TXT1268701

UPDATE KIT
FOR

ITWX4048

ELECTRICAL HARNESS REPAIR KIT

Application:2010 Emissions Model Year

MaxxForce 7, MaxxForce DT, 9 & 10

USER GUIDE SUPPLEMENT

4-09-2012 (Version 14)
 Table of Contents

Tool Circuit Page Number

Acronym Identification 2

Harness Guide Overview 3

49303 (ITWX49303) 4

49304 (ITWX49304) 4

49305 (ITWX49305) 5

49308 (TXT126870102) 5

401714 (TXT126870103) 6

405780 (TXT126870133) 6

Connector Maintenance/Splice - Heat Shrink Procedures 7

Connector Matrix 8

Replacement Parts 9

1
 Acronym Identification
AFTFIS After Treatment Fuel Inlet Sensor
CMP/CKP Cam/Crank Position
EBPV Exhaust Brake Pressure Valve
ECT/EOT Engine Coolant/Engine Oil Temperature
EGR Exhaust Gas Recirculation
EGT/EGCIT Exhaust Gas Coolant In Temperature
EGT/EGCOT Exhaust Gas Coolant Out Temperature
ETV Engine Throttle Valve
FP Fuel Pump
FH Fuel Heater
HPP High Pressure Pump
HS Humidity Sensor
MAF/AIT Manifold Air Flow/Air Intake Temperature
IMT Intake Manifold Temperature
IAHR Intake Air Heater Relay
TCWC Turbocharger Waste Gate Control
UVC Under Valve Cover
IMP Intake Manifold Pressure
EOP Engine Oil Pressure
FDP Fuel Delivery Pressure
WIF Water In Fuel Sensor
EBP Exhaust Back Pressure
IPR Injection Pressure Regulator
AFTFP2 After Treatment Fuel Pressure 2
AFTFSV After Treatment Fuel Shutoff
AFTFD After Treatment Doser
AFTFP1 After Treatment Fuel Pressure 1

2
 Electrical Harness Repair Kit Overview

The purpose of this guide is to assist the technician in the use of the
Update kit for the TWX4048 Repair Kit. Some of the tools shown in this
guide were issued in the original kit. The 3 new tools supplied in this kit are
also shown in this guide. The proper repair procedures for the electrical
systems are outlined in the appropriate service manuals provided by Navistar
Service.
Outlined in this guide are the proper procedures for the use of the
terminal release tools, crimping, and heat shrink procedures.
When attempting to remove the terminal from the connector, it is
important to push the terminal into the connector before inserting the tool to
release the locking tab on the terminal. Failure to do so will cause the
terminal tool to bend the tab on the terminal and make it difficult to remove it
from the connector. Because some of the connectors have a limited space for
the terminal tools, care must be taken during the removal procedure to prevent
damage to the terminal tool.
Please note the tool usage instructions are representations of the
connectors on the harness. Please refer to the drawer lid decals to determine
which tool is used on each connector in the kit. The correct pigtail and tool
for each connector is noted on these decals.

3
 Terminal Removal Instructions

49303 (ITWX49303)
Two different connectors shown.
Push the wire forward into the connector and hold, insert the tool into the front of the
connector over the terminal until the tool bottoms out. This will release the tabs on the
terminal. Gently pull the wire out of the rear of the connector. Detail shown is the tip of
the tool.

49304 (ITWX49304)
Remove the insert using tool number 439305 Push the wire forward into the connector
and hold, insert the tool into the front of the connector next to the terminal. Push the
release tab to release the terminal. Gently pull the wire out of the rear of the connector.
Detail shown is the tip of the tool.

4
49305 (ITWX49305)
This tool is used to remove the locking inserts installed in some connectors. Place the
hook into a hole or slot in the locking tab or insert and pull to remove. Next use the
appropriate tool to remove the terminal from the connector. Detail shown is the tip of the
tool.

49308 (TXT126870102)
Push the wire forward into the connector and hold, insert the tool into the front of the
connector over the terminal until the tool bottoms out. This will release the tabs on the
terminal. Gently pull the wire out of the rear of the connector. Detail shown is the tip of
the tool.

5
401714 (TXT126870103)
Carefully move the alignment retainer approximately 1/16th inch to allow access for the
tool into the end of the connector. If the connector doesnt have the retainer, use the tool
to remove the terminal. (see illustration A) Care must be taken as the retainer is not
available separately and is very fragile. Push the wire forward into the connector and
hold, insert the tool into the front of the connector over the terminal until the tool bottoms
out. This will release the tabs on the terminal. Gently pull the wire out of the rear of the
connector. Detail shown is the tip of the tool.

Figure A Figure B

405780 (TXT126870133)
Remove the blue retainer pin from the connector. Push the wire forward into the
connector and hold, insert the tool into the front of the connector over the terminal until
the tool bottoms out. This will release the tabs on the terminal. Gently pull the wire out
of the rear of the connector. Detail shown is the tip of the tool.

6
 Connector Maintenance
Never attempt to insert the probe of the test meter lead into the pin sockets, rather
touch the probe to the face of the pin. Damage to the socket will result and may
cause intermittent open connections. When cleaning connectors that have corrosion
or moisture problems, use a fast drying, ozone-safe contact cleaner. For best
results, use a cleaning brush with stainless steel bristles to remove the corrosion.
Flush with contact cleaner until clean. Make sure sockets are dry before
reassembly. Compressed air is acceptable to use if contact cleaner is not available.

Splice and Heat Shrink Procedures

See detail of the splice, solder, and heat shrink operation here. Remove the slugs
from the pigtail, put the heat shrink on the wire and insert wires into the splice and
then solder. Heat the splice with the solder gun until the solder flows around the
wire and into the splice. Use an appropriate heat source and heat the heat shrink
until the sealer starts to flow out of the heat shrink cover.

7
 TXT1268701 Update Kit Connector Matrix
MaxxForce MaxxForce 7
Drawer Part No. Connector Acronym DT,9,10 (2010) (2010) Pigtail Tools

B ITWX404840K AC COMPRESSOR X N/A N/A

D TXT126870105 AFTFP2 X TXT126870117 TXT126870103

D TXT126870106 ECT/EOT/AFTFSV X (AFTFSV) X ITWX404833 ITWX49303

D TXT126870107 ETV X X TXT126870124 TXT126870133

ITWX49305
D TXT126870108 MAF/AIT X X ITWX404829 ITWX49304

D TXT126870109 EBPV X TXT126870119 TXT126870133

ITWX49305
D TXT126870110 IMT X X ITWX404826 ITWX49304

D TXT126870111 AFTFD X TXT126870117 TXT126870103

D TXT126870112 AFTFP1 X TXT126870117 TXT126870103

ITWX49305
D TXT126870113 EGR X X TXT126870123 ITWX49304
ITWX49305
D TXT126870114 EGT/EGCIT X X TXT126870121 ITWX49304
ITWX49305
D TXT126870115 FUEL PUMP X TXT126870122 ITWX49304

D TXT126870116 FUEL PUMP X TXT126870121 ITWX49304

D TXT126870127 AFTFIS/HUMIDITY SENSOR X X TXT126870117 TXT126870103

ITWX49305
D TXT126870134 UVC #1 X TXT126870120 ITWX49304
ITWX49305
D TXT126870135 UVC #2,3, & 4 X TXT126870120 ITWX49304

D TXT126870136 HPP JUMPER X TXT126870128 ITWX49304

D TXT126870137 IAHR RELAY X X TXT126870130 ITWX49304

ITWX49305
D TXT126870138 EGT/EGCOT X ITWX404876 ITWX49304

D TXT126870143 FUEL HEATER X X TXT126870129 TXT126870102

D TXT126870144 TCWC X X TXT126870125 ITWX49303

D TXT126870145 HPP JUMPER X TXT126870118 ITWX49304

ITWX49305
A ITWX404814 WIF X X ITWX404826 ITWX49304
ITWX49305
A ITWX404809 IMP/EOP/FDP/EBP X X ITWX404830 ITWX49304

A ITWX404813 IPR X ASSEMBLY N/A

ITWX49305
A ITWX404801 CKP/CMP X (CKP) X (CMP) ITWX404826 ITWX49304
ITWX49305
A ITWX404815 CMP/CKP X (CMP) X (CKP) ITWX404826 ITWX49304

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 Replacement Parts
Navistar Part Number Description Quantity in Kit Order Quantity
TXT126870141 10-12 ga. Splices 25
TXT126870104 14-16 ga. Splices 25
TXT126870101 18-22 ga. Splices 25
TXT126870105 Connector 2
TXT126870106 Connector 2
TXT126870107 Connector 3
TXT126870108 Connector 2
TXT126870109 Connector 2
TXT126870110 Connector 3
TXT126870111 Connector 2
TXT126870112 Connector 2
TXT126870113 Connector 2
TXT126870114 Connector 3
TXT126870115 Connector 2
TXT126870116 Connector 2
TXT126870127 Connector 2
TXT126870134 Connector 2
TXT126870135 Connector 2
TXT126870136 Connector 2
TXT126870137 Connector 3
TXT126870138 Connector 2
TXT126870143 Connector 2
TXT126870144 Connector 3
TXT126870145 Connector 2
TXT126870139 Connector Back Shell 3
TXT126870140 Connector Back Shell 3
TXT126870142 Heat Shrink 30
TXT126870117 Pigtails (1 tube of 12) 3
TXT126870118 Pigtails (1 tube of 12) 1
TXT126870119 Pigtails (1 tube of 12) 2
TXT126870120 Pigtails (1 tube of 12) 1
TXT126870121 Pigtails (1 tube of 12) 1
TXT126870122 Pigtails (1 tube of 12) 1
TXT126870123 Pigtails (1 tube of 12) 1
TXT126870124 Pigtails (1 tube of 12) 1
TXT126870125 Pigtails (1 tube of 12) 1
TXT126870128 Pigtails (1 tube of 12) 1
TXT126870129 Pigtails (1 tube of 12) 1
TXT126870130 Pigtails (1 tube of 12) 1
ITWX404833 Pigtails (1 tube of 12) 1
TXT126870102 (49308) Terminal Tool 1
TXT126870103 (401714) Terminal Tool 1
TXT126870133 (405780) Terminal Tool 1

Replacement parts should be ordered through Navistar

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NOTES

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