NHTSA ID Number: 10115440
Manufacturer Communication Number: IK1201117
TSB/Document Date: 2017-08-16
Summary
Open Crankcase Breather
IK1201117 Open Crankcase Breather
Page 1 of 5
Countries:
RUSSIA, AUSTRALIA, CANADA, UNITED Document
STATES, MEXICO, PUERTO RICO, NEW
ID:
ZEALAND
Availability:
ISIS, Bus ISIS, FleetISIS
Revision:
22
Major
System:
IK1201117
ENGINES
Created:
4/18/2014
Current
Language:
English
Last
Modified:
6/9/2016
Other
Languages:
NONE
Author:
Sean
McGannon
Viewed:
33634
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Title : Open Crankcase Breather
Applies To : 2010 + MaxxForce DT, 9 & 10 Engines
CHANGE LOG
2016/05/20 - Removed model description from SRT table, added note for SRT table.
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
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
Page 2 of 5
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
Page 3 of 5
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
Page 4 of 5
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
1885590C93
1
Replace ANYTIME tube is removed
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.
NOTE: Use the Kit Part Number in the table below to determine which SRT(s) you can apply to the claim.
SRT
Kit Part
Number
CCOS Open
Conversion
Open Conversion
Contains time for
breather, valve cover
2512559C9*
replacement and
Turbocharger cleaning
Valve Cover
Replacement
Valve Cover and/or Gasket, R&R or
Replace
2512558C9*
Crankcase Breather, Replace
2512557C9*
2513484C9*
2513485C9*
2513486C9*
2513487C9*
Repair
CCOS
Replacement
ECM
ECM, I-6 Engines, Replace
Replacement
Engine Harness
Engine Harness, Replace
Replacement
ECM Reprogram ECM-Engine, Reprogram
Notes
2513484C9*
2513484C9*
2513485C9*
2513484C9*
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IK1201117 Open Crankcase Breather
Page 5 of 5
2513485C9* Required for all 2013
2513486C9* and later engines,
2513487C9* 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
Feedback Information
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Comments
You received the following feedback From: dy40246 Efrain Lopez Email Address: [email protected] Job Classification: SE008,
Service Technician Dealer: RUSH TRK CTR OF UT Feedback: the part numbers that are listed for the open crankcase breather are miss
leading. I have ordered the part # 2512556c91 to receive the whole kit which it says contains and valve cover and CCOS but I only receive
DY40246
the Duct for the air filter cleaner and the tube that attaches to the exhaust port on the CCOS, and I have ordered kit # 2512559c91 and have
received the whole kit, including the valve cover and CCOS, which on the IK article it says that none of the should come in the kit. I just
advise on fixing this problem to stop the confusion going on when ordering these kits. thank you.
Created
Date
6/23/2016
10:23:01 AM
U01E786
You received the following feedback From: u01e786 - Greg Diehl Email Address: SMTP:{Gregory.Diehl@Navistar
.com}
Gregory.Diehl@Navistar.com Feedback: Should this Iknow letter contain the part numbers for closed breather systems for engine serial
numbers that are not eligible to be updated to an open breather system?
6/29/2016
8:45:25 AM
U00TEA1
You received the following feedback From: U00TEA1 - Tom Abbott Email Address: SMTP:{Thomas.Abbott@navistar.com}
Thomas.Abbott@navistar.com Feedback: The part number for the closed crankcase breather replacement (Kit, full breather replacement) is
7093618C92 per Ben Krejcie. This part goes on vehicles in which the open breather replacement is not appropriate.
6/29/2016
12:39:20 PM
Copyright © 2016 Navistar, Inc.
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TSB/Document ID: IK1201117
Replacement Service Bulletin Number:
MFR Communication Date: 2016-06-09
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
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