NHTSA ID Number: 10117276
Manufacturer Communication Number: IK1201090
TSB/Document Date: 2017-09-08
Summary
Coolant in the Intake
IK1201090 2010 2013 11/13L Coolant in the Intake
Page 1 of 6
Countries:
AUSTRALIA, CANADA, UNITED Document
STATES, MEXICO, PUERTO
ID:
RICO
IK1201090
Availability:
Major
System:
Current
Language:
Other
Languages:
ISIS, FleetISIS
Revision:
4
Created:
3/11/2014
English
Last
Modified:
6/25/2014
NONE
Author:
Aaron
Wenthold
Viewed:
1444
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Title : 2010 - 2013 11/13L Coolant in the Intake
Applies To : EPA 2010 MaxxForce 11/13 and N13 Engines
CHANGE LOG
2014/06/24 Link HT EGR cooler leak to iKNow (HT core removal)
2014/06/02 Deleted Special Requirments section. Added Warranty coding for LPCAC and HP turbo air inlet duct.
2014/05/14 - Link LT EGR cooler leak to new iKNows (LT core removal)
2014/04/11 Launch to field
DESCRIPTION
This document is supplement to IK1201066 (Coolant Consumption and/or SPN-111 FMI-1) for coolant in
the intake.
SYMPTOMS
Visible coolant and/or white coolant residue in intake piping.
SPECIAL TOOLS
Tool Description
Tool Number
Comments
Plastic Plug / Cap Kit
ZTSE4891
Used for sealing components during repairs
Radiator Pressure Testing Kit
ZTSE2384
Coolant Cap Pressure Testing Kit
0904001
Perform with warm engine
Coolant Management Tool
KL5007NAV
Cooling system drain and vacuum fill
EGR Cooler Leak Detection Test Kit
KL20060NAV
HT and LT EGRC Pressure Tester
"New" procedure tests with valve installed
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IK1201090 2010 2013 11/13L Coolant in the Intake
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EGR Cooler Alignment Tool
12-892-01
If replacing an HT or LT EGRC section
EGR Cooler Lifting Bracket
1289203
If removing EGR Cooler
Kit, Charge Air Cooler Test
ZTSE6042
LPCAC Pressure Test Tool
COOLANT IN INTAKE DIAGNOSTIC PROCEDURE
GOVERNMENT REGULATION: Engine fluids
(oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and
other contaminated materials (e.g., filters rags) in
accordance with applicable regulations. Recycle or
dispose of engine fluids, filters, and other
contaminated materials according to applicable
regulations.
WARNING:
To prevent personal injury or death, make sure the engine has cooled before removing components.
WARNING:
To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using hand
cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine fluids.
POSSIBLE CAUSES
Failed EGR Cooler
Failed High Pressure Turbocharger air inlet duct
Failed Low Pressure Charge Air Cooler (LPCAC)
Step
1
Action
Inspect for coolant or white coolant residue in ETV Housing or CAC
pipe:
Decision
ETV Housing/EGR Cooler
outlet tubes: Go to step 2
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IK1201090 2010 2013 11/13L Coolant in the Intake
•
Disconnect CAC pipe from Engine Throttle Valve housing.
Inspect for wet coolant coming out of the EGR Cooler outlet
tubes and inspect for white coolant residue in the CAC
pipe.
Page 3 of 6
NOTE:There may only be white coolant residue in the CAC pipe and the
HPCAC if the HP turbocharger air inlet duct or the LPCAC are causing
the coolant consumption concern.
Where is coolant or coolant residue present?
Step
2
Action
Pressure test Low Temp (LT) and High Temp (HT) EGR cooler, in
vehicle, following procedures in the Engine Service Manual
:
Decision
Yes: Go to step 3
Using KL 20060 NAV - EGR Cooler Leak Detection Test Kit,
pressure test EGR cooler following the procedure in the Engine
Service Manual.
No: Restore the engine to
operational condition and
retest cooling system.
Is there a leak present in either of the EGR Cooler sections?
Step
3
Action
Verify which section of the EGR Cooler is leaking:
Which Section of the EGR Cooler is leaking?
Step
4
Action
Change the engine oil, filter and soot centrifuge oil filter (if equipped):
Decision
HT EGR Cooler: Replace
HT EGR Cooler core, see
IK1201113, then go to
step 4.
LT EGR Cooler: Replace
LT EGR Cooler core, see
IK1201100. Repair
complete
Both LT and HT: Follow
the individual instructions
above. Neither procedure
interferes with the other,
so there's no set order of
repair. Then go to step 4.
Decision
Repair Complete
Step
5
Action
Inspect for coolant or coolant residue in HP turbocharger air inlet duct
and LPCAC:
Remove HP turbocharger center section with HP turbocharger
air inlet duct. See service manual for procedure.
Decision
HP Turbo Air inlet duct:
Go to step 6
LPCAC: Go to step 7
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IK1201090 2010 2013 11/13L Coolant in the Intake
Page 4 of 6
Where is coolant or coolant residue present?
Figure 1: Porous HP turbocharger air inlet duct leaking coolant into the intake.
Step
6
Action
Visually inspect HP turbocharger air inlet duct for signs of coolant
and/or coolant residue.
Inspect for coolant seeping through the casting (porosity).
Figure 1 shows a porous HP turbocharger air inlet duct
leaking coolant into the intake.
Decision
Yes: Replace HP
turbocharger air inlet
duct following the
procedure in the Engine
Service Manual. Repair
complete.
No: Go to step 7
Is the HP turbocharger air inlet duct leaking?
Step
7
Action
Pressure test LPCAC:
Remove LPCAC following the Engine Service Manual.
Using ZTSE6042 pressure test the LPCAC on bench.
Is the LPCAC leaking?
Decision
Yes: Replace the
LPCAC following the
procedure in the Engine
Service Manual.
Repair complete.
No: Restore the engine
to operational condition
and retest cooling
system. Repair
complete.
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IK1201090 2010 2013 11/13L Coolant in the Intake
Page 5 of 6
SERVICE PART(s) INFORMATION:
Kit Description
Part Number
Quantity Required
Ordering Instructions
HT EGR Cooler
3014254C95
1
Order from Navistar
LT EGR Cooler
3015862C94
1
Order from Navistar
Oxygen/Lamda Sensor (O 2
S)
3006233C1
1
Order from Navistar
Engine oil 15W40 CJ4
Gallon
2598508C1
Varies
Obtain locally
Oil Filter Kit
3007498C93
1
Order from Navistar
Soot Centrifuge Filter Kit
2606467C92
1
Order from Navistar
HP turbocharger air inlet duct 3005313C*
1
Order from Navistar
LPCAC
1
Order from Navistar
3005756C1
WARRANTY INFORMATION
Warranty Claim Coding:
EGR Cooler
Group:
12000
Noun:
892 EGR Cooler
LPCAC
Group:
12000
Noun:
570 Intercooler
HP Turbo Air Inlet Duct
Group:
12000
Noun:
685 Interstage Charge Air Cooler - Coolant
Manifold/pipes/connections
Warranty Coding Manual CTS-1025
STANDARD REPAIR TIME(S):
Standard Repair Time Manual
12 - EGR COOLER
Hours
Code
7.9
N12-3892U-34
7.4
Q12-3892U-34
7.6
R12-3892U-34
Model
WorkStar
TranStar
ProStar
Engine
Qualifier 1
|MAXXFORCE 11/13|
Replace Low Temp or
Both Coolers
|MAXXFORCE 11/13|
Replace Low Temp or
Both Coolers
|MAXXFORCE 11/13|
Replace Low Temp or
Both Coolers
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IK1201090 2010 2013 11/13L Coolant in the Intake
Page 6 of 6
12 - EGR LOW TEMPERATURE COOLER CORE, REPLACE
Hours
Code
Model
Engine
2.1
N12-6892U-40
WorkStar
|MAXXFORCE
11/13|
2.1
Q12-6892U-40
TranStar
|MAXXFORCE
11/13|
1.7
R12-6892U-40
ProStar
|MAXXFORCE
11/13|
1.8
R12-6892U-41
ProStar
|MAXXFORCE
11/13|
2.1
TC12-6892U-40
CAT CT660
|MAXXFORCE
11/13|
Qualifier 1
Qualifier 2
With 2010
Emission Engines
With 2010
Emission Engines
With 2010
Emission Engines
122 BBC
With 2010
Emission Engines
113 BBC
With 2010
Emission Engines
OTHER RESOURCES
IK1201066 2010 MaxxForce 11 & 13L Coolant Consumption and SPN-111 FMI-1
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Copyright © 2014 Navistar, Inc.
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- Contains Alugard Plus for compatibility with all ethylene...
- Fights corrosion, scaling and rust while protecting all...
- High-quality additives protect against leaks and won’t...
- Pre-mixed yellow formula is ready-to-use in a 50/50 ratio...
- Contains 30 – 50 ppm of denatonium benzoate as a bittering...
- 5 year/150, 000 mile . Silicate-free, long-life, phosphate...
- Formulated to replace the OEM fluid in Asian make vehicles...
- The long life formula provides protection for all cooling...
- Meets the following OEM and industry specifications...
- Contains 30 – 50 ppm of denatonium benzoate as a bittering...
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TSB/Document ID: IK1201090
Replacement Service Bulletin Number:
MFR Communication Date: 2014-06-25
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
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