FIELD SERVICE CAMPAIGN – 16125
18 October 2016
SUBJECT:
Wiring Repair for vehicles built with new VCM (0508095) and Remote Start / Stop W /
Emergency Pump feature (0060ABD)
MODELS INVOLVED:
DuraStar®, WorkStar®
DEFECT DESCRIPTION:
Certain DuraStar® and WorkStar® models may have been built without the necessary
ground circuit for the emergency pump relay resulting in the pump to run at all times
when the ignition is in the run position.
ELIGIBILITY:
This procedure applies ONLY to vehicles marked in the International® Service PortalSM
with FSC 16125. Also complete any other open campaigns listed on the Service Portal
at this time.
TOOLS REQUIRED:
No special tools are required for this procedure.
PARTS REQUIRED:
Part Number
3510311R1
3534164C1

Description
18 Ga. Gray TXL wire, 17.3 in (440
mm)
Terminal, Cable Female Unsealed
Tangless
10A Fuse or Breaker

3534209C1 or
3727577C1
N/A
Black Tape
Table 1 Parts Information

Quantity
Obtain Locally
2
1
As Needed

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WORK INSTRUCTIONS

WARNING! To prevent property damage, personal injury, and / or death, park
vehicle on hard flat surface, turn the engine off, set the parking brake, and install
wheel chocks to prevent the vehicle from moving in both directions.
WARNING! To prevent personal injury and / or death, always wear safe eye
protection when performing vehicle maintenance.
WARNING! To prevent property damage, personal injury, and / or death, keep
flames or sparks away from vehicle and do not smoke while servicing the
vehicle’s batteries. Batteries expel explosive gases.
1. Bring vehicle into shop and park on flat surface.
2. Shift transmission to Park or Neutral and set parking brakes.
3. Install wheel chocks.

Figure 1. Power Distribution Module (PDM) – Fuse Blocks 8 and 9
1. Fuse Block 8
2. Fuse Block 9

4. Access PDM on passenger side of instrument panel and locate Fuse Block 8
(Figure 1, Item 1) and Fuse Block 9 (Figure 1, Item 2).
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Figure 2. Fuse Block – Underside View
1. Fuse Block 8
2. Fuse Block 9

5. Viewing bottom of PDC, remove any fuses or circuit breakers and relays in Fuse
Block 8 (Figure 2, Item 1) and Fuse Block 9 (Figure 2, Item 2).
6. Remove terminal position locks from Fuse Block 8 (Figure 2, Item 1) and Fuse
Block 9 (Figure 2, Item 2).

Figure 3. Emergency Pump Circuit
1. Fuse Block 9, Cavity A4
2. Fuse Block 9, Cavity B4

7. In Fuse Block 9, remove wire A59CA from Cavity B4 (Figure 3, Item 2) and insert
terminal into Cavity A4 (Figure 3, Item 1).

© 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

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Figure 4. Fuse Block 9
1. Fuse Block 9, Cavity C3
2. Fuse Block 9, Cavity C4

8. In Fuse Block 9, remove wires A104C/D and A13C from Cavity C3 (Figure 4,
Item 1) and Cavity C4 (Figure 4, Item 2).
9. Cut wire A104C/D at wire end of double crimped terminal. Cut as close to
terminal as possible, taking care not to damage insulation on other wire.
10. Reinsert terminal with wire removed into Cavity C4 (Figure 4, Item 2).

© 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

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Figure 5. Cavity Jumper Wire
1. Fuse Block 9, Cavity C3
2. Fuse Block 8, Cavity B1

11. Create a Jumper Wire (A104V), consisting of 440 mm of 19 ga. gray TXL wire
with a 3534164C1 terminal on both ends.
12. Connect one terminal of jumper wire to Cavity B1 on Fuse Block 8 (Figure 5, Item
2). Connect other terminal to Cavity C3 on Fuse Block 9 (Figure 5, Item 1).

© 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

Page 5

Figure 6. Fuse Block 8
1. Fuse Block 8, Cavities A1 and B1

13. In Fuse Block 8, install additional 10A fuse or circuit breaker at Cavities A1 and
B1 (Figure 6, Item 1).
14. Reinstall all previously removed terminal position locks to Fuse Blocks 8 and 9.
15. Reinstall PDM cover.
16. Remove wheel chocks.

LABOR INFORMATION
Operation number must appear on all claims.

Table 2 Labor Information
Operation Number
A40-16125-1

Description
Emergency Pump Relay Wiring Repair

Time
0.5 hr

WARRANTY CLAIMS

Warranty claim expense is to be charged to Warranty. Claims are to be submitted in the
normal manner, making reference to Field Service Campaign 16125.
Section 7 of the Warranty Policy and Procedures Manual contains further information
related to the submission and processing of AFC / Recall claims.

© 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

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As with all claim submissions, items acquired locally must be submitted in the “Other
Charges” tab. The cost of any bulk items (such as a bag of cable tie straps, roll of wire,
barrel of oil, or tube of silicone) should be prorated for the cost of the individual pieces /
amount used during each repair.
To make sure this important improvement is made in a timely manner, all claims for
16125 activity must be submitted by 18 October 2017 or within the normal warranty
period for the component, if after 18 October 2017.

© 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

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