IK1201067 Service Bulletin/Repair Instructions

IK1201067 ­ 15L PayStar to ProStar Conversion
Page 1 of 8
Countries:
CANADA, UNITED STATES Document ID: IK1201067
Availability:
ISIS, FleetISIS
Revision:
1
Major System:
ENGINES
Created:
2/6/2014
Current Language: English
Last Modified: 2/17/2014
Other Languages: NONE
Author:
Viewed:
Caleb Iverson
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Title : 15L PayStar to ProStar Conversion

Applies To : EPA 10 MaxxForce 15L Engines
CHANGE LOG

REVISED SRT (REVISION 2)

REVISED PARTS INFORMATION (REVISION 2)
DESCRIPTION

This iknow article provides the steps necessary to retrofit a plant assembled 15L made for a PayStar®

model truck to fit into a ProStar® model truck. Due to clearance issues, the following parts must be replaced in order for the

PayStar® engine to fit into the ProStar® chassis correctly.
SERVICE PART(s) INFORMATION
Part Number Description
Quantity
Ordering Instructions
2513053C91
1
Order From Navistar
Kit, PayStar to Prostar
Torque Specs:

For torque specs refer to bottom of this iknow article or the Engine service manual.

REPAIR STEP(s)

REMOVAL PROCEDURE FOR TURBOCHARGER EXHAUST OUTLET AND RIGHT REAR ENGINE MOUNT

On the engine received, while sitting on the engine pallet remove the Following:
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IK1201067 ­ 15L PayStar to ProStar Conversion
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1. Fuel Supply Line

2. Coolant Supply and Return Lines

3. Bolts (2)

1. Remove the Fuel supply line from the Aftertreatment Fuel Injector.

2. Remove the Coolant Supply Lines from the Aftertreatment Fuel Injector.

3. Remove the two mounting bolts and the Aftertreatment Fuel Injector.

4. Save the AFI, bolts, and Gasket for re-use.
1. Pre-DOC Clamp

2. M10 X 50 Bolts

3. Engine Brake Gasket

4. 11 ID X 20 OD X 24L Spacers (3)

5. M10 X 20 Hex Bolts (3)

6. Pre­DOC Support Assembly

5. Remove Pre­Diesel Oxidation Catalyst (PDOC) clamp.

6. Remove three bolts with Pre-DOC from engine.

7. Save Pre-DOC, Gasket, Pre-DOC support bolts for re-use.
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IK1201067 ­ 15L PayStar to ProStar Conversion
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1. Turbocharger Exhaust Duct.

2. M8 X 45 Bolts (7)

3. Heat Shield Spacer

4. 9 I.D. X 16 O.D. X 15L Spacers (5)

8. Remove seven bolts, heat shield spacer, five spacers and turbocharger exhaust duct from engine. Discard turbocharger

exhaust duct.

9. Save Bolts, Spacers, and Heat Shield Spacer for re-use.
1. Right Rear Engine Bracket

2. Pre­DOC Support Bracket

3. Bolts

4. Washers
10. Remove six bolts, washers, Pre-DOC Support, and right rear mounting bracket from engine. Save bolts, washers, PDOC

support, and right rear mounting bracket.

11. Remove right rear mount on the engine being replaced.
INSTALLATION PROCEDURE
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IK1201067 ­ 15L PayStar to ProStar Conversion
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1. Right Rear Engine Bracket

2. Pre­DOC Support Bracket

3. Bolts

4. Washers

1. Install right rear mounting bracket from engine being replace with new Pre-DOC support, six washers and six new bolts.
1. Turbocharger Exhaust Duct.

2. M8 X 45 Bolts (7)

3. Heat Shield Spacer

4. 9 I.D. X 16 O.D. X 15L Spacers (5)

2. Install new turbocharger exhaust duct on engine with five spacers, heat shield spacer, and seven bolts.
1. Pre-DOC Clamp

2. M10 X 50 Bolts

3. Engine Brake Gasket
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IK1201067 ­ 15L PayStar to ProStar Conversion
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4. 11 ID X 20 OD X 24L Spacers (3)

5. M10 X 20 Hex Bolts (3)

6. Pre­DOC Support Assembly
3. Install Pre-DOC on engine with three bolts and three spacers.

4. Install Pre­DOC clamp.
1. Fuel Supply Line

2. Coolant Supply and Return Lines

3. Bolts (2)

5. Install AFI and AFI gasket with 2 bolts.

6. Install the coolant supply and return lines onto AFI.

7. Install the Fuel supply line onto AFI.
REMOVAL PROCEDURE FOR FAN DRIVE
Low mount Horton® fan bracket (typical)
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IK1201067 ­ 15L PayStar to ProStar Conversion
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1. Horton® fan bracket

2. 1/2–13 x 5 5/8 taperlock stud (2)

3. 1/2–13 hex nut (4)

4. 1/2–13 x 2.72 taperlock stud (2)

5. 13.5 x 25.5 hardened washer (4)

1. Remove four 1/2–13 hex nuts, four 13.5 x 25.5 hardened washers, and the Horton® fan bracket.

2. Remove two 1/2–13 x 2.72 taperlock studs, discard.
INSTALLATIONAL PROCEDURE FOR FAN DRIVE
High mount Horton® fan bracket (typical)

1. Horton® fan bracket

2. 1/2–13 x 2.72 taperlock stud (2)

3. 1/2–13 hex nut (4)

4. 1/2–13 x 5 5/8 taperlock stud (2)

5. 13.5 x 25.5 hardened washer (4)

1. Install two 1/2–13 x 2.72 taperlock studs. Tighten the taperlock studs until they bottom out in the front cover.

2. Position the Horton® fan bracket and install four 13.5 x 25.5 hardened washers and four 1/2–13 hex nuts. Tighten 1/2–13

hex nuts to special torque (page 348).
REMOVAL PROCEDURE FOR FRONT ENGINE MOUNT
1. 1/2-13 x 5 in hex flange bolts (8)
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IK1201067 ­ 15L PayStar to ProStar Conversion
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2. Front Engine Mount Support

1. Remove 8 bolts, 8 washers and Front Engine Mount Support Bracket from engine.
INSTALLATIONAL PROCEDURE FOR FRONT ENGINE MOUNT
1. 1/2-13 x 5 in hex flange bolts (8)

2. Front Engine Mount Support

1. Install new front engine mounting bracket with new bolts, re-use washers.
REMOVAL PROCEDURE FOR OIL COOLER

Refer to Engine Service Manual for removal of Oil Cooler.
NOTE: Discard Water pump inlet, LTR Supply, LTR bypass, LTR return, ISC Outlet connector, CCV

supply hose when removing oil cooler

Remove oil cooler with water pump outlet, DISCARD WATER PUMP OUTLET.
INSTALLATION PROCEDURE FOR OIL COOLER

INSTALL oil cooler with NEW water pump outlet.
NOTE: INSTALL NEW Water pump inlet, NEW LTR Supply HOSE, NEW LTR bypass HOSE, NEW LTR

return HOSE, NEW ISC Outlet connector, NEW CCV supply hose when INSTALLING oil cooler

Refer to Engine Service Manual for INSTALLATION of Oil Cooler.
SRT INFORMATION:

USE T-TIME OF 7 HOURS IN WARRANTY CLAIM
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Copyright © 2014 Navistar, Inc.
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