Navistar N9 and N10 Engine Workshop Repair Service Manual

-
This Workshop Service Repair manual PDF download for the N9 and N10 Navistar Engine has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

Navistar N9 and N10 Engine
EPA 10 - US, Canada, Mexico


TABLE OF CONTENTS :

Foreword
Service Diagnosis
Safety Information
Engine Identification
Mounting Engine on Engine Stand
Engine Electrical
Down Stream Injection (DSI) & Related Components
Dual Stage Turbocharger and Exhaust Brake
Exhaust Gas Recirculation (EGR) System
Intake, Inlet, and Exhaust Manifolds
Fuel and High-Pressure Oil Systems
Engine Brake
Air Compressor and Power Steering Pump
Oil System Module Assembly
Oil Pan and Oil Suction Tube
Front Cover, Cooling System, and Related Components
Cylinder Head and Valve Train
Flywheel and Flywheel Housing
Power Cylinders
Crankcase, Crankshaft, and Camshaft
Abbreviations and Acronyms
Terminology
Appendix A – Specifications
Appendix B – Torques
Appendix C – Special Service Tools


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 0000004021
Total Pages : 515


This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

-

toc
Table of Contents
Safety Terminology
Safety Instructions
Work Area
Safety Equipment
Protective Measures
Vehicle
Engine
Fire Prevention
Batteries
Compressed Air
Tools
Fluids Under Pressure
Fuel
Removal of Tools, Parts, and Equipment
Table of Contents
Engine Identification
Engine Serial Number
Engine Serial Number Examples
Engine Serial Number Codes
Engine Emission Label
Engine Accessory Labels
Engine Description
Standard Features
Optional Features
Optional Cold Climate Features
Chassis Mounted Features
Engine Component Locator
Table of Contents
Engine Preparation
Clean Engine
Drain Coolant
Drain Oil
Removing Engine from Vehicle
Boost Control Harness Assembly and Turbocharger 2 Wastegate Control (TC2WC) Valve
Turbo Air Inlet Duct Assembly
NOxIN Concentration Sensor and Module assembly
Hydrocarbon Injector Assembly
Throttle Coupling Assembly
Exhaust Brake Valve Assembly
ISC Inlet Duct Assembly
ISC Cooler Assembly
Turbo Oil Supply Assembly
Turbo Wastegate Assembly
Dual Stage Turbo Assembly
Drain High Fin Density EGR Cooler
High Fin Density EGR Cooler Assembly
Oil Filter Removal
Oil Cooler Removal Assembly
Mounting Engine Stand Bracket and Engine
Mounting Engine Stand Bracket
Table of Contents
Illustrations
Electronic Components – Top
Electronic Components – Front
Electronic Components – Exhaust Side
Electronic Components – Intake Side
Electronic Components – Rear
Removal
Boost Control Harness Assembly and Turbocharger 2 Wastegate Control (TC2WC) Valve
Crankshaft Position (CKP) Sensor
Camshaft Position (CMP) Sensor
Exhaust Back Pressure (EBP) Sensor
Engine Control Module (ECM) and Mounting Bracket
Engine Coolant Temperature 1 (ECT1) Sensor
CCOS Sensor
NOxIN Concentration Sensor and Module
Electric Fuel Pump Connector
Fuel Delivery Pressure (FDP) Sensor
Exhaust Gas Recirculation (EGR) Valve Connector
Exhaust Gas Temperature (EGT) Sensor
Engine Oil Pressure (EOP) Sensor
Engine Oil Temperature (EOT) Sensor
Fuel Heater (250 watt)
Intake Air Heater (IAH) Relay Assembly
Injection Control Pressure (ICP) Sensor
Engine Throttle Valve (ETV) Assembly Connector
Injection Pressure Regulator (IPR) Valve Connector
Intake Manifold Pressure (IMP) Sensor
Intake Manifold Temperature (IMT) Sensor
Downstream Injection (DSI) Assembly Connectors
Water In Fuel (WIF) Sensor
Engine Harness Assembly
Valve Cover Gasket Assembly
Inspect
Inspect Wiring Harness, Connectors, and Electrical Components
Installation
Engine Harness Assembly and Camshaft Position (CMP) Sensor
Boost Control Harness Assembly and Turbocharger 2 Wastegate Control (TC2WC) Valve
Crankshaft Position (CKP) Sensor
Exhaust Back Pressure (EBP) Sensor
Electronic Control Module (ECM) and Mounting Bracket
Engine Coolant Temperature 1 (ECT1) Sensor
CCOS Sensor
NOxIN Concentration Sensor and Module
Fuel Delivery Pressure (FDP) Sensor
Exhaust Gas Recirculation (EGR) Control Valve Connector
Electric Fuel Pump Connector
Exhaust Gas Temperature (EGT) Sensor
Engine Oil Pressure (EOP) Sensor
Engine Oil Temperature (EOT) Sensor
Fuel Heater (250 watt) Connector
Intake Air Heater (IAH) Relay Assembly
Injector Control Pressure (ICP) Sensor
Engine Throttle Valve (ETV) Assembly Connector
Injection Pressure Regulator (IPR) Valve Connector
Intake Manifold Temperature (IMT) Sensor
Intake Manifold Pressure (IMP) Sensor
Downstream Injection (DSI) Assembly Connectors
Water In Fuel (WIF) Sensor
Valve Cover Gasket Assembly
Table of Contents
Exploded Views
Down Stream Injection (DSI) Assembly
Hydrocarbon Injector Assembly
Removal
Down Stream Injection (DSI) Assembly
Injection Unit Inlet Tube Assembly
Hydrocarbon Injector Assembly
Cleaning and Inspection
Hydrocarbon Injector (HCI) / Aftertreatment Fuel Injector (AFI) Cleaning
Exhaust Back Pressure Valve Housing Cleaning
Installation
Hydrocarbon Injector Assembly
Injection Unit Inlet Tube Assembly
Down Stream Injection (DSI) Assembly
Table of Contents
Exploded View
Removal
Interstage Inlet Duct Assembly
Interstage Cooler (ISC)
Throttle Coupling
Turbocharger Oil Supply Tube Assembly
Exhaust Brake Valve and Turbocharger Outlet Elbow
Turbocharger Air Inlet Duct
Turbocharger Wastegate Actuator Assembly
Dual Stage Turbocharger Assembly
High-Pressure Turbocharger Center Section
Cleaning, Inspection, and Testing
Inspect and Clean Dual Stage Turbocharger Assembly and Related Parts
Dual Turbocharger Compressor Cleaning and Inspection
Inspection
Removal of Turbocharger Compressor Covers
Assembly
Inspect Turbine and Compressor
Inspect High-Pressure Turbine Housing
Crossover Tube Seal
Installation
High Pressure Turbocharger Center Section Assembly
Dual Stage Turbocharger Assembly
Turbocharger Wastegate Actuator Assembly (without precise regulated shop air pressure)
Turbocharger Wastegate Actuator Assembly (with precise regulated shop air pressure)
Turbocharger Air Inlet Duct
Exhaust Brake Valve and Turbocharger Outlet Elbow
Turbocharger Oil Supply Tube Assembly
Throttle Coupling
Interstage Cooler (ISC)
Interstage Inlet Duct Assembly
Table of Contents
Exploded View
Removal
Draining High Fin Density EGR Cooler
High Fin Density EGR Cooler and Components
EGR Valve Assembly
Engine Throttle Valve (ETV) Assembly
Air and EGR Mixer Duct Assembly
Cleaning, Inspecting, and Testing
Cleaning and Inspecting EGR System Components
Air and EGR Mixer Duct Assembly
EGR Valve Assembly
Engine Throttle Valve Assembly
High Fin Density EGR Cooler
Pressure Testing High Fin Density EGR Cooler
EGR Cooler Vent Tool
EGR Cooler Coolant Port Tool
EGR Cooler Exhaust Inlet Tool
EGR Cooler Exhaust Outlet Tool
SAE J512 Plugs
EGR Cooler Leak Test
Installation
Air and EGR Mixer Duct Assembly
Engine Throttle Valve (ETV) Assembly
EGR Valve Assembly
High Fin Density EGR Cooler and Components
Table of Contents
Exploded View
Removal
Exhaust Manifold
Intake Manifold, Fuel Valve, and Fuel Rail Plugs
Cleaning, Inspection, and Measurements
Exhaust Manifold
Exhaust Back Pressure (EBP) Sensor Tube Assembly
Intake Manifold
Installation
Exhaust Manifold
Intake Manifold, Fuel Valve, and Fuel Rail Plugs
Table of Contents
Exploded Views
Periodic Service
Fuel Strainer
Fuel Filter
Draining Water From Fuel Filter Assembly
Removal
Water In Fuel (WIF) Sensor, Fuel Delivery Pressure (FDP) Sensor, and 250 Watt Fuel Heater
Water Drain Valve Assembly
Brushless Electric Fuel Pump Assembly
Fuel Pressure Regulator Valve Assembly
Fuel Filter Assembly
High-pressure Oil Hose and Elbows
High-pressure Oil Pump Assembly and Injection Pressure Regulator (IPR) Valve Assembly
High-pressure Oil Manifold
Injector Oil Inlet Adapter (Puck) Assembly
Fuel Injector Assemblies
Cleaning and Inspection
Fuel Filter Assembly Service Recommendations
High-pressure Oil System Components
Installation
Fuel Injector Assemblies
Injector Oil Inlet Adapter (Puck) Assembly
High-pressure Oil Manifold
High-pressure Oil Pump Assembly and Injection Pressure Regulator (IPR) Valve Assembly
High-pressure Oil Hose and Elbows
Fuel Filter Assembly
Water Drain Valve Assembly
Brushless Electric Fuel Pump Assembly and Fuel Strainer
Fuel Pressure Regulator Valve Assembly
Water In Fuel (WIF) Sensor, Fuel Delivery Pressure (FDP) Sensor, and 250 Watt Fuel Heater
Table of Contents
Exploded View and Description
High-pressure Oil Manifold (Brake)
Periodic Service
Engine Brake Lash Adjustment
Removal
Engine Compression Brake (ECB) Valve
Engine Compression Brake Pressure (ECBP) Sensor
Valve Cover Gasket (Harness) Assembly (Brake)
High-pressure Oil Manifold (Brake)
Oil Pressure Relief Valve
Brake Actuator Piston Assembly
Cleaning and Inspection
Installation
Brake Actuator Piston Assembly
Oil Pressure Relief Valve
High-pressure Oil Manifold (Brake)
Valve Cover Gasket (Harness) Assembly (Brake)
Engine Compression Brake Pressure (ECBP) Sensor
Engine Compression Brake (ECB) valve assembly
Table of Contents
Illustrations
Air Compressor
Power Steering Pump
Description
Air Compressor
Power Steering Pump
Removal
Power Steering Pump
Air Compressor
Cleaning and Inspection
Installation
Air Compressor
Power Steering Pump Without Air Compressor
Power Steering Pump With Air Compressor
Table of Contents
Exploded View and Description
Removal
Drain Coolant
Oil Cooler Module
Disassemble
Pressure Regulator Valve (Oil)
Thermal Valve (Oil)
Oil Cooler
Cleaning, Inspection, and Testing
Clean Oil Cooler Housing
Oil Cooler Pressure Test
Assemble
Oil Cooler
Thermal Valve (Oil)
Regulator Valve (Oil)
Installation
Oil Cooler Module
Oil Filter
Prime Lubrication System
Priming System
Cranking Method (Alternate)
Table of Contents
Exploded Views
Front Sump
Rear Sump
Removal
Drain Engine Oil
Oil Pan and Gasket
Suction Tube Assembly
Cleaning and Inspecting
Oil Pan and Suction Tube
Installation
Suction Tube Assembly
Oil Pan and Gasket
Fill Engine with Oil
Table of Contents
Exploded View
Removal
Dual Drive Belt
Single Drive Belt
Dual Idler Pulleys
Alternator Support
Secondary Compressor Support, Flat Idler Pulleys, and Idler Support Plate
Coolant Supply Housing (Refrigerant Compressor Mount)
Water Outlet Tube and Thermostat
Water Pump Assembly
Water Inlet Elbow
Fan Drive
Spin-on Fan Drive
Horton DriveMaster® Fan Drive
Vibration Damper, Hub, and Wear Sleeve
Vibration Damper—Single Drive Belt Engines
Vibration Damper—Dual Drive Belt Engines
Damper Hub
Oil Pump Assembly
Front Engine Mount
Front Cover (Front Half)
Idler Gears
Front Cover (Rear Half)
Cleaning, Inspection, and Measurement
Cleaning and Inspection
Measuring Gear Backlash
Lower Idler Gear Backlash
Upper Idler Gear Backlash
Camshaft Gear Backlash
Measuring Oil Pump Side Clearance
Measuring Oil Pump End Clearance
Installation
Front Cover (Rear Half)
Idler Gears
Front Cover (Front Half)
Front Engine Mount
Oil Pump Assembly
Vibration Damper, Hub, and Wear Sleeve
Damper Hub
Vibration Damper—Dual Drive Belt Engines
Vibration Damper—Single Drive Belt Engines
Fan Drive
Spin-on Fan Drive
Horton DriveMaster® Fan Drive
Water Outlet Tube and Thermostat
Water Pump Assembly
Water Inlet Elbow
Coolant Housing (Refrigerant Compressor Mount)
Alternator Support
Dual Idler Pulleys
Secondary Compressor Support, Flat Idler Pulleys, and Idler Support Plate
Single Drive Belt
Dual Drive Belt
Table of Contents
Illustrations and Description
Exploded View of Cylinder Head and Valve Train Components
Description
Periodic Service
Valve Lash Adjustment
Removal
Valve Cover
Rocker Arm Assembly
Rocker Arms
Cylinder Head
Roller Tappets and Guides
Cleaning, Inspection, Measurement, and Testing
Measuring Camshaft Lobe Lift
Cylinder Head Cleaning
Cleaning and Inspection of Roller Tappets and Guides
Cleaning and Inspection of Push Rods
Measuring Rocker Shaft
Inspection and Measurement of Rocker Arms
Measuring Cylinder Head Warpage
Measuring Cylinder Head Thickness
Measuring Valve Seat Leakage
Inspecting Cylinder Head for Cracks
Cylinder Head Pressure Test
Reconditioning
Removal of Valves from Cylinder Head
Inspection and Measurement of Valve Guides
Replacing Valve Guides
Inspecting and Measurement of Valve
Refacing Valves
Valve Face
Refacing Valve Stem Tip
Valve Face-to-Seat Contact Inspection
Resurfacing Valve Seats
Replacing Valve Seats
Removal
Installation
Valve Spring Inspection
Inspecting Valve Rotators and Retainers
Inspecting Valve Spring Retainer Keys
Replacing Fuel Injector Sleeves
Removal
Tool Removal
Cleaning
Installation
Installing Valves
Cleaning
Assembly
Installation
Roller Tappets and Guides
Cylinder Head
Torque Procedure for Torque-to-yield Head Bolts
Rocker Arms
Rocker Arm Assembly
Valve Cover
Table of Contents
Exploded View and Description
Flywheel housing SAE 1
Flywheel housing SAE 1A
Flywheel housing SAE 2
Flywheel housing (Bus) SAE 2
Flywheel and Flexplate Applications
Manual Transmissions
Automatic Transmissions
Removal
Flywheel Assembly
Flexplate (Automatic Transmissions)
Allison 2000 Series Transmissions
MD-3000 Series Transmissions
Crankshaft Timing Disk
Rear Oil Seal Assembly
Flywheel Housing
Cleaning, Inspection, and Measurement
Clean and Inspect
Measurement of Flywheel Housing Face Runout
Measurement of Flywheel Housing Bore Concentricity
Measurement of Crankshaft Pilot Concentricity
Measurement of Flywheel Surface Runout
Recondition
Resurface Flywheel
Replacement of Flywheel Ring Gear
Installation
Flywheel Housing and Rear Engine Mounting Brackets
Rear Oil Seal
Crankshaft Timing Disk
Flywheel Assembly
Flexplate (Automatic Transmissions)
Allison 2000 Series Transmissions
MD-3000 Series World Transmissions
Table of Contents
Exploded View and Description
Removal
Piston Cooling Tubes
Piston Protrusion Measurement – Preliminary Check
Piston and Connecting Rod Assembly
Piston Pin and Rings
Cylinder Sleeve
Cleaning, Inspecting, and Measuring
Cleaning and Inspecting
Measuring Pistons
Top Compression Ring Grooves
Intermediate and Oil Control Ring Groove
Piston-to-Cylinder Sleeve Running Clearance
Measuring Piston Rings
Measuring Piston Pins
Measuring and Inspecting Connecting Rods
Piston Pin Bushing
Connecting Rod Bolt Holes Inspection
Connecting Rod Bearing Bore (Big End)
Connecting Rod Bend and Twist
Bearing Fitting Procedures
Measuring Bearing Running Clearance
Measuring Connecting Rod Side Clearance
Measuring Cylinder Sleeves
Telescoping Gauge Method
Dial Bore Gauge Method
Feeler Gauge Method
Measuring Counterbore Depth
Cylinder Liner Height Gauge Method
Depth Micrometer Method
Measuring Cylinder Sleeve Protrusion
Reconditioning
Resurfacing Counterbore
Preparation
Mounting the Counterbore Reconditioning Tool
Tool Settings
Cutting Counterbore Ledge
Tool Care and Maintenance
Installation
Cylinder Sleeve
Piston Rings
Piston Pin
Piston and Connecting Rod Assembly
Torque-to-yield Procedure for Connecting Rods
Piston Cooling Tubes
Engine Run-in Procedure
Table of Contents
Exploded Views and Description
Centrifuge Oil Filter
Crankcase Breather Assembly with Turbine
Crankcase, Crankshaft, and Camshaft
Removal
Centrifuge Oil Filter
Crankcase Ventilation System
Oil Level Gauge Assembly
Coolant Heater Assembly (optional)
Crankcase Ladder Assembly
Camshaft Gear
Camshaft Assembly
Camshaft Bearings
Main Bearing Caps, Crankshaft, and Main Bearings
Oil Pump Spline Drive and Crankshaft Gear
Cleaning, Inspection, and Measurement
Camshaft Assembly
Centrifuge Oil Filter Cleaning and Inspection
Crankcase Breather Assembly
Crankcase, Cup Plugs, and Piston Cooling Tubes
Crankshaft and Main Bearings
Camshaft End Play Measurement
Camshaft Lobes and Journals Measurement
Crankshaft End Play Measurement
Installation
Camshaft Bearings
Camshaft Assembly
Camshaft Gear
Crankshaft Gear and Oil Pump Spline Drive
Upper Main Bearings and Crankshaft Assembly
Main Bearing Fit Procedure
Main Bearings and Caps
Torque Procedure for Torque-to-yield Main Bearing Cap Bolts
Crankcase Ladder Assembly
Coolant Heater Assembly (optional)
Oil Level Gauge Assembly
Crankcase Ventilation System
Centrifuge Oil Filter
Table of Contents
Abbreviations and Acronyms
Abbreviations and Acronyms
Table of Contents
Terminology
Terms
Table of Contents
Specifications
Fuel and High-Pressure Oil Systems
Engine Brake
Air Compressor and Power Steering Pump
Oil System Module Assembly
Oil Pan and Oil Suction Tube
Front Cover, Cooling System, and Related Components
Cylinder Head and Valve Train
Flywheel and Flywheel Housing
Power Cylinders
Crankcase, Crankshaft, and Camshaft
Table of Contents
General Torque
Bolt Identification
General Torque Guidelines
Standard Torque Charts
Using a Torque Wrench Extension
Special Torque
Mounting Engine on Engine Stand
Engine Electrical
Down Stream Injection (DSI) & Related Components
Dual Stage Turbocharger and Exhaust Brake
Exhaust Gas Recirculation (EGR) System
Intake, Inlet and Exhaust Manifolds
Fuel and High-pressure Oil Systems
Engine Brake
Air Compressor and Power Steering Pump
Oil System Module Assembly
Oil Pan and Oil Suction Tube
Front Cover, Cooling System, and Related Components
Cylinder Head and Valve Train
Flywheel and Flywheel Housing
Power Cylinders
Crankcase, Crankshaft, and Camshaft
Table of Contents
Tool Ordering Information
Special Tools
Mounting Engine on Engine Stand
Dual Stage Turbocharger and Exhaust Brake
Exhaust Gas Recirculation (EGR) System
Intake, Inlet and Exhaust Manifolds
Fuel and High-pressure Oil Systems
Engine Brake
Oil System Module Assembly
Oil Pan and Oil Suction Tube
Front Cover, Cooling System, and Related Components
Cylinder Head and Valve Train
Flywheel and Flywheel Housing
Power Cylinders
Crankcase, Crankshaft, and Camshaft
Photos of Essential Tools
tables
N9 and N10 Diesel Engines
Engine Component Locations
Component
Location
Valve Seat Insert Selection Chart
Piston Ring Gauge Pin Selection
Water Pump Pulley Diameters and Spin Ratios
Fan Drive Configurations Diameters and Ratios (DriveMaster®) — Dual Drive Belt
Valve Specifications
Valve Spring Specifications
Cylinder Head and Valve Train Specifications
Flywheel Housing
Crankshaft Pilot
Flywheel
Flywheel Resurfacing Specifications
Connecting Rod Specifications
Piston Specifications – N9 and N10
Piston Ring Specifications (in 116.573 mm diameter gage ring)
Piston Pin Specifications
Cylinder Sleeve Specifications
Crankcase Specifications
Camshaft Specifications
Camshaft Bearing Specifications
Crankshaft Specifications
Crankshaft Specifications (continued)
Standard Torque Values - Class 10.9 Metric Flange Head Bolts and Studs

-