ENGINE DIAGNOSTIC BREAKOUT

HARNESS QUICK REFERENCE GUIDE

®

EGES-545
 ®

Engine Diagnostic Breakout Harness

Quick Reference Guide
MaxxForce® MaxxForce® 2007 2010 2007 2010
2007 2007 2010 2011
Breakout Connector MaxxForce® MaxxForce® MaxxForce® MaxxForce®
MaxxForce® 5 MaxxForce® 7 MaxxForce® 7 MaxxForce® 15
Part Number Harness End View DT, 9, and 10 DT, 9, and 10 11 and 13 11 and 13

Intake Air Temp (IAT) Intake Air Temp (IAT) Intake Air Temp (IAT) Intake Air Temp (IAT) Intake Air Temp (IAT)
ZTSE4483 A B Sensor Sensor Sensor Sensor Sensor

4483 CV4483

Engine Coolant Level

(ECL) Sensor, Ambient Air
Injection Pressure Injection Pressure Injection Pressure Temp (AAT) Sensor,
ZTSE4484 Regulator (IPR) Valve Regulator (IPR) Valve Regulator (IPR) Valve and Engine Compression
Brake 1-3 (ECB 1-3)
2 1 Solenoids

4484 CV4484

F A
Accelerator Position Accelerator Position
Accelerator Pedal Accelerator Pedal Accelerator Pedal Accelerator Pedal Accelerator Pedal Accelerator Pedal
ZTSE4485A Position (APP) Sensor Position (APP) Sensor Position (APP) Sensor
Sensor / Idle Validation
Position (APP) Sensor
Sensor / Idle Validation
Position (APP) Sensor Position (APP) Sensor
Switch (APS/IVS) Sensor Switch (APS/IVS) Sensor

4485 CV4485
87
4
3 Electronic Control Engine Fan (EFAN)
ZTSE4596 85 86
Module (ECM) Relay Relay and Starter Relay
2 1 5

30
4596 CV4596

Engine Coolant
Engine Oil Temp (EOT) Engine Oil Temp (EOT) Engine Oil Temp (EOT)
Temp (ECT) Sensor, Engine Engine Oil Temp (EOT)
2 1 Sensor, Engine Fuel Sensor, Engine Fuel Sensor, Engine Coolant
Oil Temp (EOT) Sensor, Sensor and Engine Aftertreatment Fuel Aftertreatment Fuel
ZTSE4602 Engine Fuel Temp (EFT)
Temp (EFT) Sensor, Temp (EFT) Sensor, and
Coolant Temp (ECT)
Temp (ECT) Sensor, and
Shutoff Valve (AFTFSV) Shutoff Valve (AFTFSV)
and Engine Coolant Engine Coolant Sensor-Aftertreatment Fuel
Sensor, and Manifold Air Sensor
Temp (ECT) Sensor Temp (ECT) Sensor Shutoff Valve (AFTFSV)
Temp (MAT) Sensor

4602 CV4602

Actuator Power (ACT PWR)

Aftertreatment (AFT) Relay
Engine Control Module Relay and Engine Control
ZTSE4674 (ECM) Relay
and Electronic Control
Module Power (ECM PWR)
Module (ECM) Relay
Relay

4674 CV4674

Fuel Pump Control Relay

ZTSE4693 and A/C Clutch Relay

4693 CV4693
EGES-545 Navistar, Inc. All rights reserved
 ®

Engine Diagnostic Breakout Harness

Quick Reference Guide
MaxxForce® MaxxForce® 2007 2010 2007 2010
2007 2007 2010 2011
Breakout Connector MaxxForce® MaxxForce® MaxxForce® MaxxForce®
MaxxForce® 5 MaxxForce® 7 MaxxForce® 7 MaxxForce® 15
Part Number Harness End View DT, 9, and 10 DT, 9, and 10 11 and 13 11 and 13
5 1

Engine Throttle Valve (EGV)

Exhaust Gas Recirculation Engine Throttle Exhaust Lamba
ZTSE4735A (EGR) Valve
and Exhaust Gas
Valve (ETV) Sensor (ELS)
Oxygen (O2S) Sensor Oxygen (O2S) Sensor
Recirculation (EGR) Valve

6 2
4735 CV4735

4 1
Variable Geometry
Turbocharger (VGT) Variable Geometry
ZTSE4739 Actuator and Fuel Volume Turbocharger (VGT)
Control Valve/Fuel Pressure Actuator
Control Valve (FVCV/FPCV)

4739 CV4739
5 3 1

Exhaust Gas Recirculation Exhaust Gas Recirculation

ZTSE4758A (EGR) Valve (EGR) Valve

6 4 2
4758 CV4758
Diesel Oxidation Catalyst Diesel Oxidation Catalyst
Diesel Oxidation
Diesel Oxidation Catalyst Exhaust Gas Temp 1-3 Inlet Temp (DOCIT) Sensor, Inlet Temp (DOCIT) Sensor,
Catalyst Inlet Temp
Inlet Temp (DOCIT) Sensor, (EGT 1-3) Sensors, Diesel Particulate Filter Diesel Particulate Filter
(DOCIT) Sensor, Diesel
2 1 Exhaust Gas Temp 1-3 Exhaust Gas Temp 1-3 Particulate Filter Inlet Exhaust Gas Temp 1-3
Diesel Particulate Filter Aftertreatment Fuel Supply Inlet Temp (DPFIT) Sensor, Inlet Temp (DPFIT) Sensor,
ZTSE4760A (EGT 1-3) Sensors (EGT 1-3) Sensors Temp (DPFIT) Sensor, and (EGT 1-3) Sensors
Inlet Temp (DPFIT) (AFS) and Aftertreatment Diesel Particulate Filter Diesel Particulate Filter
Sensor, and Diesel Fuel Drain (AFD) Valves, Outlet Temp (DPFOT) Outlet Temp (DPFOT)
Diesel Particulate Filter
Particulate Filter Outlet and Aftertreatment Fuel Sensor, and Exhaust Sensor, and Exhaust
Outlet Temp (DPFOT)
Temp (DPFOT) Sensor Injector (AFI) Gas Recirculation Gas Recirculation
Sensor
4760 CV4760 Temp (EGRT) Sensor Temp (EGRT) Sensor

1 3

Exhaust Gas Differential Exhaust Gas Differential Exhaust Gas Differential Exhaust Gas Differential Diesel Particulate Filter Exhaust Gas Differential Diesel Particulate Filter Diesel Particulate Filter
ZTSE4761A Pressure (EGDP) Sensor Pressure (EGDP) Sensor Pressure (EGDP) Sensor Pressure (EGDP) Sensor Differential Pressure Pressure (EGDP) Sensor Differential Pressure Differential Pressure
(DPFDP) Sensor (DPFDP) Sensor (DPFDP) Sensor

4761 CV4761

ZTSE4762 16-Pin Electrical Connector 16-Pin Electrical Connector 16-Pin Electrical Connector

4762 CV4762

14
13 15
3 7

ZTSE4764 12
5

4
1
8

2
9
15-Pin Electrical Connector
3
11 10

4764 CV4764
EGES-545 Navistar, Inc. All rights reserved
 ®

Engine Diagnostic Breakout Harness

Quick Reference Guide
MaxxForce® MaxxForce® 2007 2010 2007 2010
2007 2007 2010 2011
Breakout Connector MaxxForce® MaxxForce® MaxxForce® MaxxForce®
MaxxForce® 5 MaxxForce® 7 MaxxForce® 7 MaxxForce® 15
Part Number Harness End View DT, 9, and 10 DT, 9, and 10 11 and 13 11 and 13
D A

ZTSE4765 Intake Throttle Valve (ITV) Intake Throttle Valve (ITV) Intake Throttle Valve (ITV)

H E
4765 CV4765

B A
Manifold Air Temp (MAT) Manifold Air Temp (MAT)
ZTSE4782 Sensor Sensor

4782 CV4782

4 1 Under Valve Cover (UVC)

Under Valve Cover (UVC)
Wiring-Injector Solenoids,
Wiring-Injector Solenoids,
Injector Control Pressure
Injector Control Pressure
(ICP) Sensor, Engine
ZTSE4793 (ICP) Sensor, Brake Control
Compression Brake (ECB)
Pressure (BCP) Sensor,
Sensor, and Compression
and Brake Shut-off
8 5 Brake Pressure (ECBP)
Valve (BSV)
Sensor
4793 CV4793

14
13 15
3 7
Under Valve Cover (UVC)
ZTSE4794 12
5

4
1
8

2
9 15-Pin Electrical Connector
3
11 10

4764 CV4764

ZTSE4808 Glow Plug Glow Plug

4808

4 2
Exhaust Gas Recirculation Cold Start Fuel Solenoid
Cold Start Fuel Solenoid
(EGR) Control Valve, (CSFS), Engine Coolant
(CSFS), Engine Coolant
Engine Coolant Temp (ECT) Temp (ECT) Sensor,
ZTSE4827 Sensor, Engine Oil Engine Oil Level (EOL)
Temp 1-2 (ECT1-2)
Sensors, and Engine
Temp (EOT) Sensor, and Sensor, and Engine Oil
Oil Temp (EOT) Sensor
Cold Start Solenoid (CSS) Temp (EOT) Sensor
1 3
4827 CV4827

1 2 Fuel Pressure Control Aftertreatment Fuel Doser

Aftertreatment Fuel Doser
Valve (FPCV), Crankshaft (AFTFD), Crankshaft (CKP)
Aftertreatment Fuel (AFTFD) and Fuel
ZTSE4828 Doser (AFTFD)
Position (CKP) Sensor, and Sensor, Camshaft (CMP)
Pressure Control
Camshaft Position (CMP) Sensor, and Fuel Pressure
Valve (FPCV)
Sensor Control Valve (FPCV)

4828 CV4828
EGES-545 Navistar, Inc. All rights reserved
 ®

Engine Diagnostic Breakout Harness

Quick Reference Guide
MaxxForce® MaxxForce® 2007 2010 2007 2010
2007 2007 2010 2011
Breakout Connector MaxxForce® MaxxForce® MaxxForce® MaxxForce®
MaxxForce® 5 MaxxForce® 7 MaxxForce® 7 MaxxForce® 15
Part Number Harness End View DT, 9, and 10 DT, 9, and 10 11 and 13 11 and 13

1 3 Aftertreatment Fuel
Fuel Rail Pressure (FRP)
Fuel Rail Pressure (FRP) Pressure 2 (AFTFP2)
ZTSE4829 Sensor
Sensor and Aftertreatment
Sensor and Fuel Rail
Fuel Pressure 2 (AFTFP 2)
Pressure (FRP) Sensor

4829 CV4829

Aftertreatment Fuel
1 4 Aftertreatment Fuel Inlet
Inlet (AFTFI) Sensor,
Manifold Absolute Sensor (AFTFIS) and
Aftertreatment Fuel Inlet Humidity/Air Intake Temp
ZTSE4830 Sensor (AFTFIS)
Pressure/ Intake Air Temp
(HS/AIT) Sensor, and
Turbocharger 2
(MAP/IAT2) Sensor Compressor Inlet
Turbocharger 2 Compressor
Sensor (TC2CIS)
Inlet Sensor (TC2CIS)

4830 CV4830

1 2 Turbocharger 1 Wastegate Turbocharger 1 Wastegate Turbocharger 2 Wastegate

Boost Control Solenoid
ZTSE4831 Control Actuator Control Actuator Control Actuator
(BCS)
(TC1WC) (TC1WC) (TC2WC)

4831 CV4831

1 4
Exhaust Gas Recirculation
Position (EGRP) Sensor
ZTSE4833 and Intake Throttle
Valve (ITV)

2 3
4833 CV4833

2 1
Exhaust Back Pressure
ZTSE4834 Valve (EBPV)
Retarder Control

6 3

4834 CV4834

1 6

ZTSE4844 Electronic Fan (EFAN) Electronic Fan (EFAN)

3 4
4844 CV4844

3
1

Aftertreatment Fuel
ZTSE4845 Pressure (AFP) Sensor

4845 CV4845
EGES-545 Navistar, Inc. All rights reserved
 ®

Engine Diagnostic Breakout Harness

Quick Reference Guide
MaxxForce® MaxxForce® 2007 2010 2007 2010
2007 2007 2010 2011
Breakout Connector MaxxForce® MaxxForce® MaxxForce® MaxxForce®
MaxxForce® 5 MaxxForce® 7 MaxxForce® 7 MaxxForce® 15
Part Number Harness End View DT, 9, and 10 DT, 9, and 10 11 and 13 11 and 13
Injection Control Pressure Intake Manifold Pressure
(ICP) Sensor, Engine Oil
(IMP) Sensor, Injection
Injection Control Pressure Pressure (EOP) Sensor,
Engine Oil Pressure (EOP) Control Pressure (ICP) Engine Coolant Pressure 1
(ICP) Sensor, Exhaust Back Engine Fuel Pressure (EFP)
Sensor, Fuel Delivery Sensor, Engine Oil (ECP1) Sensor, Intake
Pressure (EBP) Sensor, Intake Manifold Pressure Sensor, Exhaust Back Intake Manifold Pressure
ZTSE4850 Engine Oil Pressure (EOP)
Pressure (FDP) Sensor,
(IMP) Sensor Pressure (EBP) Sensor,
Pressure (EOP) Sensor,
(IMP) Sensor
Manifold Pressure (IMP)
and Exhaust Back Fuel Delivery Pressure Sensor, and Crankcase
Sensor, and Fuel Delivery Manifold Absolute Pressure
Pressure (EBP) Sensor (FDP) Sensor, and Pressure Sensor (CCPS)
Pressure (FDP) Sensor (MAP) Sensor, and Brake
Exhaust Back Pressure
Control Pressure (BCP)
4850 CV4850 Sensor (EBP) Sensor

Coolant Mixer Valve Coolant Mixer Valve Coolant Mixer Valve

ZTSE4870 (CMV) (CMV) (CMV)

4870 CV4870

4 3
Ambient Air Temp (AAT) Ambient Air Temp (AAT) Coolant Flow Valve (CFV)
Ambient Air Temp (AAT)
ZTSE4871 Sensor
Sensor and Coolant Sensor and Coolant and Two-Speed Engine
Flow Valve (CFV) Flow Valve (CFV) Fan Control (EFC)

4871 CV4871
4 2

Engine Fuel Pressure Fuel Delivery Pressure Engine Fuel Pressure

ZTSE4881 (EFP) Sensor (FDP) Sensor (EFP) Sensor

1 3
4881 CV4827
4 2

Engine Oil Pressure (EOP) Engine Oil Pressure (EOP) Engine Oil Pressure (EOP)
ZTSE4882 Sensor Sensor Sensor

1 3
4882 CV4827
4 2

Manifold Air Temp (MAT) Intake Manifold Temp (IMT) Intake Manifold Temp (IMT)
ZTSE4883 Sensor Sensor Sensor

1 3
4883 CV4827

5
8 9
1
ZTSE4885 2 Cold Start Relay (CSR) Cold Start Relay (CSR) Cold Start Relay (CSR)

7 6
3
4885 CV4885
EGES-545 Navistar, Inc. All rights reserved
 ®

Engine Diagnostic Breakout Harness

Quick Reference Guide
MaxxForce® MaxxForce® 2007 2010 2007 2010
2007 2007 2010 2011
Breakout Connector MaxxForce® MaxxForce® MaxxForce® MaxxForce®
MaxxForce® 5 MaxxForce® 7 MaxxForce® 7 MaxxForce® 15
Part Number Harness End View DT, 9, and 10 DT, 9, and 10 11 and 13 11 and 13

30 86
Engine Interface
Starter Relay and Engine Starter Relay and Engine Module/Aftertreatment
ZTSE4908 Starter Motor Control
Fan (EFAN) Relay Fan (EFAN) Relay Control Module (EIM/ACM)
Relay
85 87
4908 CV4908

Exhaust Gas Temp (EGT)

ZTSE4946 2 1 Sensor

4946 CV4946

Exhaust Gas Recirculation

ZTSE4948 (EGR) Valve

4 3 2 1
4948 CV4948

2 1 Camshaft Position (CMP) Camshaft Position (CMP) Crankshaft Position (CKP) Crankshaft Position (CKP)
ZTSE4950 Sensor Sensor Sensor Sensor

4950 CV4950

2 1 Crankshaft Position (CKP) Crankshaft Position (CKP) Camshaft Position (CMP) Camshaft Position (CMP) Crankcase Oil Separator
ZTSE4951 Sensor Sensor Sensor Sensor Speed (CCOSS) Sensor

4951 CV4951

Injection Control
Pressure (ICP) Sensor,
4 1 Engine Compression
ZTSE4952 Brake (ECB) Sensor,
and Engine Compression
8 5 Brake Pressure (ECBP)
Sensor
4952 CV4952

Fuel Pressure Control

A B Valve (FPCV) and Fuel
ZTSE4958 Volume Control
Valve (FVCV)

4958
C CV4958
EGES-545 Navistar, Inc. All rights reserved
 ®

Engine Diagnostic Breakout Harness

Quick Reference Guide
MaxxForce® MaxxForce® 2007 2010 2007 2010
2007 2007 2010 2011
Breakout Connector MaxxForce® MaxxForce® MaxxForce® MaxxForce®
MaxxForce® 5 MaxxForce® 7 MaxxForce® 7 MaxxForce® 15
Part Number Harness End View DT, 9, and 10 DT, 9, and 10 11 and 13 11 and 13

Mass Air Flow/Air

Mass Air Flow (MAF) Mass Air Flow (MAF) Mass Air Flow (MAF)
ZTSE4960 E A Intake Temp (MAF/AIT)
Sensor Sensor Sensor
Sensor

4960 CV4960

Exhaust Gas Temp (EGT) Intake Manifold Charge Air Cooler Outlet Charge Air Cooler Outlet
ZTSE4993 2 1 Sensor Temp (IMT) Sensor Temp (CACOT) Sensor Temp (CACOT) Sensor

4993 CV4993

6 1

Under Valve Cover (UVC)

ZTSE6000 Injector 12-Pin Connector

12 7
6000 CV6000

ZTSE6001 2 1 Electric Fuel Pump

6001 CV6001

2 1 Water In Fuel (WIF) Water In Fuel (WIF) Water In Fuel (WIF) Water In Fuel (WIF) Water In Fuel (WIF)
ZTSE6002 Sensor Sensor Sensor Sensor Sensor

6002 CV6002

6 1

ZTSE6003 Air Control Valve (ACV) Air Control Valve (ACV)

10 6
6003 CV6003

2 1
Engine Compression Brake
Engine Compression
ZTSE6004 Brake (ECB)
(ECB) and Oil
Level Sensor (OLS)
Intake Manifold Temp (IMT)
4 3 Sensor
6004 CV6004
EGES-545 Navistar, Inc. All rights reserved
 ®

Engine Diagnostic Breakout Harness

Quick Reference Guide
MaxxForce® MaxxForce® 2007 2010 2007 2010
2007 2007 2010 2011
Breakout Connector MaxxForce® MaxxForce® MaxxForce® MaxxForce®
MaxxForce® 5 MaxxForce® 7 MaxxForce® 7 MaxxForce® 15
Part Number Harness End View DT, 9, and 10 DT, 9, and 10 11 and 13 11 and 13

3 1
Engine Throttle Valve (ETV) Engine Throttle Valve (ETV)
ZTSE6016 and Exhaust Gas and Exhaust Gas
Recirculation (EGR) Valve Recirculation (EGR) Valve

6 4
6016 CV6016

12 1
24-Pin Engine Electrical
ZTSE6020 Connector

24 13
6020 CV6020

Crankshaft Position (CKP)

ZTSE6021 Sensor and Camshaft
1 2 Position (CMP) Sensor

6021 CV6021

3 1

ZTSE6023 Fuel Pump Control (FPC)

6 4
6023 CV6023

1 2
Inlet Air Heater (IAH)
Inlet Air Heater (IAH) Inlet Air Heater (IAH)
ZTSE6025 Glow Plug Relay Relay and Fan
Relay Relay
Clutch Control (optional)

6025 CV6025

Aftertreatmeant Fuel
ZTSE6027 Pressure (AFTFP) Sensor
1 3

6027 CV6027

6 1
Under Valve Cover (UVC)
ZTSE6038 Rail Fuel Pressure (FRP)
Sensor

12 7
6038 CV6038
EGES-545 Navistar, Inc. All rights reserved
 ®

Engine Diagnostic Breakout Harness

Quick Reference Guide
MaxxForce® MaxxForce® 2007 2010 2007 2010
2007 2007 2010 2011
Breakout Connector MaxxForce® MaxxForce® MaxxForce® MaxxForce®
MaxxForce® 5 MaxxForce® 7 MaxxForce® 7 MaxxForce® 15
Part Number Harness End View DT, 9, and 10 DT, 9, and 10 11 and 13 11 and 13

ZTSE6058 E A Engine Fan

6058 CV6058

EGES-545 Navistar, Inc. All rights reserved

 Navistar, Inc.
4201 Winfield Road
Warrenville, IL 60555, U.S.A.

Printed in United States of America

© 2011 Navistar, Inc.