IK1201066 ­ 2010 - 2013 11 & 13L Liter Coolant Consumption and SPN-111 FMI­1

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IK1201066

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4/7/2014
Aaron
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Title : 2010 - 2013 11 & 13L Liter Coolant Consumption and SPN-111 FMI-1
Applies To : 2010 Emissions MaxxForce 11L & 13L

CHANGE LOG
Initial Launch ­ 03/06/2014
Added step based 4/1/14
Modified symptom and diagnostic procedure.

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DESCRIPTION
This document addresses low coolant (SPN 111 FMI 1) and/or coolant consumption on 2010 to 2013 - 11 and 13 liter engines.The
procedure will guide the user through common failure areas, diagnostic tools, SRTs, and warranty filing.

SYMPTOM:
Consistent need to refill deaeration tank and active or previously active DTCs related to the cooling system.

Diagnostic Trouble Code & Dashboard Indicator Light:
DTC/Light

Description

SPN 111 FMI 1

Low Coolant

Malfunction Indicator Light (MIL)

Red Stop Lamp (RSL)

Customer Observations or Concerns:
- Malfunction Indicator Light (MIL)
­ Red Stop Lamp (RSL)
­ Coolant consumption
- Low coolant
- Coolant puddling under engine
­ White smoke from the exhaust
- Coolant in the oil or oil analysis

SPECIAL TOOLS

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IK1201066 ­ 2010 - 2013 11 & 13L Liter Coolant Consumption and SPN-111 FMI-1

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 Kit

KL20060NAV

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Instructions

HT and LT EGRC Pressure Tester
"New" procedure tests with valve installed
EGR Cooler Alignment Tool

12­892­01

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

OVERVIEW
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.

Before beginning, it is important to review a few areas of the vehicle, to prevent unnecessary repair. Each of the following can
manifest in "consumption" or low coolant level.
i. Is AFC 12917 open?
ii. Was the vehicle recently in for a repair in which the cooling system was not properly filled (air pockets)?
iii. Was the vehicle recently repaired and the fault code not successfully cleared?
iv. Is the operator aware of the proper filling procedure (overfill)?
If the coolant leak path is known (white smoke from exhaust, coolant in oil samples, etc) proceed to the respective steps or iKNows,
noted below. Otherwise, continue with Step 1.
Step 1 - External Leaks

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IK1201066 ­ 2010 - 2013 11 & 13L Liter Coolant Consumption and SPN-111 FMI­1

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iKnow 1201089 - Coolant in the exhaust
iKnow 1201090 - Coolant in the intake
iKnow 1201091 - Coolant in the oil

COOLANT CONSUMPTION DIAGNOSTIC PROCEDURE:
If diagnosing a 111-1 code and have no associated coolant loss concern, go to 111-1 code circuit troubleshooting in the Engine
Diagnostic Manual under Circuit Diagnostics > ECL Switch (Engine coolant level).

Step

Action

Decision

Visually inspect all components and hoses for external coolant leaks.

1

Yes: Repair as
necessary. Restore
the engine to
operational
condition and retest
cooling system.

WARNING:
To prevent personal injury or death, do the following when removing the
radiator cap or deaeration cap:


Allow engine to cool for 15 minutes.



Wrap a thick cloth around radiator cap or deaeration cap.



Loosen cap slowly a quarter to half turn counterclockwise to vent pressure.



Pause for a moment to avoid being scalded by steam.



Continue to turn cap counterclockwise to remove.



Remove deaeration tank cap.


Install Radiator Pressure Testing Kit ZTSE2384 with Surge Tank Cap Adaptor on
deaeration tank.


No: Go to step 2

Pressurize cooling system to 117 kPa (17 psi) for a minimum of 15 minutes.

Are any external coolant leaks visible?

Step
2

Action
Remove deaeration tank cap. Pressurize cap to its rated pressure.


Decision
Yes: Reinstall deaeration
cap. Go to step 3

Remove deaeration tank cap.


Connect Radiator Pressure Testing Kit ZTSE2384 with Surge Tank Cap No: Replace deaeration cap.
Adaptor to deaeration cap.
Restore the engine to

Pressurize deaeration cap to its rated pressure.
operational condition and
retest cooling system.
Does the deaeration cap hold its rated pressure?

Step
3

Action
Start engine. With engine at operating temperature and operating at high idle speed,
inspect for coolant overflow out of deaeration tank.

Decision
Yes: Go to Coolant Overflow
symptom diagnostics in the
Engine Diagnostic Manual.
Under Engine Symptom

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IK1201066 ­ 2010 - 2013 11 & 13L Liter Coolant Consumption and SPN-111 FMI­1

Is coolant overflowing out of the deaeration tank?

Step
4

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Diagnostics > Coolant System >
Coolant Overflow.
No: Go to step 4

Action
Inspect for coolant in the exhaust.

Decision
Yes: Go to Coolant
in the Exhaust
Symptom based
diagnostics. Refer
to iKNow article
IK1201089.

WARNING:
To prevent personal injury or death, do the following when removing the
radiator cap or deaeration cap:


Allow engine to cool for 15 minutes.



Wrap a thick cloth around radiator cap or deaeration cap.



Loosen cap slowly a quarter to half turn counterclockwise to vent pressure.



Pause for a moment to avoid being scalded by steam.



Continue to turn cap counterclockwise to remove.



Remove deaeration tank cap.


Install 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.



Disconnect exhaust pipe at PRE­DOC and inspect for coolant

No: Go to step 5

Is coolant visible in the exhaust system?

Step
5

Action
Inspect for coolant and/or white coolant residue in the charge air intake.




Disconnect CAC pipe at ETV housing.
Inspect CAC pipe for visual signs of white coolant residue.
Inspect the ETV Housing for visual signs of coolant.

Decision
Yes: Go to Coolant in Intake
symptom based diagnostics.
Refer to iKNow article
IK1201090.
No: Go to step 6

Is coolant and/or white coolant residue present in intake?

Step
6

Action
Inspect for visible evidence of coolant on the engine oil level gauge (dipstick).
Remove and inspect the engine oil dipstick for visible evidence of
contamination.

Oil contaminated with coolant generally causes the oil to thicken and
coagulate, giving the oil a light gray sludgy appearance.


Decision
Yes: Go to Coolant in Lube
Oil symptom based
diagnostics. Refer to iKNow
article IK1201091.

No: Restore the engine to
operational condition and
retest cooling system.
Does the lube oil show signs of visible contamination?

WARRANTY INFORMATION

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IK1201066 ­ 2010 - 2013 11 & 13L Liter Coolant Consumption and SPN-111 FMI­1

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NOTE: There are multiple noun groups that the diagnostic time could be charged to. Be sure to add the diagnostic T-Time
to the proper repair made.

Warranty Claim Coding:
Group: Mutliple Groups - Code to repair made
Noun: Mulltiple Nouns - Code to repair made

Standard Repair Time(s):
Step

Description

1

T­time

SRT Link

Hours
0.5hrs

1-2

T-time

0.7hrs

1­3

T-time

0.8hrs

1­4

T-time

1.1hrs

1­5

T-time

1.3hrs

1­6

T-time

1.4hrs

Link to the Standard Repair Time Manual: Click Here
Special Requirements:
- EGR Cooler Step Based Diagnostics
-Cooling package components (radiators) require a photo attachment, per WPL 10­010G
OTHER RESOURCES
- EGR Cooler Resource Center (RC1200004)

Feedback Information

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Staff
ID

Client
ID
U00T714

Comments
You received the following feedback From: U00T714 - Bryan Fresse Email Address: bryan.fresse@navistar.com Job Classification: SE008,
Service Technician Dealer: Field Personnel Feedback: we have an srt to psi test the cooling system. A09-9022A. includes visualy inspection
and pressure testing the cap.

Created
Date
4/7/2014
10:59:12 AM

Copyright © 2014 Navistar, Inc.

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