NHTSA ID Number: 10115462
Manufacturer Communication Number: IK1201118
TSB/Document Date: 2017-08-16
Summary
Charge Air Cooler Outlet Temperature Sensor Damaged; equipped with N13, MaxxForce 11, 13 engines
IK1201118 Big Bore Charge Air Cooler Outlet Temperature Sensor Damaged
Page 1 of 12
Countries:
AUSTRALIA, CANADA,
UNITED STATES, NEW
ZEALAND
Document
ID:
IK1201118
Availability:
ISIS, FleetISIS
Revision:
5
Major System: ENGINES
Created:
5/1/2014
Current
Language:
English
Last
Modified:
3/17/2015
Other
Languages:
NONE
Author:
Ted
Grzeskowiak
Viewed:
1727
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Title : Big Bore Charge Air Cooler Outlet Temperature Sensor Damaged
Applies To : Prostar 113 Equipped with 2010 Emissions MaxxForce 11/13L and N13
Engines
CHANGE LOG
2015/03/16 - Changed name from intake air teperature sensor to charge air cooler outlet temperature
2015/01/29 - Fixed warranty noun code (Group 16000 to 16003)
2014/12/08 - Revised formatting, new information/procedure for repair
2014/05/01 - Initial Article Release
DESCRIPTION
There are certain applications of ProStar+113 trucks with 2010+ Emissions MaxxForce 11/13 or 2013+ N13
engines, that have interference issues with the Charge Air Cooler Outlet Temperature (CACOT) sensor and the
hood. Prior repairs called for bodywork that needed to be performed by a body shop; however, the new repair can
be completed in any shop, with minimal downtime. The following document will guide the tech through
the diagnostics and repair including the modification and patching of the hood if needed.
SYMPTOMS
Diagnostic Trouble Codes & Dashboard Indicator Lights:
DTC/Light
Description
SPN 2630 FMI 2
CACOT Signal Does Not Agree With Other Sensors
SPN 2630 FMI 3
CACOT Signal Out of Range High
SPN 2630 FMI 4
CACOT Signal Out of Range Low
SPN 2630 FMI 7
CACOT Signal Not Responding as Expected
SPN 2630 FMI 16
CAC Under cooling
Customer Observations or Concerns:
Malfunction Indicator Light
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IK1201118 Big Bore Charge Air Cooler Outlet Temperature Sensor Damaged
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SPECIAL TOOLS
Tool Description
Tool Number
Comments
Instructions
Obtain Locally
OR sun light
Obtain Locally
Tools Resource Center
SERVICE PARTS INFORMATION
Kit Description
Part Number
Qty Notes
Kit, Hood Repair
2514324C91
1
3M Sanding Pad or equivalent
1
Obtain Locally, needed for roughing patch
area
Sensor Assembly, Temperature
3006479C91
1
If damaged
DIAGNOSTIC STEPS
Step Action
Check for a damaged Charge Air Cooler Outlet Temperature
sensor.
Decision
Yes. Replace sensor and repair
harness as needed. Clear
codes. Go to Step 2.
Locate the CACOT sensor on the Engine Throttle Valve (ETV)
casting.
1
Is the sensor damaged,broken or is there evidence of rubbing on the
hood?
No. Reference the Engine
Diagnostic Manual to diagnose
the fault.
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IK1201118 Big Bore Charge Air Cooler Outlet Temperature Sensor Damaged
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Figure 1: Damaged CACOT Sensor
Step Action
Verify hood to sensor contact.
2
Decision
1. Yes. Proceed to hood
modification procedure, below.
• Inspect the inside of the hood for markings from rubbing the CACOT
sensor. See figure #2 below for an example of hood rubbing marks.
• Are there witness marks on the hood?
2. No. Diagnostic is finished.
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IK1201118 Big Bore Charge Air Cooler Outlet Temperature Sensor Damaged
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Figure 2: Rub mark in the hood from CACOT sensor contact (air inlet cowl).
REPAIR STEPS
1.
Remove the three bolts securing the driver side front inner fender to the hood.
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Figure 3: Removal of inner fender.
Item 1: Hood
Item 2: Front Inner Fender
Item 3: Mounting Screws
2.
4.
Fold the template from the kit, as instructed, and secure it to the air inlet cowl on the hood, as shown in Figure
The template should sit approximately 1.5 inches over the "top right" corner of
the air inlet cowl.
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Figure 4: Hood modification template
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Figure 5: Hood modification template position
3.
Use a marker to transfer the outline of the template onto the air inlet cowl.
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Figure 6: Template traced on air inlet duct.
4.
Use a cutoff wheel die grinder to remove the outlined section of the air inlet cowl.
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Figure 7: Die grinder material removal.
5.
Use the 3M pad (and tool) to rough up the area (roughly 7x7 inch square) around the removed section.
Sandpaper can be substituted, if necessary. Ensure no dirt/debris are still on
the cowl and the surface finish is rough.
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Figure 8: Sanding/roughing of the patch area.
6.
Use an air gun to clean the dust from the patch area.
7.
Cut a section of the Easy Patch into a 6 x 6 inch square.
8. Remove the Easy Patch backing and apply to the air inlet duct, as shown in Figure 9. Form the patch into
place (pressing firmly) and then remove the protective plastic film.
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Figure 9: Patch placed and formed.
9. Allow the patch to dry with UV light for 10 minutes. Alternatively, let the hood/patch sit in direct sunlight for 10
minutes (drying times will vary depending on lighting conditions). Once dry, the patch will no longer be "tacky" and
will be similar hardness to the cowl parent material.
10.
Reinstall the front inner fender
WARRANTY INFORMATION
Claim Requirements/Approvals:
No special requirements.
Warranty Claim Coding:
Group: 16003 - Cab
Noun: 309 Hood
Standard Repair Times:
SRT
Step
Description
Chassis
Hours
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IK1201118 Big Bore Charge Air Cooler Outlet Temperature Sensor Damaged
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CACOT Sensor Replacement
ProStar+113 MF 11/13 or N13
R128013U
0.4
Hood Alteration
ProStar+113 MF 11/13 or N13
R201003A
0.8
SRT Manual
OTHER RESOURCES
Master Service Information Site
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Copyright © 2015 Navistar
, Inc.
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TSB/Document ID: IK1201118
Replacement Service Bulletin Number:
MFR Communication Date: 2015-03-17
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING
MFR Component System:
MFR Component Subsystem:
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