NHTSA ID Number: 10131101
Manufacturer Communication Number: IK1201090
TSB/Document Date: 2018-04-02
Summary
Coolant in the Intake
IK1201090 2010 2013 11/13 LIter Coolant in the Intake
Page 1 of 5
Countries:
AUSTRALIA, CANADA, COLOMBIA, UNITED
STATES, MEXICO, PUERTO RICO
Document
ID:
IK1201090
Availability:
ISIS, FleetISIS
Revision:
0
Created:
Last
Modified:
3/11/2014
Major System: ENGINES
Current
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Author:
4/11/2014
Aaron
Wenthold
393
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Title : 2010 2013 11/13 LIter Coolant in the Intake
Applies To : 2010 MaxxForce 11/13
CHANGE LOG
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Initial Launch 04/2014
DESCRIPTION
Provide repair advice for 2010 - 2013 11/13 Liter vehicles that exhibit Coolant in the Intake, after following IK1201066 2010 MaxxForce
11 & 13L Coolant Consumption and SPN-111 FMI-1
SYMPTOMS
Visible coolant and/or white coolant residue in intake piping.
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
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 IN INTAKE DIAGNOSTIC PROCEDURE
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IK1201090 2010 2013 11/13 LIter Coolant in the Intake
Page 2 of 5
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.
POSSIBLE CAUSES
Failed EGR Cooler
Failed High Pressure Turbocharger air inlet duct
Failed LPCAC
Step
1
Action
Inspect for coolant or white coolant residue in ETV Housing or CAC pipe:
Decision
ETV Housing/EGR Cooler outlet
tubes: Go to step 2
•
Disconnect CAC pipe from Engine Throttle Valve housing. Inspect for wet coolant
coming out of the EGR Cooler outlet tubes and inspect for white coolant residue in
the CAC pipe.
CAC Pipe/HPCAC: Go to step 5
NOTE:There may only be white coolant residue in the CAC pipe and the HPCAC if the HP
turbocharger air inlet duct or the LPCAC are causing the coolant consumption concern.
Where is coolant or coolant residue present?
Step
2
Action
Pressure test Low Temp (LT) and High Temp (HT) EGR cooler, in vehicle, following procedures
in the Engine Service Manual:
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
Using
No: Restore the engine to
operational condition and retest
cooling system.
Is there a leak present in either of the EGR Cooler sections?
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IK1201090 2010 2013 11/13 LIter Coolant in the Intake
Step
3
Action
Verify which section of the EGR Cooler is leaking:
Page 3 of 5
Decision
HT EGR Cooler: Replace HT
EGR Cooler, then go to step 4.
LT EGR Cooler: Replace LT
EGR Cooler, then go to step 4.
Both LT and HT: Replace both
the LT and HT EGR Cooler
sections, then go to step 4.
Which Section of the EGR Cooler is leaking?
Step
4
Action
Change the engine oil, filter and soot centrifuge oil filter (if equipped):
Decision
Repair Complete
Step
5
Action
Inspect for coolant or coolant residue in HP turbocharger air inlet duct and LPCAC:
Remove HP turbocharger center section with HP turbocharger air inlet duct. See
service manual for procedure.
Where is coolant or coolant residue present?
Decision
HP Turbo Air inlet duct:
Go to step 6
LPCAC: Go to step 7
Figure 1: Porous HP turbocharger air inlet duct leaking coolant into the intake.
Step
6
Action
Visually inspect HP turbocharger air inlet duct for signs of coolant and/or coolant
residue.
Decision
Yes: Replace HP
turbocharger air inlet duct
following the procedure in the
Engine Service Manual.
Repair complete.
Inspect for coolant seeping through the casting (porosity).
Figure 1 shows a porous HP turbocharger air inlet duct leaking coolant into the
intake.
No: Go to step 7
Is the HP turbocharger air inlet duct leaking?
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IK1201090 2010 2013 11/13 LIter Coolant in the Intake
Step
7
Action
Pressure test LPCAC:
Page 4 of 5
Decision
Yes: Replace the LPCAC
following the procedure in the
Engine Service Manual.
Repair complete.
Remove LPCAC following the Engine Service Manual. Using ZTSE6042 pressure
test the LPCAC on bench.
No: Restore the engine to
operational condition and
retest cooling system. Repair
complete.
Is the LPCAC leaking?
SERVICE PART(s) INFORMATION
Kit Description
Part Number Quantity Required Ordering Instructions
HT EGR Cooler
3014254C95
1
Order from Navistar
LT EGR Cooler
3015862C94
1
Order from Navistar
Oxygen/Lamda Sensor
(O 2 S)
3006233C1
1
Order from Navistar
Engine oil 15W40 CJ4
Gallon
2598508C1
Varies
Obtain locally
Oil Filter Kit
3007498C93
1
Order from Navistar
Soot Centrifuge Filter Kit 2606467C92
1
Order from Navistar
HP turbocharger air inlet
3005313C*
duct
1
Order from Navistar
LPCAC
1
Order from Navistar
3005756C1
WARRANTY INFORMATION
Warranty Claim Coding:
Group: 12000
Noun:
892 EGR Cooler
Warranty Coding Manual CTS-1025
Standard Repair Time(s)
Standard Repair Time Manual
Description
SRT Link
Hours
|MAXXFORCE 11/13| EPA 2010 7600
N12-6892U-22
3.9
|MAXXFORCE 11/13| EPA 2010 8600
Q12-6892U-22
3.6
|MAXXFORCE 11/13| EPA 2010 ProStar
R12-6892U-22
3.9
|MAXXFORCE 11/13| EPA 2010 7600 EGR Cooler, Pressure Test w/ Cooler Replacement
N12-6892U-1
0.8
|MAXXFORCE 11/13| EPA 2010 7600 Low Temperature or High Temperature Cooler, Replace
N12-6892U-3
0.5
|MAXXFORCE 11/13| EPA 2010 8600 EGR Cooler, Pressure Test w/ Cooler Replacement
Q12-6892U-1
0.8
12 - ENGINE OIL AND FILTER CHANGE
A121889U
0.6
12 - EGR COOLER PRESSURE TEST, IN VEHICLE (no cooler replacement)
12 - EGR COOLER PRESSURE TEST, IN VEHICLE (Add-on for Cooler replacement)
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IK1201090 2010 2013 11/13 LIter Coolant in the Intake
Page 5 of 5
|MAXXFORCE 11/13| EPA 2010
12 CENTRIFUGE OIL FILTER CHANGE (If equipped) All engines
A12-4656A
0.3
Special Requirement(s):
EGR Cooler iApprove
Cooling package components (radiators) require a photo attachment, per WPL 10010G
OTHER RESOURCES
IK1201066 2010 MaxxForce 11 & 13L Coolant Consumption and SPN-111 FMI-1
RC1200004 2010 MaxxForce 11/13 EGR Cooler Resource Center
Feedback Information
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Staff
ID
C lient
ID
C omments
Created
Date
U025676
You received the following feedback From: u025676 - Charles Schroeder Email Address: chuck.schroeder@navistar.com Job Classification: Dealer: Field
Personnel Feedback: Could only find in IK1201066. Could not find in iKNow search.
4/7/2014
2:44:52 PM
DY21815
You received the following feedback From: dy21815 vishun RAMOUDIT Email Address: ramouditv @rushenterprises.net Job Classification: SE008, Service
Technician Dealer: RUSH TRK CTR OF GA Feedback: diagnostic question number 1 does not include the words yes or no in the results options. Could be
confusing
4/17/2014
2:20:59 PM
Copyright © 2014 Navistar, Inc.
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TSB/Document ID: IK1201090
Replacement Service Bulletin Number:
MFR Communication Date: 2014-04-11
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING:COOLING SYSTEM
MFR Component System:
MFR Component Subsystem:
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