IK1201117 ­ Open Crankcase Breather

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Countries:

RUSSIA, AUSTRALIA, CANADA, UNITED Document
STATES, MEXICO, PUERTO RICO, NEW
ID:
ZEALAND

Availability:

ISIS, Bus ISIS, FleetISIS

Revision:

21

Major
System:

IK1201117

ENGINES

Created:

4/18/2014

Current
Language:

English

Last
Modified:

4/19/2016

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NONE

Author:

Sean
McGannon

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30367
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Title : Open Crankcase Breather
Applies To : 2010 + MaxxForce DT, 9 & 10 Engines

CHANGE LOG
2016/04/18 - Added breather conversion SRT
2016/03/28 - Updated kit selection form
2016/03/08 - Added link for kit selection form
2016/02/05 - Rearranged layout
2016/01/28 - Simplified kit decision process
2015/12/10 - Corrected Coding for Fleets
2015/12/1 - Corrected kit part numbers for 2010 emissions engines
2015/11/19 Updated ESN ranges for I 367 parts kit, changed note for I 367 Standard Torque




DESCRIPTION
When an applicable truck (see note below) suffers from turbocharger coking or Crankcase Oil Separator (CCOS) failure, retrofit to an open
breather equipped CCOS. The following provides guidelines and part numbers necessary for the conversion.

2013 HDOBD "Standard Torque" (215 and 230 HP) engines CANNOT be converted to open
breather. In the event of a failure, replace only the CCOS unit.

SYMPTOMS/DIAGNOSTICS
All information available through the diagnostic manuals is current and robust. Follow them for all symptom and/or diagnostic
information.
2010 MaxxForce DT, 9, and 10
2013 MaxxForce DT, 9, and 10 (HD OBD)

­

Low Power Symptom Diag - Oil in the Intake Diag
Low Power Symptom Diag ­ Oil in the Intake Diag

SPECIAL TOOLS / SOFTWARE
No tools necessary for this document.

SERVICE PARTS INFORMATION

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IK1201117 ­ Open Crankcase Breather

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Utilize service kit selection form or see engine components (2010 engines) or ESN range (2013 engines) below to determine
proper kit.
Engine Type: MaxxForce DT/9/10 (2010-2012) kits
ESN between 3300001 and 3335658 or between 3400000 and 3499999

Kit
Selector
Form

Link to
Form

Kit Description

Baffled
New
Part Number Qty Valve Cover CCOS
(figure 1)
(figure 2)

Kit, Open Breather
Conversion

2512556C91

1 Yes

Yes

Kit, Open Breather
Conversion

2512557C91

1 Yes

No

Kit, Open Breather
Conversion

2512558C91

1 No

Yes

Kit, Open Breather
Conversion

2512559C91

1 No

No

For baffled valve cover identification see figure 1 in diagnostics section below
For new CCOS identification see figure 2 in diagnostics section below
Engine Type: MaxxForce DT/9/10 (2013 OBD) kits
ESN between 3336436 and 3339999 or between 3500000 and 3529999
Kit
Selector
Form

Kit Description

Part Number Qty ESN Range

Kit, Open Breather Conversion 2513484C92

1 3500000 - 3518458

Kit, Open Breather Conversion 2513485C91

1 3518459 ­ 3519972

Kit, Open Breather Conversion 2513486C91

1 3519973 ­ 3520987

Kit, Open Breather Conversion 2513487C91

1

Link to
Form

3520988 ­ 3526177
or 3336436 - 3339999

SERVICE KIT "DIAGNOSTICS"

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IK1201117 ­ Open Crankcase Breather

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Figure 1: Valve cover baffling vs non-baffled
Item 1: No baffle
Item 2: Stamped steel baffle

Figure 2: CCOS Part Number
New CCOS units are part number 7092631C91 or greater

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IK1201117 ­ Open Crankcase Breather

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Additional Parts (for reference, only replace/use if necessary)

Kit Description

Part Number

Qty Notes

Kit, Turbo Super Cartridge (HP)

2512354C91

1

In event of failed turbo

Kit, Low Pressure Turbocharger

1889487C93

1

"Standard" Torque (w/o LP CAC)

Kit, Low Pressure Turbocharger

1889489C94

1

"High" Torque (w/LP CAC)

Kit, Turbo Compressor Cleaning

7091592C91

1

Fluid, Cleaning (5 gal)

2512460C1

1

CAC Cleaning

Tube Assy, Turbo Oil Supply

1885590C93

1

Replace ANYTIME tube is removed

Seal, LP Turbo

1881990C1

1

WITHOUT LP CAC

Seal, Crossover Tube

1858048C2

1

With LP CAC

WARRANTY INFORMATION
Warranty Claim Coding:
Group: 12000 - Engine
Noun: 215 - Filter, Oil Separator, Crankcase Vent
Standard Repair Times:
Due to the variety of chassis/engine configurations, please reference the SRT link for the correct repair times and elemental
step document.
Repair

Model

Engine

SRT

Kit Part
Number

Notes

CCOS Open
Conversion

All

2010­
2012

Open Conversion

Contains
time for
breather,
valve cover
2512559C9*
replacement
and
Turbocharger
cleaning

Valve Cover
Replacement

All

20102012

Valve Cover and/or Gasket, R&R
or Replace

2512558C9*

Crankcase Breather, Replace

2512557C9*
2513484C9*
2513485C9*
2513486C9*
2513487C9*

CCOS
Replacement
ECM
Replacement
Engine Harness
Replacement

All

All
All

All

2013
ECM, I-6 Engines, Replace
and later
2013
Engine Harness, Replace
and later

2513484C9*
2513484C9*
2513485C9*

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IK1201117 ­ Open Crankcase Breather

ECM Reprogram All

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2013
ECM-Engine, Reprogram
and later

2513484C9*
2513485C9*
2513486C9*
2513487C9*

Required for
all 2013 and
later
engines,
regardless of
kit used

NOTE: Follow diagnostics or repair procedures for all applicable SRTs. For example, if Low Power lead to Turbocharger and
CAC cleaning, reference the symptom based diagnostics action plan.

OTHER RESOURCES
Master Service Information Site
IK1200938 - HP Turbo Center Section Replacement Procedure
IK1201238 - LP Turbo Center Section Replacement Procedure

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Comments

Created
Date

You received the following feedback From: dy22084 - Andrew Mortimer Email Address: [email protected] Job Classification: SE008,
Service Technician Dealer: RWC GROUP Feedback: IN 2010 MAXXFORCE DT/9/10 MANUAL FOLLOWING SYMPTOM OF OIL IN INTAKE
7.2 STEP 5 HAS ME CHECK VALVE COVER FOR BAFFLE AND CHANGING IT BEFORE CHECKING BREATHER ON STEP 6. STEP 6
4/21/2016
DY22084
REFERNCES IK1201117. THAT IKNOW STATES THAT THE KIT FOUND PER THE EMBEDDED LINK WILL BE ALL THATS NECESSARY. 1:58:55 PM
WILL I NEED THE VALVE COVER OR DOES IT COME IN THE KIT BY USING THE FORM? IN MY CASE VIN CB399422, ESN 3310615,
NO STEEL BAFFLES AND OLD PN ON BREATHER. I DONT WANT TO ORDER A VALVE COVER IF IT COMES IN THE KIT.

U01C166

You received the following feedback From: U01C166 ­ Randy Geweniger Email Address: SMTP:{Randy.Geweniger@Navistar.com}
Randy.Geweniger@Navistar.com Feedback: Please add a Note (Highlighted in RED) that informs the technician to install the complete
4/27/2016
crankcase breather and not just the top. due to the oil jet in the bottom housing is a different size that increases the crankcase breather speed 10:29:48 AM
over stock.

Copyright © 2016 Navistar, Inc.

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