IK1201117 ­ Open Crankcase Breather

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Countries:

RUSSIA, AUSTRALIA, CANADA, UNITED
STATES, MEXICO, PUERTO RICO, NEW
ZEALAND

Document
ID:

IK1201117

Availability:

ISIS, Bus ISIS, FleetISIS

Revision:

15

Created:
Last
Modified:

4/18/2014

Major System: ENGINES
Current
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Author:

12/11/2015
Sean
McGannon

21139
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Title : Open Crankcase Breather
Applies To : 2010 + MaxxForce DT, 9 & 10 Engines

CHANGE LOG
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 I­367 parts kit, changed note for I-367 Standard Torque
2015/11/09 - Author updated, formatting/grammar revisions, consolidated PDF, removed "performance" diagnostics (added links to manuals)
2015/09/03 - added note in step 4 about breather kit details
2015/08/25 - Fixed some formatting issues.
2015/07/27 - Added Australia, Mexico, New Zealand, Russia, and Puerto Rico to country coding.
2015/07/20 Updated PDFs in Step 4




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
See "diagnostics" below for proper kit.
Kit Num. Kit Description

Part Number

Notes
Qty

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IK1201117 ­ Open Crankcase Breather

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2010_1

Kit, Open Breather Conversion 2512556C91

1

2010_2

Kit, Open Breather Conversion 2512557C91

1

2010_3

Kit, Open Breather Conversion 2512558C91

1

2010_4

Kit, Open Breather Conversion 2512559C91

1

2013_1

Kit, Open Breather Conversion 2513484C92

1

2013_2

Kit, Open Breather Conversion 2513485C91

1

2013_3

Kit, Open Breather Conversion 2513486C91

1

2013_4

Kit, Open Breather Conversion 2513487C91

1

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

SERVICE KIT "DIAGNOSTICS"
Step Action
Engine Type:
Is the engine a 2010 or 2013 (OBD) build?
1

Alternatively, find and review the (7 digit) Engine Serial Number (ESN).
NOTE: In ServiceMaxx, Engine Type will be either "MaxxForce DT/9/10 (20102012) or "MaxxForce DT/9/10 (2013+)."

Step Action

Decision
2010:
ESN between 3300001 and 3335658
OR between 3400000 and 3499999. Go
to Step 3.
2013 OBD:
ESN between 3336436 and 3339999
OR between 3500000 and 3529999. Go
to Step 2

Decision

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IK1201117 ­ Open Crankcase Breather

Determine which kit is necessary for conversion:

2

Depending on the build period of the engine, it will require one of four kits. Early
build engines require an ECM, Engine Harness and CCOS speed sensor. Some
engines have the required pins in the ECM, and thus require only the harness
and CCOS speed. The last two require only breather conversion components (ie,
were built with updated ECM/harness).
Reference ESN; which kit is required?

Step Action

Page 3 of 5

ESN between 3500000 and 3518458
Kit 2013_1
ESN between 3518459 and 3519972
Kit 2013_2
ESN between 3519973 and 3520987
Kit 2013_3
ESN between 3520988 and 3526177
or 3336436 and 3339999:
Kit 2013_4

Decision

Determine if the engine has a baffled valve cover:
Step 4
3

Remove the breather hose from the valve cover and visually inspect for baffle
plate. Reference Figure 1 below.
Is the valve cover baffled?

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

Step Action
4

Determine if the engine has the latest CCOS:

Decision
Step 3: No (non­baffled valve cover)
Step 4: No ("old" CCOS)

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IK1201117 ­ Open Crankcase Breather

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Inspect the oil separator for the etched part number.
Is the part number 7092631C91 or greater (see Figure 2)?

Kit 2010_4
Step 3: No
Step 4: Yes
Kit 2010_3
Step 3: Yes
Step 4: No
Kit 2010_2
Step 3: Yes
Step 4: Yes
Kit 2010_1

(non-baffled v/c)
("new" CCOS)
(baffled v/c)
("old" CCOS)
(baffled v/c)
("new" CCOS)

Figure 2: CCOS Part Number

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.
Step Repair

Model

Engine

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

Valve Cover Replacement

All

All

CCOS Replacement

All

All

Crankcase Breather, Replace

ECM Replacement
Engine Harness Replacement
ECM Reprogram

All
All
All

All
All
All

ECM, I-6 Engines, Replace
Engine Harness, Replace
ECM-Engine, Reprogram

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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IK1201117 ­ Open Crankcase Breather

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You received the following feedback From: U00JFG2 - John Gislason Email Address: SMTP:{John.Gislason@Navistar.com}
John.Gislason@Navistar.com Feedback: The steps for EPA'10 and EPA'13 appear to be comingled causing confusion. If you have an early
EPA'13 engine you are directed to 2013_1 kit in step #3, but steps 4 and beyond indicate if you have a baffle and updated CCOS to use kit
2010_1; so which is it?

Created
Date
1/4/2016
10:57:43 AM

Copyright © 2016 Navistar, Inc.

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