NHTSA ID Number: 10117277
Manufacturer Communication Number: IK1201091
TSB/Document Date: 2017-09-08
Summary
Coolant Leak to Lube Oil
IK1201091 2010 2013 11/13L Coolant Leak to Lube Oil
Page 1 of 5
Countries:
AUSTRALIA, CANADA, UNITED
STATES, MEXICO, PUERTO RICO
Document
ID:
IK1201091
Availability:
ISIS
Revision:
4
Created:
Last
Modified:
3/11/2014
Major System: ENGINES
Current
English
Language:
Other
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Viewed:
6/25/2014
Aaron
Wenthold
Author:
1004
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Title : 2010 - 2013 11/13L Coolant Leak to Lube Oil
Applies To : 2010 MaxxForce 11/13 Coolant and N13 Engines
CHANGE LOG
2014/06/25 Link HT EGR cooler leak to new iKNow (HT core removal)
2014/06/02 Deleted the Special Requirements section. Added Air compressor warranty code info.
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 SPN-111 FMI-1 for coolant in the oil.
SYMPTOM:
Engine oil with a light gray and sludgy appearance. The crankcase may also be overfilled.
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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IK1201091 2010 2013 11/13L Coolant Leak to Lube Oil
Page 2 of 5
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 LEAK TO LUBE OIL DIAGNOSTIC PROCEDURE:
Possible Causes
Failed EGR Cooler
Cracked cylinder liner
Failed cylinder Head rear gear train freeze plug
Failed air compressor
Cracked oil cooler housing
Missing/damaged oil cooler gaskets
Missing/damaged oil filter module gasket
Missing mounting bolts for the oil filter module to the crankcase
Step
1
Action
Decision
Yes: Go to step 2
Check lube oil for proper level and visible contamination.
•
Oil contaminated with coolant generally causes the oil
to thicken and coagulate, giving the oil a light gray
sludgy appearance.
No: Take an oil sample for
analysis. Restore the
engine to operational
condition and retest
cooling system.
Does the lube oil show signs of visual contamination?
Step
2
Action
Pressure test Low Temp (LT) and High Temp (HT) EGR cooler, in
vehicle, following procedures in the Engine Service Manual
.
•
Using KL 20060 NAV - EGR Cooler Leak Detection Test
Kit, pressure test EGR cooler following the procedure
in the Engine Service Manual.
Decision
Yes: Go to step 3
No: Reinstall removed
components then, go to step
4.
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?
Decision
HT EGR Cooler: Replace HT
EGR Cooler core, see
IK1201113, then go to step
8.
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
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IK1201091 2010 2013 11/13L Coolant Leak to Lube Oil
Page 3 of 5
there's no set order of
repair.
Step
4
Action
Decision
Yes: Go to step 5.
Remove oil pan following procedures in the Engine Service
Manual. Inspect the inside of the crankcase for evidence of
coolant leakage.
•
Remove deareation tank cap.
•
nstall Radiator Pressure Testing Kit ZTSE2384 with
Surge Tank Cap Adaptor on deaeration tank.
Pressurize cooling system to 117 kPa (17 psi) for a
minimum of 15 minutes.
•
No: Restore the engine to
operational condition and
retest cooling system.
Is coolant leakage present inside the crankcase?
Step
5
Action
Identify where the coolant leakage in the crankcase
originates.
(Cylinder Liners or Rear Gear
Train)
•
•
Inspect for coolant at bottom edge of cylinder liners.
Inspect for coolant evident at the rear gear train area.
Decision
Cylinder Liners: Go to step
7.
Rear Gear Train Area:
Inspect cylinder head
freeze plugs for leaking
coolant. Repair as
necessary. Then go to step
8.
Neither Area: Go to step 6.
What area does the coolant leakage originate from?
Step
6
Action
Identify where the coolant leakage in the crankcase
originates.
(Air Compressor or Oil Cooler)
•
•
Inspect for coolant evident at the Air Compressor
drain.
Inspect for coolant evident at the Oil Cooler drain.
Decision
Air Compressor Drain:
Replace Air Compressor.
Then go to step 8
Oil Cooler Drain: Check for
leaking oil cooler module
gasket as per the Engine
Service Manual. Repair as
necessary.Then go to step
8.
Neither Area: Restore the
engine to operational
condition and retest
cooling system.
What area does the coolant leakage originate from?
Step
Action
Decision
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IK1201091 2010 2013 11/13L Coolant Leak to Lube Oil
Page 4 of 5
7
Yes: Replace failed
cylinder liner o-ring (s).
Then go to step 8.
No: Go to “Coolant
Overflow” Symptom
diagnostic section in the
Engine Diagnostic Manual
for further testing.
Inspect lower edges of cylinder liners for coolant leaks.
•
Note cylinder number(s) where coolant leakage is
identified.
Is coolant leakage present between cylinder liner and crankcase?
Step
8
Action
Change the engine oil, filter and soot centrifuge oil filter (if
equipped).
Decision
Repair Complete.
SERVICE PARTS INFORMATION:
Kit Description
Part Number
Quantity Required
Ordering Instructions
HT EGR Cooler
3014254C95
1 (If Required)
Order from Navistar
LT EGR Cooler
3015862C94
1 (If Required)
Order from Navistar
3007498C93
1 (If Required)
Order from Navistar
Soot Centrifuge Filter
2606467C92
1 (If Required)
Order from Navistar
WARRANTY INFORMATION:
Group: 12000
Noun:
892 EGR Cooler
186 EGR Cooler Coolant Manifolds/Pipes/Connections
192 Cylinder Liner
Air Compressor
Group: 04000
Noun:
202 Air Compressor, Air Brake
Warranty Coding Manual CTS-1025
Standard Repair Times:
Standard Repair Time Manual
12 - EGR COOLER
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IK1201091 2010 2013 11/13L Coolant Leak to Lube Oil
Hours
Code
Model
7.9
N12-3892U-34
WorkStar
7.4
Q12-3892U-34
TranStar
7.6
R12-3892U-34
ProStar
Page 5 of 5
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
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
12 - ENGINE OIL AND FILTER CHANGE
Hours
0.6
Code
A12-1889U
Model
WorkStar
Engine
|MAXXFORCE
11/13|
Qualifier 1
Qualifier 2
With 2010 Emission
Engines
NOTE: Oil Change is included in EGR Cooler service plan SRT.
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: IK1201091
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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