NHTSA ID Number: 10177875
Manufacturer Communication Number: IK1201198
TSB/Document Date: 2020-08-04
Summary
MaxxForce 15L Engine Oil Leaks; an aid in repairing engine oil leaks on the MaxxForce 15L engine.
IK1201198 - MaxxForce 15L Engine Oil Leaks
Page 1 of 14
Countries:
CANADA, TAIWAN, UNITED STATES,
MEXICO, GUAM, KOREA, SOUTH
KOREA
Document
ID:
IK1201198
Availability:
ISIS, FleetISIS, NotSIR
Revision:
4
Major System: ENGINES
Created:
8/27/2014
Current
Language:
English
Last
Modified:
7/7/2020
Other
Languages:
NONE
Author:
Josh
Bowman
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Title : MaxxForce 15L Engine Oil Leaks
Applies To : EPA 2011 MaxxForce 15L Engine
CHANGE LOG
2020/07/07 - Republished article, retired in error. Updated links and part numbers
2015/08/24 - Added Crankcase Pressure Specification (per feedback)
2015/08/12 - Fixed spelling error.
2014/11/13 - Initial Article Release
DESCRIPTION
This document has been designed as an aid in repairing engine oil leaks on the MaxxForce 15L engine. It should be utilized in
conjunction with the Engine Service Manual (0000001746) and the Engine Diagnostics/Troubleshooting Manual (eges515).
SYMPTOMS
Diagnostic Trouble Codes & Dashboard Indicator Lights:
DTC/Light
Description
SPN 101 FMI 16 Excessive Crankcase Pressure
Customer Observations or Concerns:
- Engine oil leaks
- Repeat oil leaks
OVERVIEW
• Steam cleaning and the use of oil dye is highly recommended to pin point an oil leak
• From the design of the deck, oil is able to run downhill and "leak" at the back of the head from either a front cover or cam
seal leaking. This has been mis-diagnosed as a head gasket replacement. The oil running down the deck is hard to see
without blotting it with a towel and/or cleaning and using oil dye.
• Always measure crankcase pressure to confirm it is not the cause of the leak
◦ High idle, no load - crankcase blow by flow specification of less than 8 in H2O
• When resealing oil leaks, use Loctite 515 on both sides of the gasket or O-ring
• Always replace the crankcase breather filter after the engine oil leak is repaired
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IK1201198 - MaxxForce 15L Engine Oil Leaks
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Camshaft Gear Cover Gasket
1. If the gasket on the camshaft cover is found leaking, remove it following the service procedures in the Engine Service Manual
(0000001746)
Figure 1: Front of Engine
Item 1: Camshaft Gear Cover
2. Once you have the camshaft gear cover removed, remove and discard the camshaft gear cover gasket
3. Clean gasket mating surfaces
4. Install new camshaft gear cover gasket with Loctite 515 on both sides
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IK1201198 - MaxxForce 15L Engine Oil Leaks
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Figure 2: Gasket Front Cover Plate
Item 1: Front Cover Plate
Item 2: Gasket
5. Follow the Engine Service Manual (0000001746) for the correct procedures and torque specifications when assembling
High-Pressure Pump Gear Cover Plate O-ring
1. If the O-ring on the high-pressure pump gear cover is found leaking, remove it following the service procedures in the Engine
Service Manual (0000001746)
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IK1201198 - MaxxForce 15L Engine Oil Leaks
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Figure 3: Front of Engine
Item 1: High-Pressure Pump Gear Cover
2. Once you have the high-pressure pump gear cover removed, remove and discard the O-ring from the cover plate
3. Clean O-ring mating surfaces
4. Install new cover plate O-ring with Loctite 515 on both sides
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IK1201198 - MaxxForce 15L Engine Oil Leaks
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Figure 4: Cover
Item 1: Cover
Item 2: O-ring
5. Follow the Engine Service Manual (0000001746) for the correct procedures and torque specifications when assembling
Gasket Oil Fill Pipe
1. If the gasket on the oil fill pipe is found leaking, remove it following the service procedures in the Engine Service Manual
(0000001746)
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IK1201198 - MaxxForce 15L Engine Oil Leaks
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Figure 5: Front of Engine
Item 1: Oil Fill Pipe
2. Once you have the oil fill pipe removed, remove and discard the gasket from the fill pipe and/or front cover
3. Clean gasket mating surfaces
4. Install new oil fill pipe gasket with Loctite 515 on both sides
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IK1201198 - MaxxForce 15L Engine Oil Leaks
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Figure 6: Oil Fill Pipe Gasket
Item 1: Oil Fill Pipe
Item 2: Gasket
5. Follow the Engine Service Manual (0000001746) for the correct procedures and torque specifications when assembling
High-Pressure Pump O-ring
1. If the O-ring on the high-pressure pump is found leaking, remove it following the service procedures in the Engine Service
Manual (0000001746)
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IK1201198 - MaxxForce 15L Engine Oil Leaks
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Figure 7: Left Side of Engine
Item 1: High Pressure Pump
2. Once you have the high-pressure pump removed, remove and discard the O-ring from the high-pressure pump
3. Clean O-ring mating surfaces
4. Install new O-ring for high pressure pump with Loctite 515 on both sides
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IK1201198 - MaxxForce 15L Engine Oil Leaks
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Figure 8: High Pressure Pump O-ring
Item 1: High Pressure Pump
Item 2: O-ring
5. Follow the Engine Service Manual (0000001746) for the correct procedures and torque specifications when assembling
High Pressure Pump Adapter O-rings
1. If the high pressure pump adapter is found leaking, remove it following the service procedures in the Engine Service Manual
(0000001746)
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IK1201198 - MaxxForce 15L Engine Oil Leaks
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Figure 9: Left Side of Engine
Item 1: Adapter, High Pressure Pump
2. Once you have the high pressure pump adapter removed, remove and discard the O-rings from the adapter
3. Clean O-ring mating surfaces
4. Install new O-rings for the high pressure pump adapter with Loctite 515 on both sides
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IK1201198 - MaxxForce 15L Engine Oil Leaks
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Figure 10: High Pressure Pump Adapter
Item 1: Adapter
Item 2: O-rings
Item 3: Groove for smaller Orings (3)
5. Follow the Engine Service Manual (0000001746) for the correct procedures and torque specifications when assembling
Crankshaft Position Sensor
1. If the CKP (crankshaft position) sensor is found leaking, remove it following the service procedures in the Engine Service
Manual (0000001746)
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IK1201198 - MaxxForce 15L Engine Oil Leaks
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Figure 11: Left Side of Engine
Item 1: CKP (crankshaft position) Sensor
2. Once you have the CKP (crankshaft position) sensor removed, discard the sensor
3. Obtain new CKP (crankshaft position) sensor and apply Loctite 515 on both sides of O-ring
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IK1201198 - MaxxForce 15L Engine Oil Leaks
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Figure 12: CKP (crankshaft position)
Item 1: CKP (crankshaft position) Sensor
Item 2: CKP (crankshaft position) Sensor O-ring
4. Install new CKP (crankshaft position) sensor
5. Follow the Engine Service Manual (0000001746) for the correct procedures and torque specifications when assembling
SERVICE PARTS INFORMATION
Part Number
Quantity
Required
Gasket Front Cover Plate
7078705C1
1
Cover O-ring
7078458C1
1
1882675C1
1
High Pressure Pump Adapter Oring
7078457C1
1
High Pressure Pump Adapter O-rings
1823790C1
3
Gasket Oil Fill Pipe
1668921C1
1
Kit Description
Notes
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IK1201198 - MaxxForce 15L Engine Oil Leaks
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Sensor Crankshaft Position
62271207038
1
Kit, Cylinder Head Removal, 15L
3016007C92
1
PTX51531
1
-
1
3007357C1
1
Loctite 515
Oil Dye
Filter Element Assy. Breather
Obtain Locally
WARRANTY INFORMATION
Warranty Claim Coding: There are multiple nouns that can be used depending on which components you replace. Please
reference the Warranty Claim Coding for the correct noun to use
Group: 12000 - Engine
170 - Sender, Crankshaft Position (CKP)
242 - Cover Gasket, Timing
Noun: 582 - Plate and Gasket, camshaft cover
722 - Lines and seals, oil
738 - Pipe and Cap Assembly, Oil Filler
Other Resources
Warranty Policy Letter 09011G Clarification of Oil Leaks Versus Oil Seepage
MaxxForce® 15L Engine Service Manual (Supersedes EGES-510)
MaxxForce® 15 Engine Diagnostic/Troubleshooting Manual
Warranty Claim Coding
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Copyright © 2020 Navistar
, Inc.
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TSB/Document ID: IK1201198
Replacement Service Bulletin Number:
MFR Communication Date: 2020-07-07
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING
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