IK1201142 ­ LeakLocator Diagnostic Procedures ­ Medium Duty

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Document ID: IK1201142

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ISIS, Bus ISIS, FleetISIS

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0

Major System:

ENGINES

Created:

6/12/2014

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10/9/2014

Author:

Josh
Bowman

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Title : LeakLocator Diagnostic Procedures - Medium Duty
Applies To : EPA 2007 and 2010 MaxxForce® 7, DT, 9, 10

CHANGE LOG
2014/10/09 ­ Initial Article Release

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DESCRIPTION
This document will aid a user in effective use of the Navistar Leak Locator tool. When used properly, the Leak Locator will
significantly reduce diagnsotic time for air leaks (including the intake, exhaust, and aftertreatment systems) leading to regen,
power and/or exhaust odor concerns.
The following information has been tailored to the 2007 + Emissions MaxxForce® 7, DT, 9 and 10.
NOTE: For heavy duty (11 and 13L), please reference IK1201216.

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Figure 1: Navistar Leak Locator and accessory kit

SYMPTOMS
- Low power or performance concerns
- Frequent regens or aftertreatment problems
- Unwanted cabin odors

SPECIAL TOOLS
Tool Description

Tool Number

Navistar® LeakLocator

19­700­01

Heavy Duty (HD) Accessory Kit

19­700­01­01­26

Tool Instruction Sheet

4328229R1

OVERVIEW

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To prevent personal injury or death, read all safety instructions in the "Safety
Information" section of the Engine Diagnostic Manual or Engine Service manual.

IMPORTANT NOTES:
• Due to the size of some engine components (as well as wide temperature ranges encountered during normal operation),

"pinhole" leaks can occur at some sealing surfaces. Generally, pinhole leaks do not result in odors or performance issues-focus on large leaks.
• Do not exceed 5 psi pressure, with the tool. Higher smoke pressures can obscure test results as teh fast-moving smoke
can be difficult to see. At lower pressures, smoke trails "curl" out smoothly and remain visible much longer.
• Smoke from the Leak Locator cannot pass through a properly operating Diesel Particualte Filter (DPF). To properly test
the Aftertreatment System, test areas before and after the DPF, seperately.
• Some components (for example the High Pressure Charge Air Cooler-HPCAC) have slight air leaks, by design. For these
components, it is necessary to perform a leak decay test (outlined in the Diagnostic Manual) to deem the part non­
conforming.

DIAGNOSTIC PROCEDURE
The diagnostics are split into three sections; Intake, Exhaust and Aftertreatment, and are hyperlinked accordingly. Perform the necessary diagnostics
relative to the customer/performance concern.

INTAKE TESTING:
1. Remove intake piping/air cleaner
2. Install intake adapter into air intake piping
3. Using air intake piping clamp, tighten clamp around adapter
4. Connect Navistar Leak Locator line to intake adapter

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Figure 2: Maxxforce 7, DT, 9 and 10 Intake adapter installed

Item 1: Intake Adapter
Item 2: Air intake piping
Item 3: Navistar leak locator line

5. Inititate pressurized smoke (3-5 psi is recommended)
6. Carefully inspect entire intake system for leaks
7. Once leak is found, remove tooling, repair leak and install removed items. Follow the service manual for correct repair procedures.

EXHAUST and AFTERTREATMENT TESTING
1. Remove intake piping/air cleaner

2. Install intake adapter into air intake piping
3. Using air intake piping clamp, tighten clamp around intake adapter
4. Install plug/block off onto the intake adapter

Figure 3: Plug installed on intake adapter
Item 1: Intake Adapter
Item 2: Air intake piping
Item 3: Plug/block off
5. Remove DOC inlet temperature sensor and install temperature sensor port adapter
6. Connect Navistar Leak Locator supply line to temperature sensor port adapter

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Figure 4: Temperature sensor port adapter installed
Item 1: Temperature sensor port adapter
Item 2: Navistar Leak Locator supply line
7. Remove exhaust diffuser
8. Remove DPF outlet temperature sensor

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Figure 5: Tail pipe
Item 1: DPF (Diesel Particulate Filter) outlet temperature
Item 2: Exhaust diffuser
9. Install power smoke adapter 2.9in into end of tail pipe and inflate
10. Install block-off coupler onto Navistar Leak Locator supply line

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Figure 6: Power smoke adapter (2.9inch) in Tailpipe
Item 1: DPF outlet temperature sensor removed
Item 2: Power smoke adapter (2.9 inch) inserted into tail pipe
Item 3: Navistar Leak Locator supply line
Item 4: Block-off coupler

To prevent personal injury or death, connect the chain on the Powersmoke Adapter to a
secure location.

11. Initiate pressurized smoke (3-5 psi is recommended)
12. Carefully inspect entire exhaust system for leaks
13. Once leak is found, remove tooling, repair leak and install removed items. Follow the service manual for correct repair procedures.

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WARRANTY INFORMATION
Warranty Claim Coding:
Due to the amount of components this repair can diagnose, please reference the coding manual for claim coding guidelines.
Coding suggestions will be added once SRTs have been evaluated.

STANDARD REPAIR TIMES:
SRTS are currently under review. In the meantime, use T-Times as necessary.

OTHER RESOURCES
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You received the following feedback From: dyyrfmg - Rich Michels Email Address: [email protected] Job Classification: SE008,
Service Technician Dealer: BRATTAIN INT'L. TRUCKS I Feedback: I wish I had this tool in the shop right now,,,,, I'm working a 2010 DT that
has 10"H2o of crankcase blow by. I'd like to put a couple of PSI of smoke in a cylinder and see it leak past the rings, then retest it with new
DYYRFMG
rings installed on the pistons. Or use it to put smoke into the intake or exhaust manifolds, to test for leaking valve guide seals. Plus, when I
was testing the blow­by, I isolated the turbo drains from the crankcase and discovered the turbo's where contributing 3" H2o to the crankcase
pressure. A smoke test to each of the turbo drains would help pin-point to where that pressure is coming from. Rich Michels

Created
Date

10/9/2014
10:26:24 PM

Copyright © 2014 Navistar, Inc.

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