NHTSA ID Number: 10166365
Manufacturer Communication Number: TSI-131206
TSB/Document Date: 2019-10-21
Summary
Deaeration Hoses, Upper Manifold Sub-Assembly, and Coolant Control Valve (CCV) Removal and Installation; only models equipped with MaxxForce 13 ED-HBD II or N13 SCR HD-OBD engines.
Technical Service Information
TSI–13–12–06
Date: AUGUST 2013
Subject File: ENGINE
Subject: Deaeration Hoses, Upper Manifold Sub-Assembly, and Coolant Control Valve (CCV) Removal and
Installation
Model: PayStar®
Model: ProStar®
Model: TranStar®
Model: WorkStar®
Engine Family: N13 with SCR (EPA 10) with HD-OBD
Engine Family: M13 with ED-OBDII
DESCRIPTION
This procedure provides the removal and installation instructions for the changed engine coolant components
on the N13 with SCR (EPA 10) with HD-OBD and M13 with ED-OBDII; coolant deaeration hoses, EGR cooler
upper manifold sub-assembly, and Coolant Control Valve (CCV).
PARTS INFORMATION
N/A
© 2013 Navistar
, Inc. All rights reserved. All marks are trademarks of their respective owners.
1
SERVICE PROCEDURE PREPARATION
WARNING: Park vehicle on hard flat surface, turn the engine off, set the parking brake, and
block the wheels to prevent the vehicle from moving in both directions. Failure to do so may result
in property damage, personal injury, and / or death.
WARNING: If the vehicle must be raised, do not work under the vehicle supported only by
jacks. Jacks can slip or fall over, potentially resulting in property damage, personal injury, and / or
death.
WARNING: Always wear safe eye protection when performing vehicle maintenance. Failure
to do so may result in personal injury and / or death.
WARNING: Keep flames or sparks away from vehicle and do not smoke while servicing
the vehicle’s batteries. Batteries expel explosive gases. Failure to do so may result in property
damage, personal injury, and / or death.
WARNING: Remove the ground cable from the negative terminal of the battery box before
disconnecting any electrical components. Always connect the ground cable last. Failure to do so
may result in property damage, personal injury, and / or death.
1. Bring truck into shop and park on flat surface.
2. Shift transmission to Park or Neutral, set parking brake, and install wheel chocks.
3. Open battery box and disconnect negative battery cable.
4. Unlatch and open hood.
5. Install Coolant Management Tool and apply maximum vacuum at deaeration tank. Leave vacuum
attached. Refer to TSI 12-12-01 for additional information about Coolant Management Tool.
TSI–13–12–06
2
DEAERATION HOSE REMOVAL AND INSTALLATION
Figure 1.
Deaeration Hoses and Fittings.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Clamp (8)
Deaeration tank to female fitting hose
Tie wrap (4)
Medium deaeration hose
Tee fitting
Long deaeration hose
Short deaeration hose
90-degree fitting (2)
Female fitting
1. Remove tie wraps (Figure 1, Item 3) as necessary.
2. Loosen two clamps (Figure 1, Item 1) and remove deaeration tank to female fitting hose (Figure 1, Item 2)
from female fitting (Figure 1, Item 9) and deaeration tank.
3. Loosen clamp (Figure 1, Item 1) and remove female fitting (Figure 1, Item 9) from long deaeration hose
(Figure 1, Item 6).
4. Loosen clamp (Figure 1, Item 1) and disconnect short deaeration hose (Figure 1, Item 7) from right-side
90-degree fitting (Figure 1, Item 8).
5. Loosen clamp (Figure 1, Item 1) and disconnect medium deaeration hose (Figure 1, Item 4) from left-side
90-degree fitting (Figure 1, Item 8) and remove hoses and tee fitting (Figure 1, Item 5) from truck.
6. Remove two 90-degree fittings (Figure 1, Item 8) from ports.
7. Loosen three clamps (Figure 1, Item 1) and remove three hoses (Figure 1, Items 4, 6, and 7) from tee
fitting (Figure 1, Item 5).
3
TSI–13–12–06
DEAERATION HOSE REMOVAL AND INSTALLATION (CONT.)
Figure 2.
Deaeration Hoses and Fittings.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Clamp (8)
Deaeration tank to female fitting hose
Tie wrap (4)
Medium deaeration hose
Tee fitting
Long deaeration hose
Short deaeration hose
90-degree fitting (2)
Female fitting
8. Connect long deaeration hose (Figure 2, Item 6) onto DGAS port of tee fitting (Figure 2, Item 5) with
clamp (Figure 2, Item 1).
9. Connect short deaeration hose (Figure 2, Item 7) onto RAD port of tee fitting (Figure 2, Item 5) with
clamp (Figure 2, Item 1).
10. Connect medium deaeration hose (Figure 2, Item 4) onto ENG port of tee fitting (Figure 2, Item 5) with
clamp (Figure 2, Item 1).
11. Install two 90-degree fittings (Figure 2, Item 8) in ports with fitting opening facing towards rear of vehicle.
12. Connect medium deaeration hose (Figure 2, Item 4) onto left-side 90-degree fitting (Figure 2, Item 8)
with clamp (Figure 2, Item 1).
13. Connect short deaeration hose (Figure 2, Item 7) onto right-side 90-degree fitting (Figure 2, Item 8)
with clamp (Figure 2, Item 1).
14. Install female fitting (Figure 2, Item 9) into long deaeration hose (Figure 2, Item 6) with
clamp (Figure 2, Item 1).
15. Connect deaeration tank to female fitting hose (Figure 2, Item 2) onto deaeration tank and female fitting
(Figure 2, Item 9) with two clamps (Figure 2, Item 1).
16. Install tie wraps (Figure 2, Item 3) as necessary.
TSI–13–12–06
4
DEAERATION HOSE REMOVAL AND INSTALLATION (CONT.)
17. Perform Service Procedure Follow-On.
UPPER MANIFOLD SUB-ASSEMBLY REMOVAL AND INSTALLATION
Figure 3.
Upper Manifold Sub-Assembly.
1.
2.
3.
4.
5.
6.
7.
8.
Coolant temperature sensor connector
Coolant temperature sensor
Spring clamp
90-degree fitting
Clamp
Hose
Upper manifold sub-assembly
EGR valve hose
1. Disconnect coolant temperature sensor connector (Figure 3, Item 1) from coolant temperature sensor
(Figure 3, Item 2).
2. Loosen clamp (Figure 3, Item 5) and remove hose (Figure 3, Item 6) from 90-degree fitting
(Figure 3, Item 4).
3. Remove spring clamp (Figure 3, Item 3) and EGR valve hose (Figure 3, Item 8) from upper manifold
sub-assembly (Figure 3, Item 7).
5
TSI–13–12–06
UPPER MANIFOLD SUB-ASSEMBLY REMOVAL AND INSTALLATION (CONT.)
Figure 4.
Upper Manifold Hoses.
1.
2.
3.
4.
5.
6.
7.
8.
Upper manifold sub-assembly
Bolt
P-clamp
Supply hose
Clamp
Return hose
Bypass hose
Hose clamp
4. Remove bolt (Figure 4, Item 2) from P-clamp (Figure 4, Item 3) on supply hose (Figure 4, Item 4).
5. Remove clamp (Figure 4, Item 5) and return hose (Figure 4, Item 6) from upper manifold sub-assembly
(Figure 4, Item 1).
6. Remove hose clamp (Figure 4, Item 8) and bypass hose (Figure 4, Item 7) from upper manifold
sub-assembly (Figure 4, Item 1).
TSI–13–12–06
6
UPPER MANIFOLD SUB-ASSEMBLY REMOVAL AND INSTALLATION (CONT.)
Figure 5.
Upper Manifold Sub-Assembly.
1.
2.
3.
4.
5.
6.
Coolant temperature sensor
Ring seal
90-degree fitting
O-ring
Upper manifold sub-assembly
Bolt (3)
7. Remove three bolts (Figure 5, Item 6) and upper manifold sub-assembly (Figure 5, Item 5) from truck.
8. Remove 90-degree fitting (Figure 5, Item 3) and O-ring (Figure 5, Item 4) from upper manifold
sub-assembly (Figure 5, Item 5). Discard O-ring.
9. Remove coolant temperature sensor (Figure 5, Item 1) and ring seal (Figure 5, Item 2) from upper
manifold sub-assembly (Figure 5, Item 5).
10. Install ring seal (Figure 5, Item 2) and coolant temperature sensor (Figure 5, Item 1) into upper manifold
sub-assembly (Figure 5, Item 5).
11. Install new O-ring (Figure 5, Item 4) and 90-degree fitting (Figure 5, Item 3) into upper manifold
sub-assembly (Figure 5, Item 5) as shown.
NOTE: Lubricate O-ring bore with P-80® before installing manifold.
12. Push upper manifold sub-assembly (Figure 5, Item 5) onto fitting and onto tube, sandwiching harness tab
behind middle bolt on harness, and install three bolts (Figure 5, Item 6).
7
TSI–13–12–06
UPPER MANIFOLD SUB-ASSEMBLY REMOVAL AND INSTALLATION (CONT.)
Figure 6.
Upper Manifold Hoses.
1.
2.
3.
4.
5.
6.
7.
8.
Upper manifold sub-assembly
Bolt
P-clamp
Supply hose
Clamp
Return hose
Bypass hose
Hose clamp
13. Install bypass hose (Figure 6, Item 7) onto upper manifold sub-assembly (Figure 6, Item 1) with hose
clamp (Figure 6, Item 8).
14. Install return hose (Figure 6, Item 6) onto upper manifold sub-assembly (Figure 6, Item 1) with clamp
(Figure 6, Item 5).
15. Install P-clamp (Figure 6, Item 3) on supply hose (Figure 6, Item 4) with bolt (Figure 6, Item 2).
TSI–13–12–06
8
UPPER MANIFOLD SUB-ASSEMBLY REMOVAL AND INSTALLATION (CONT.)
Figure 7.
Upper Manifold Sub-Assembly.
1.
2.
3.
4.
5.
6.
7.
8.
Coolant temperature sensor connector
Coolant temperature sensor
Spring clamp
90-degree fitting
Clamp
Hose
Upper manifold sub-assembly
EGR valve hose
16. Connect EGR valve hose (Figure 7, Item 8) onto upper manifold sub-assembly (Figure 7, Item 7) with
spring clamp (Figure 7, Item 3).
17. Crimp spring clamp (Figure 7, Item 3) with Oetiker clamp crimp tool.
18. Install hose (Figure 7, Item 6) onto 90-degree fitting (Figure 7, Item 4) with clamp (Figure 7, Item 5).
19. Connect coolant temperature connector (Figure 7, Item 1) to coolant temperature sensor (Figure 7, Item 2).
20. Perform Service Procedure Follow-On.
9
TSI–13–12–06
COOLANT CONTROL VALVE (CCV) ASSEMBLY REMOVAL AND
INSTALLATION
Figure 8.
Coolant Control Valve (CCV) Assembly.
1. Hose clamp (spring type)
2. Supply hose
3. Low temperature hose assembly
4. Hose clamp (spring type) (2)
5. Coolant Mixer Valve (CMV) connector
6. CMV
7. Coolant Flow Valve (CFV)
8. CFV connector
9. Harness connector
10. Connector
11. Harness adapter
12. M8 X 60 stud bolt
13. CCV assembly
1. Loosen hose clamp (Figure 8, Item 1) and remove supply hose (Figure 8, Item 2) from CCV assembly
(Figure 8, Item 10).
2. Loosen two hose clamps (Figure 8, Item 4) and remove low temperature bypass hose assembly (Figure
8, Item 3) from truck.
3. Disconnect CMV connector (Figure 8, Item 5) from CMV (Figure 8, Item 6).
4. Disconnect CFV connector (Figure 8, Item 8) from CFV (Figure 8, Item 7).
5. Disconnect connector (Figure 8, Item 10) from harness connector (Figure 8, Item 9).
6. Remove harness adapter (Figure 8, Item 11) from stud bolt (Figure 8, Item 12).
TSI–13–12–06
10
COOLANT CONTROL VALVE (CCV) ASSEMBLY REMOVAL AND INSTALLATION
(CONT.)
Figure 9.
CCV Assembly.
1.
2.
3.
4.
5.
M8 X 60 stud bolt (2)
CCV assembly
M8 X 60 bolt
Harness
M8 Nut
7. Remove nut (Figure 9, Item 5) and harness (Figure 9, Item 4) from bottom stud bolt (Figure 9, Item 1).
8. Remove bolt (Figure 9, Item 3), two stud bolts (Figure 9, Item 1), and CCV assembly (Figure 9, Item
2) from engine.
9. Clean CCV bore with chlorinated water and a clean shop towel.
10. Install CCV assembly (Figure 9, Item 2) on engine with two stud bolts (Figure 9, Item 1) and bolt (Figure
9, Item 3).
11. Using torque wrench, torque two stud bolts (Figure 9, Item 1) and bolt (Figure 9, Item 3), in an alternating
pattern, to 23 lb-ft (31 N•m).
12. Install harness (Figure 9, Item 4) on bottom stud bolt (Figure 9, Item 1) with nut (Figure 9, Item 5).
11
TSI–13–12–06
COOLANT CONTROL VALVE (CCV) ASSEMBLY REMOVAL AND INSTALLATION
(CONT.)
Figure 10.
Coolant Control Valve (CCV) Assembly.
1. Hose clamp (spring type)
2. Supply hose
3. Low temperature hose assembly
4. Hose clamp (spring type) (2)
5. Coolant Mixer Valve (CMV) connector
6. CMV
7. Coolant Flow Valve (CFV)
8. CFV connector
9. Harness connector
10. Connector
11. Harness adapter
12. M8 X 60 stud bolt
13. CCV assembly
13. Install harness adapter (Figure 10, Item 11) on top stud bolt (Figure 10, Item 12).
14. Connect connector (Figure 10, Item 10) to harness connector (Figure 10, Item 9).
15. Connect CFV connector (Figure 10, Item 8) to CFV (Figure 10, Item 7).
16. Connect CMV connector (Figure 10, Item 5) to CMV (Figure 10, Item 6).
17. Install low temperature hose assembly (Figure 10, Item 3) on CCV assembly (Figure 10, Item 13) and
upper manifold sub-assembly with two hose clamps (Figure 10, Item 4).
18. Install supply hose (Figure 10, Item 2) on CCV assembly (Figure 10, Item 13) with hose clamp (Figure
10, Item 1).
19. Perform Service Procedure Follow-On.
TSI–13–12–06
12
SERVICE PROCEDURE FOLLOW-ON
1. Fill cooling system using Navistar Coolant Management Tool KL5007NAV. Refer to TSI 12-12-01 for
additional information about Coolant Management Tool.
2. Connect negative battery cable and close battery box.
3. Run engine to verify proper operation, no leaks, and no fault codes.
4. Close and latch hood.
5. Remove wheel chocks.
13
TSI–13–12–06
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TSB/Document ID: TSI-131206
Replacement Service Bulletin Number:
MFR Communication Date: 2013-09-15
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING
MFR Component System:
MFR Component Subsystem:
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