VT 275 and MaxxForce 5 Case to Head Tube and Plug D-Ring Seal Deterioration
Workhorse Start Date: 06/01/2004 End Date: 01/10/2008
Family: VT 275 MaxxForce 5
Plug Assembly (M12) part information added.
Step 36 after Figure 13 has been revised.
High pressure oil leakage internally within the engine can eventually lead to
no start and hard start conditions resulting from lack of high pressure oil to
power the fuel injectors.
Case-to-head Tubes and Plugs Kit
Plug Assembly (M12)
NOTE: There are a lot of graphics in this procedure. Please wait for them
to load. 13 graphics.
To prevent personal injury or death, make sure the
engine is in neutral or park, parking brake is set, and wheels are blocked
before doing diagnostic or service procedures on engine or vehicle.
To prevent personal injury or death, remove ignition
key or disconnect battery so engine can not be started while you are working on
the front of the engine.
To prevent personal injury or death, let a hot engine
cool sufficiently before doing diagnostic or service procedures.
To prevent personal injury or death, do not let engine
fluids stay on your skin. Clean skin and nails with hand cleaner and wash with
soap and water. Wash or discard clothing and rags contaminated with engine
Remove Case to Head Tube
1. Open hood assembly.
2. Remove engine housing cover.
3. Remove air cleaner housing assembly.
4. Remove charge air cooler intake hose.
5. Remove oil filler tube.
6. Remove oil dipstick tube mount bolt from head.
7. Remove oil dipstick tube.
8. Disconnect Injection Control Pressure (ICP) sensor.
9. Remove Injection Control Pressure (ICP) sensor.
10. Remove high pressure turbocharger assembly crossover tube.
11. Remove engine lifting bracket (right rear).
12. Reposition engine wiring harness from on top of the valve cover.
13. Remove oil fill tube adapter from valve cover.
14. Remove right valve cover mount bolts (9 M6 x 35M bolts) (Figure 1).
15. Remove right valve cover from vehicle (Figure 2).
Figure 1. Valve Cover (Right
Figure 2. Valve Cover Removal
Figure 3. High Pressure Oil
Rail (left Shown)
High pressure oil rail (left)
Rail port plug
Case-to-head tube plug
M6 x 40 bolt (7)
NOTE: Limited access prevents removing
case-to-head tube assemblies. Depending on how the assembly comes out, a service
tool in Figure 7 might have to be used to remove the tube held in the oil
manifold; or, if the tube and plug come out together, they will have to be
separated to complete removal.
16. Remove case-to-head tube plug and the rail port plug with a 10 mm hex bit
socket or wrench (Figure 4).
NOTE: On occasion, the case-to-head tube
(lower) will come out along with the case-to-head plug. If this occurs, discard
entire case-to-head tube assembly. Refer to case-to-head tube assembly (Figure
Figure 4. Removing
Crankcase-to-Head Tube Plug (square head socket shown)
Figure 5. Crankcase-to-Head
NOTE: The square socket identifies the
short crankcase-to-head tube plug. The hex socket identifies the longer
crankcase-to-head tube plug (with check valve).
NOTE: The square socket short
crankcase-to-head tube plug and crankcase-to-head tube assembly is not available
for service (Figure 7, Items 1 and 2; service with Items 3 and 4).
Figure 6. Crankcase-to-Head
Crankcase-to-head tube plug (short)
Crankcase-to-head tube (used with Item 1)
Crankcase-to-head tube plug (long - with check valve)
Crankcase-to-head tube (used with Item 3)
17. Using the needed service tool (Figure 7), remove the crankcase-to-head
tube assembly from the high-pressure oil rail (Figure 6, Item 4). If the tube
cannot be removed due to chassis interference, go to Step 20.
NOTE: The lower crankcase-to-head tube
(Item 4, Figure 6), used with the long crankcase-to-head tube plug, may remain
in the crankcase.
- If crankcase-to-head tube remains in the
crankcase, continue with Step 18.
- If crankcase-to-head tube assembly was removed,
continue with Step 19.
NOTE: The tool set ZTSE4694-FLDUPD was automatically shipped June 5,
2008 to all US and Canadian service dealers. This tool set was shipped per the
Dealer Sales/ Maintenance Agreement and at no charge to the Dealer.
ZTSE4694-FLDUPD - Field Upgrade Components (extended rod and sleeve)
These components extend the length of the current service tool ZTSE4694 and
with this change effective update the existing tools into the ZTSE4694A. These
tools components are being supplied to Navistar's Dealer network at no charge
and will be included in a direct mailing.
Figure 7. ZTSE4694-FLDUPD
Figure 8. Crankcase-to-Head
Tube Removal Tool
Tube Removal Tool ZTSE4694A
Lower Plug and Tube Removal Tool ZTSE4923
Broken Lower Plug Removal Tool ZTSE4922
18. Insert the Crankcase-to-head tube Removal Tool (Item 1, Figure 8) into
the crankcase-to-head tube, tighten T-handle, and pull out tube. If the lower
portion of the plug remains in the lower crankcase-to-head tube, use tool 2 to
attach to the lower plug and pull out plug and tube.
If the lower portion of the plug has had the
threaded top broken off, use tool 3 to hook the plug and pull out plug and tube.
NOTE: Do Steps 20 and 21 only if there is
not enough clearance to remove the case-to-head tube.
19. Discard crankcase-to-head tube and go to Step 26.
20. Loosen and remove seven M6 x 40 bolts securing the oil rail assembly to
the rocker arm carrier.
Figure 9. Oil Rail Bolts
21. Lift oil rail assembly straight away from injectors and case-to-head tube
assembly. Allow oil to drain back to the sump or other suitable container
(Figure 10). Go to Step 17 to remove broken case-to-head tube assembly
To prevent engine damage, do not remove the 1¼ x 20
UNF oil rail end plugs or single ball tubes. Service parts are not available to
support these components.
Figure 10. Non-serviceable oil
Single ball tube (3)
Oil rail end plug (2)
NOTE: The procedure for removing the
case-to-head tube assembly is the same for both sides of the engine.
New service tools were shipped
the week of May 19, 2008 to accommodate the situation that might occur on the
removal of the case-to-head tubes. These new tools are shown in Figure 8.
To prevent engine damage, replace case-to-head tubes
and rail port plugs if removed. D-ring seals are not replaceable. Inspect each
D-ring carefully for cuts, abrasions, and twisting. Never use a tube with any of
If high pressure oil rail was not removed, go to Step 26.
22. Install right High Pressure Oil Rail (HPOR).
Figure 11. Align Oil Rail
Assembly to Injector Oil Inlets
23. Using both hands, align the oil rail assembly with the oil inlets of each
fuel injector. Push down evenly until oil rail assembly is firmly seated (Figure
24. Install oil rail assembly M6 x 40 bolts finger tight.
(Right click on graphic to bring up an option
Figure 12. Oil Rail Torque
25. Tighten M6 x 40 bolts to 13 Nm (115 lbf-in) torque in the above sequence
26. Lubricate the D-rings on the case-to-head tube (Figure 6, Item 4) with
clean engine oil and install into the branch tube.
27. Install right case-to-head tube plug (Figure 6, Item 3) and rail port
28. Tighten case-to-head tube assembly to special torque 82 N-m (60 lbf-ft).
Figure 13. Engine Compartment
with Cover Removed
29. Remove access plate on left side of engine cover (Figure 13). (Plate may
be held on with rivets that will have to be drilled out.)
30. Disconnect crankcase ventilation breather assembly hose from breather.
31. Remove left valve cover mount bolts.
32. Remove left valve cover and breather from vehicle.
33. Remove left Case-to-Head Tube assembly and rail port plug.
34. Install left case-to-head tube assembly.
35. Install rail port plug .
36. Remove and replace M12 Plug Assembly (P/N(NNN) NNN-NNNN91) on the left hand
side HPOR that corresponds in location to the ICP sensor on the right hand side
HPOR. Torque Plug Assembly to 27 N-m (20 lbf-ft).
37. Install left valve cover and torque to 9 N-m (84 lbf-in). Replace the
o-ring on the CCV breather fitting in the valve cover with the o-ring supplied
in the service kit.
38. Connect crankcase ventilation breather assembly hose to breather.
39. Install left side floor access panel (caulk edges of panel before putting
it in place to make sure it is sealed).
40. Install accelerator pedal position sensor.
41. Install right valve cover and torque to 9 N-m (84 lbf-in).
42. Install oil filler tube adapter to valve cover.
43. Position engine wiring harness over valve cover.
44. Install high pressure turbocharger assembly crossover tube.
45. Install Injection Control Pressure sensor (ICP) and torque to 27N-m (20
lbf-ft), per IK(NNN) NNN-NNNNdated 11/14/07.
46. Connect Injection Control Pressure (ICP) sensor.
47. Install oil dipstick tube mount bolts.
48. Install right rear engine lifting bracket.
49. Install oil filler tube.
50. Install tie straps as necessary.
51. Install charge air cooler intake hose.
52. Install air cleaner housing assembly.
53. Start engine assembly and check for proper operation.
54. Install engine housing cover.
55. Top off engine oil.
56. Close hood assembly.