximately 10°F (5.5°C) during engine crank, go to Cold Start Fuel
Igniter Test (CSFI) Test (page 12).
l If IMT increases approximately 10°F (5.5°C), Cold Start Assist is working correctly.
Signal Before After
IMT

EGED-520-2 © 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. Page 11 of 12
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Cold Start Fuel Igniter (CSFI) Test

Tools
•EXP-1000 HD by Midtronics - Current Clamp
•DMM
 Use ServiceMaxx™ software to open 2010 BB Actuator session.
 Connect current clamp around CSFI power circuit.
 Select Cold Start Igniter from Actuator drop-down menu.
 Press Start Test button and monitor current draw.
Specification Actual
Current Draw
20A

l If current draw is less than specification, see Cold Start Fuel Igniter in EGES-515-1 Electronic Control Systems
Diagnostics.
l If current draw is above specification, CSFI is working correctly. Go to Fuel Supply at Cold Start Fuel Solenoid (CSFS)
Test.

Fuel Supply at Cold Start Fuel Solenoid (CSFS) Test

Tools
•ZTSE4409 - Pressure Test Kit
•ZTSE6059-1 - Cold Start Solenoid Test Adapter Kit
 Disconnect fuel supply to CSFS.
 Use Cold Start Solenoid Test Adapter Kit ZTSE6059-1 to connect Pressure Test Kit ZTSE4409 to CSFS fuel supply line.
 Crank engine while monitoring Pressure Test Kit ZTSE4409.
Signal Specification Actual
Cold Start Assist Fuel Pressure 10 psi

l If Cold Start Assist Fuel Pressure is below specification, verify fuel line is not restricted. If fuel line is not restricted,
pressure regulator is faulty. Replace secondary fuel filter housing.
l If Cold Start Assist Fuel Pressure is within specification, go to Fuel Supply at Cold Start Fuel Igniter (CSFI) Test.

Fuel Supply at Cold Start Fuel Igniter (CSFI) Test

Tools
•ZTSE4409 - Pressure Test Kit
Note: This test can only be run if ECT1 is below 50°F (10°C), or ServiceMaxx™ software can run Cold Start Assist
procedure.
 Use ServiceMaxx™ software to open Hard Start No Start Session.
 Reconnect fuel supply line to CSFS.
 Disconnect fuel supply to CSFI.
 Use Cold Start Solenoid Test Adaptor Kit to connect Pressure Test Kit ZTSE4409 to CSFI fuel supply line.
 When Wait To Start Lamp stops flashing, crank engine while monitoring Pressure Test Kit ZTSE4409.
Gauge Specification Actual
CSFI Fuel Supply Pressure 10 psi
l If pressure is below specification, verify fuel line is not restricted. If fuel line is not restricted, replace CSFS following
procedures in Engine Service Manual.
l If pressure is within specification, replace CSFI.

Page 12 of 12 EGED-520-2 © 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.