NHTSA ID Number: 10115474
Manufacturer Communication Number: IK1201255
TSB/Document Date: 2017-08-16
Summary
High Pressure Fuel Pump and Oil Fill Hose Oil Leak Repair Procedure
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IK1201255
Availability:
ISIS, Bus ISIS, FleetISIS
Revision:
4
Major System: ENGINES
Created:
1/9/2015
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Title : Big Bore High Pressure Fuel Pump and Oil Fill Hose Oil Leak Repair Procedure
Applies To : 2010 MaxxForce 11L 13L and N13 Engines
CHANGE LOG
2015/03/15 - Added tool information for tightening oil fill adapter to Tool Table and repair step. Added two nouns to Warranty coding table.
2015/02/17 - Changed some part numbers to "see parts catalog". Changed title to include Oil Fill Hose.
2015/02/16 - Modified description to include oil fill hose and tube. Corrected a part description in the parts table. Added details to oil filler hose and
tube section. Added link to new SRT for HPP mounting reseal.
2015/01/29 - Initial Article Release
DESCRIPTION
This document has been designed as an aid in repairing High Pressure Fuel Pump oil leaks, oil fill hose or oil fill tube leaks on
the MaxxForce 11L and 13L and N13 engine. It should be utilized in conjunction with the Engine Service Manual
.
SYMPTOMS
Diagnostic Trouble Codes:
DTC (SPN-FMI) Description
N/A
N/A
Customer Observations or Concerns:
Oil Leak on driver's side near high pressure fuel pump
SPECIAL TOOLS / SOFTWARE
Tool Description
Tool Number Comments
MaxxForce 11&13L Cap & Plug
ZTSE4891
Universal Fluorescent Dye
TP-9770-0108
FRX241
HPP Drive Holding Plate
ZTSE6044
For leak between HPFP and the accessory drive housing
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High-Pressure Pump Removal
Tool
12-454-01
For leak between the HPFP and the accessory drive
housing
Fuel System Priming Tool
1292201
Hand Prime if tool is not available
Hex socket bit driver 11/16" hex
(3/4 drive x 3-1/2" long)
Obtain locally Used to torque oil fill adapter
Tools Resource Center
SERVICE PARTS INFORMATION
Kit Description
Part Number
Qty
Notes
Loctite 515 - 50ml tube
Obtain locally or LOC38655
(direct ship not stocked in
PDC)
Portion
of
Required for all HPP oil leak repairs
container
Tube Assy, HP Pump to Rail
3005763C92
1
P-80 o'ring lube
2511097C1
Portion
Case of 6 pints. Required only if pump is
of
removed from accessory drive housing
container
Oring HPFP 100 x 3.349
1882675C1
1
Required only if pump is removed from
accessory drive housing
Special Bolt 7/16-20 12-Point
3535854C1
1
Required for use at steering gear
Lock Washer .469X.922X .105 PH 26272R1
1
Required for use at steering gear
Lock Nut, Engine Support Shaft
7/16-NF PHC P/T
273896
1
Required for use at steering gear
Loctite 545
Obtain locally
Fill tube pclamp
Fill tube hose
Fill tube
Fill tube adapter
2018938C1
572010C1
See parts catalog
3015232C2
Obtain locally
Required for all HPP oil leak repairs
Portion
of
As needed for Oil Fill Hose repairs
container
2
Required for all HPP oil leak repairs
1
Required for all HPP oil leak repairs
1
As needed for Oil Fill Tube repairs
1
As needed for Oil Fill Hose repairs
as
needed
OVERVIEW
Steam cleaning and the use of oil dye is highly recommended to pin point an oil leak
Due to the design, oil is able to run downhill and "leak" at the high pressure fuel pump from either an oil fill tube leak OR a leak
at one of the two high pressure pump sealing surfaces.
When resealing oil leaks on the HPP, use Loctite 515 or equivalent on the sealing surfaces. Loctite 545 is recommended for
the oil fill adapter.
REPAIR STEPS
1. Steam Clean and insert dye into the engine oil.
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2. Road test the vehicle, bringing up to operating temperature. Inspect for oil leaks or seepage at the following locations.
• Oil Filler Hose, Tube, Clamps and Adapter Figure 1 Items 1 and 2
• High Pressure Fuel Pump Accessory Drive Housing to Engine Block Figure 3 Item 1
• High Pressure Fuel Pump Mounting O-ring (to Accessory Drive Housing) Figure 3 Item 2
3. Refer to repair steps below and the Engine Service Manual or Instruction sheet 4328057R2 for additional instructions.
4. Inspect oil filler tube for cracks and replace, as needed.
OIL FILLER HOSE AND TUBE REPAIR
Figure 1 Oil Filler Hose and Tube
Item 1: Oil Filler Hose to Oil Filler Tube
Item 2: Oil Filler Hose to Adapter and Adapter to HPFP drive housing
1. Remove and discard the oil filler hose and clamps.
2. If a leak is present at Figure 1 Item 2, remove and discard the adapter. If a leak is present at Figure 1 Item 1, go to Step 6.
3. Clean the adapter threads with a soft cloth.
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4. On the new adapter, apply Loctite 545 sealing compound, 360 degrees around the first three adapter threads (Figure 2).
Figure 2 Oil Filler Adapter Sealant Application
Item 1: Adapter with Loctite, handstarted
5. Hand start and rundown adapter. Tighten adapter to 26 ft lbs (35 Nm) using the 1-1/16" hex socket driver.
6. Install new oil filler hose and clamps. Reinstall oil filler tube. Torque constant tension clamps to 46 in lbs (5.1 Nm).
7. Complete installation per Engine Service Manual or Instruction sheet 4328057R2
HIGH PRESSURE PUMP OIL LEAK REPAIR
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Figure 3 High Pressure Fuel Pump
Item 1: HPFP Accessory Drive Housing to Engine Block Mounting Surface
Item 2: HPFP Mounting Gasket (to Accessory Drive Housing)
High Pressure Fuel Pump Accessory Drive Housing to Engine Block Repair (Figure 3, Item 1)
1. For leaks between the HPFP accessory drive housing and engine, remove the HPFP/accessory drive housing as an
assembly. Follow service procedures in the Engine Service Manual or Instruction sheet 4328057R2. Discard the steering gear
special bolt, lock nut and washer, and HPFP rail to pump tube assembly. Discard the oil filler hose and clamps.
2. Clean mating surfaces and apply Loctite 515 on either the accessory drive housing mating surface or the engine block
mounting surface.
3.
Follow the Engine Service Manual or Instruction sheet 4328057R2 for the correct procedures and torque specifications when
reassembling.
4. Install a new HPFP rail to pump tube assembly (torque to specification) and steering gear special bolt, lock nut and
washer. Install new oil filler hose and clamps. Reinstall oil filler tube. Torque constant tension clamps to 46 in lbs (5.1 Nm).
5. Make sure to prime the fuel system using the Fuel System Priming Tool or hand priming method.
6. Bring engine up to operating temperature and retest for oil leaks.
High Pressure Fuel Pump Mounting O-ring (to Accessory Drive Housing) Figure 3 Item 2
1. For leaks between the HPFP and accessory drive housing, remove the HPFP/accessory drive housing as an assembly.
Follow service procedures in the Engine Service Manual or Instruction sheet 4328057R2. Discard the steering gear special bolt,
lock nut and washer, and HPFP to rail tube assembly. Discard the oil filler hose and clamps.
2. Remove and discard the O-ring from the high-pressure pump.
3. Clean mating surfaces.
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4.
Install a new high pressure pump Oring with P80 lubricant.
5. Follow the Engine Service Manual or Instruction sheet 4328057R2 for the correct procedures and torque specifications when
reassembling.
6. Install a new HPFP rail to pump tube assembly (torque to specification) and steering gear special bolt, lock nut and washer.
Install new oil filler hose and clamps. Reinstall oil filler tube. Torque constant tension clamps to 46 in lbs (5.1 Nm).
7. Make sure to prime the fuel system using the Fuel System Priming Tool or hand priming method.
8. Bring engine up to operating temperature and retest for oil leaks.
WARRANTY INFORMATION
Warranty Claim Coding:
Group: 12000- Engine
454- High Pressure Fuel Pump
Noun: 738 Pipe & Cap Assembly, Oil Filler
930 - Coupling, Accessory Drive
Group: 15084 - Fuel System
Noun:
875 - Gasket, Mounting
Standard Repair Times:
Step Description
Chassis
ProStar
PayStar
High Pressure Fuel Pump & Drive Gear, Replace O'ring LoneStar
TranStar
WorkStar
ProStar
PayStar
High Pressure Fuel Pump & Drive Gear, Replace O'Ring
TranStar
WorkStar
High Pressure Fuel Pump & Drive Gear,
All
Reseal Accessory Drive Housing to Engine Block
ProStar
Oil dipstick (fill) tube, replace or repair leak
TranStar
WorkStar
Engine
SRT
Hours
R12-7454U-20
T12-7454U-20
2010+ MaxxForce
S12-7454U-20
11/13
Q12-7454U-20
N12-7454U-20
R12-7454US
T122192US
N13
Q127454US
N127454US
3.0
3.0
3.0
3.0
3.0
3.0
3.0
3.0
3.0
All
2.5
A12-7454U
R12-4695L
2010+ MaxxForce
Q124695L
11/13
N124695L
0.5
0.5
0.5
SRT Manual
OTHER RESOURCES
Master Service Information Site
EPA 2010 MaxxForce 11, 13, N13, and 15 Service Resource Center
2010 MaxxForce 11/13 Diagnostic Manual
2010 MaxxForce 11/13 Service Manual
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Copyright © 2015 Navistar, Inc.
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- 3X Stronger than the leading full synthetic*
- 10X Better high stress performance**
- 20,000 miles between oil changes***
- Viscosity breakdown as measured in Kurt Orbahn test on 5W...
- As measured in Seq IX test under high load/torque conditions...
- Phosphorus Replacement Technology to help extend the life of...
- Reduces leaks, oil burnoff and power robbing deposits
- 15,000 miles between oil changes*
- Meets or exceeds the following specifications: API SP/SN...
- Or one year, whichever comes first
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TSB/Document ID: IK1201255
Replacement Service Bulletin Number:
MFR Communication Date: 2015-03-17
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, GASOLINE
MFR Component System:
MFR Component Subsystem:
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