note:donotfollowmpgbasednormalservicevehicle note ... ·...

SECTION 5 – MAINTENANCE SCHEDULE AND SERVICE PROCEDURES

Maintenance Schedule

NOTE: No maintenance is required on the Doser Injector,it is not a serviceable component. Failed parts should bereplaced, not serviced. The Doser is warranted under basemechanical and or emission warranty.

NOTE: Do not follow MPG based normal service vehicleinterval for severe service applications.

NOTE: For RV andmotor home applications only, oil changeinterval duration is every 12 months instead of 6 months.Maximum hours and distance between oil change intervalsremain the same.

Page 65


Maintenance Schedule (cont.)Table 1 Navistar® N13 Maintenance Intervals

Item Miles / Kilometers Hours Months

Fuel Filter Every oil change

Coolant Filter (if equipped) 50,000 / 80,437 1500 12

Drain water separator on both engine andframe-mounted fuel filters:

Every oil change

OR

when “Water in Fuel” message appears on driver display

Check coolant freeze point Every oil change or twice yearly

Clean or change fuel strainer Every oil change

Inspect electrical system Every oil change or twice yearly

Inspect belts, air intake piping, clamps Every oil change or twice yearly

Page 66


Maintenance Schedule (cont.)Table 2 Oil Drain Intervals

Duty Cycle Miles /Kilometers

Hours Months Items

Severe Service

Severe service vehicles are those used in vocations such asrefuse, mixer, dump truck, logging, heavy equipment hauling,or similar vocations that average up to 30,000 miles (48,280km) per year.

15,000 /24,140

400 6 oil and filter

Normal Service

Normal service vehicles are those with an annual mileage over30,000 miles (48,280 km) per year.

Refer to Figure 38 “Drain Intervalfor Normal Service based on

MPG”(Figure 38)

oil and filter

Page 67


Maintenance Schedule (cont.)Service Procedures

GOVERNMENT REGULATION: Engine fluids(oil, fuel, and coolant) may be a hazard to humanhealth and the environment. Handle all fluids andother contaminated materials (e.g. filters, rags) inaccordance with applicable regulations. Recycleor dispose of engine fluids, filters, and othercontaminated materials according to applicableregulations.

WARNING: To prevent personal injury or death, shifttransmission to park or neutral, set parking brake, and blockwheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, do notlet engine fluids stay on your skin. Clean skin and nailsusing hand cleaner and wash with soap and water. Wash ordiscard clothing and rags contaminated with engine fluids.

OIL LEVEL

Service Interval: Before Engine Operation

1. Park vehicle on level ground.

NOTE: Do not check oil level if engine is running orimmediately after engine shutdown.

2. Shut down the engine and wait 5 minutes.

3. Remove oil level gauge from oil level gauge tube.

Figure 29 Oil level gauge (typical)

CAUTION: To prevent engine damage, do the following:

• Make sure oil level readings are within the crosshatchedoperating range on the oil level gauge.

• Do not overfill the engine with oil.

• Do not operate engine if oil level is above or below theoperating range.

4. If oil level is below operating range, fill with recommendedoil for operating climate. The ADD mark indicates 6 quarts(5.8 liters) of oil should be added. See Engine Oil Qualityand Service Categories (page 35).

Page 68


Service Procedures (cont.)COOLANT LEVEL


NOTE: Nitrite-Free formula required. Use only yellowNitrite-Free Ultra ELC (pre-diluted 50 / 50 or concentratedmixed 50 / 50) meeting Navistar B1 Type 3A specifications.Do not mix with conventional coolants, SupplementalCoolant Additives (SCAs), or ELC coolants containingnitrites.

Nitrite-Free Ultra Extended Life Coolant (ELC) Premix 50 / 50 isthe standard factory fill for the cooling system. Nitrite-Free UltraELC Premix 50 / 50 is used to replenish coolant loss and ensurethat glycol / water concentrations stay in balance.



1. Park vehicle on level ground, set the parking brake, and shutdown the engine.

2. Check coolant level in the coolant tank.

• For cold engine check, coolant level should be betweenthe COLD MIN and COLD MAX marks.

• For hot engine check, coolant level should be at theCOLD MAX mark (top of coolant tank).

• If coolant level is below the COLD MIN mark on a coldengine or below the COLD MAX mark on a hot engine,continue with steps 2 and 3.

WARNING: To prevent personal injury or death, do thefollowing when removing the radiator cap or coolant tankcap:

• Allow the engine to cool for 15 minutes or more.

• Wrap a thick cloth around the radiator cap or coolant tankcap.

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

• Pause for a moment until all pressure has escaped to avoidbeing scalded by steam.

• Continue to turn cap counterclockwise to remove.

3. Remove coolant tank cap.

• If engine is cold, add coolant up to the COLDMAXmark.

Page 69


Service Procedures (cont.)

COOLANT LEVEL (cont.)

• If engine is hot, add coolant up to the bottom of thecoolant tank fill neck.

4. Install and tighten coolant tank cap.

EXTERNAL LEAKAGE


WARNING: To prevent personal injury or death, shutdown engine, set parking brake, and block wheels beforeinspecting for external leakage.

1. Check for the following conditions:

• Cracked hoses

• Loose hose connections

• Coolant stains

• Oil stains

• Fuel stains

• Leakage at water pump

2. Correct problems.

AIR CLEANER RESTRICTION


Figure 30 Air cleaner restriction indicator

Check air restriction indicator reading.

If the yellow position indicator has locked in the red zone, install anew air filter to prevent low engine power, reduced fuel economy,or engine damage.

Page 70



AIR CLEANER RESTRICTION (cont.)

1. Remove the plugged air filter element and discard.

CAUTION: To prevent engine damage, do not use compressedair to clean filter housing.

2. Use a clean water-dampened cloth to clean the inside of theair filter housing.

3. Inspect the air filter housing for damage or distortion. Installa new housing if necessary.

4. Verify nothing has fallen into the filter housing prior toinstalling a new filter element.

5. Install a new air filter element.

6. Push reset button on the air restriction indicator. The yellowindicator returns to zero.

WATER DRAIN VALVE

Service Interval: When “Water in fuel” message appears indigital display in instrument panel


WARNING: To prevent personal injury or death, do notsmoke and keep fuel away from flames and sparks.

1



WATER DRAIN VALVE (cont.)

WARNING: To prevent personal injury or death, storediesel fuel properly in an approved container designed forand clearly marked DIESEL FUEL.

CAUTION: The engine fuel filter works in conjunction with thechassis mounted water separator. Along with the water beingdrained from the chassis water separator, the water must bedrained from the engine mounted fuel filter housing at theService Interval. If the water is not drained at the ServiceInterval, water will accumulate inside the fuel filter housing,causing fuel system corrosion.

1. Engine-mounted Filter

Figure 31 Fuel filter assembly

1. Fuel primer pump2. Fuel filter cover3. Fuel filter housing4. Water drain valve (closed)

Page 72




NOTE: Drain until no water or other contaminants areobserved exiting from the drain valve.

a. Attach a .75 inch (19 mm) I.D. hose to the end of thewater drain valve.

b. Put a suitable clear container under the hose from thewater drain valve.

c. Turn the water drain valve to open and allow the water /fuel mixture to drain out.

NOTE: If the fuel / water mixture does not flow from thedrain, push the knob on fuel primer pump once to displacefuel in the filter.

d. Close water drain valve.

e. Recycle or dispose of fuel according to applicableregulations.

2. Frame-mounted Filter (Racor) - If Equipped

Figure 32 Fuel filter assembly (frame-mounted) - ifequipped

1. Fuel filter element2. Fuel primer pump3. Clear collection bowl4. Water In Fuel (WIF) sensor5. Water drain valve (closed)

Page 73




a. Put a suitable clear container under the hose from thewater drain valve.

NOTE: Drain until the water / fuel mixture becomes only fuel.The water / fuel mixture will drain slowly and may take up toa minute to attain pure fuel flow. The clear collection bowlshould aid in determining when all water and or sedimenthas been drained.

b. Turn the water drain valve to open and allow the water /fuel mixture to drain out.

c. Close water drain valve.

d. Recycle or dispose of fuel according to applicableregulations.

3. Frame-mounted Filter (DAVCO) - If Equipped

Figure 33 Fuel filter assembly (frame-mounted) - ifequipped

1. Clear fuel filter cover2. Fuel filter cover cap3. Retaining Ring4. Water In Fuel sensor5. Drain valve

Page 74




a. Remove any dirt that has collected on the clear filtercover, the cap on top of clear filter cover, or the filtercover retaining ring.

b. Loosen cap on top of clear filter cover with special filterwrench p/n 380134 (metal wrench from DAVCO).

Figure 34 Optional Davco fuel filter wrench

1. Cover cap opening2. Retaining ring opening

NOTE: Drain until no water or other contaminants areobserved existing from the drain valve.

c. Place a suitable container under the drain valve (or drainhose) and open the drain valve.

d. Close drain valve and cap on top of clear filter cover.

e. Dispose of the contaminated fuel per applicableregulations.

Page 75


Service Procedures (cont.)BELT, AIR INTAKE PIPING AND CLAMPS

Service Interval: At every oil change or 15,000 miles (24,000km), 6 months, or 550 hours

Figure 35 Cracks in belt ribs

1. Belt in good condition2. Belt ready for replacement3. Belt ribs4. Cracks in belt

Inspect condition of all drive belts (Figure 35). Install a new beltif any of the following conditions exist:

• Excessive wear

• Missing material

• Grease or oil contamination

• Over three cracks per inch in a belt rib

Removing the Belt

1. Attach a 1/2–inch drive breaker bar with a 15–mmsocket onto bolt on auto tensioner.

2. Rotate the auto tensioner in the appropriate direction tomove it away from the belt path and remove the belt fromthe auto tensioner pulley and other pulleys as required.

3. Slowly release the breaker bar; the auto tensionerautomatically adjusts.

4. Remove the breaker bar and socket.

Page 76



BELT, AIR INTAKE PIPING AND CLAMPS (cont.)

Figure 36 Accessory belt routing - low mount fan drive

Figure 37 Accessory belt routing - high mount fan drive

Installing the Belt

1. Attach a 1/2–inch drive breaker bar with a 15–mmsocket onto bolt on auto tensioner.

2. Rotate the auto tensioner in the appropriate direction tomove it away from the belt path and install the belt ontothe auto tensioner pulley and other pulleys as required.

3. Slowly release the breaker bar; the auto tensionerautomatically adjusts.

Page 77



BELT, AIR INTAKE PIPING AND CLAMPS (cont.)

4. Remove the breaker bar and socket.

AIR INTAKE PIPING AND CLAMPS

Inspect hoses, pipes, and clamps for any of the followingconditions, install new parts:

• Loose hoses or clamps, tighten or replace as required

• Ruptured hoses

• Cracked air cleaner housing

COOLANT FREEZE POINT

Service Interval: At engine oil change or 6 months

Nitrite-Free ULTRA ELC 50 / 50 Premix provides freezeprotection to -34°F (-36°C) and maximum corrosion protection.Nitrite-Free ULTRA ELC 50 / 50 Premix is used to replenishcoolant loss and ensure that glycol / water concentrations stayin balance.

Freeze Point Protection Levels Provided by Nitrite-FreeUltra Concentrate (ethylene glycol) and Water Mixtures

Concentrate and WaterMixtures

Freeze Point Protection

40% Ultra ELC Concentrate and60% water

-12°F (-24°C)


-34°F (-37 °C)


-62°F (-52°C)


-95°F (-71°C)

For vehicles operating in extremely cold climates, coolantmixtures of 60%Nitrite-Free Ultra Concentrate and 40%water or67% Nitrite-Free Ultra ELC Concentrate and 33% water provideadditional freeze protection as shown in table above. Mixtureshaving more than 67% Nitrite-Free Ultra ELC Concentrate arenot recommended due to risk of additive fallout.

Page 78



COOLANT FREEZE POINT (cont.)

Check freeze point with a refractometer.

1. Put drop of coolant on refractometer window.

2. Look through eyepiece and focus.

3. Record freeze point.

4. Adjust coolant concentration as necessary to achievedesired freeze point protection.

ENGINE OIL AND FILTER

WARNING: To prevent personal injury or death, wearsafety glasses and avoid moving components such as fans,pulleys, and belts when taking an engine oil sample.

Engine oil sampling can be utilized for the following:

Engine Oil Sampling - Optional

1. Determine if specified engine oil change intervals shouldbe shortened, based upon specific engine application.

2. Catch contaminants which, if left unattended, may resultin engine failure.

The oil sample valve, if equipped, is located on the centrifugal oilfilter or a port on the right side of the engine. If the vehicle doesnot have a centrifugal oil filter or if the vehicle was not orderedwith a factory installed oil sampling valve, an oil sampling valvemay be retrofitted. See your local dealer for assistance. Itis recommended to take the sample from an engine that iswarm and running. For safety information, refer to your EngineOperation and Maintenance Manual and Vehicle OperatorManual.

Page 79



ENGINE OIL AND FILTER (cont.)

Table 3 Oil Drain Interval for Normal Service vehicles

Engine Type Less than5.0 MPG (2Kmpl)

5.0 to6.5 MPG(2.0–2.75Kmpl)

More than 6.5MPG (2.75Kmpl)

Navistar® N13engine

18,000 miles(29,000 km)

See DrainIntervalfor NormalService Basedon MPG(Figure 38)

40,000 miles(64,000 km)

MPG Based Oil Change Interval

CAUTION: To prevent engine damage, DO NOT use thefollowing service schedule chart for severe service use orapplication.

Page 80




Figure 38 Drain interval for Normal Service based on MPG

1. Park the vehicle on level ground. Set the parking brake andshift the transmission to park or neutral.

2. Run the engine until operating temperature is reached, thenshut down the engine.


WARNING: To prevent personal injury or death, wearprotective clothing when draining hot oil.


NOTE: Engine oil filter should always be changed beforedraining engine oil pan. Dirty oil in filter housing will drainto oil pan through an internal valve when changing filter.

Page 81




NOTE: To prevent damage to coolant hoses, do not letengine oil drip onto hoses during oil filter removal orinstallation. If oil does drip onto coolant hoses, wipe offthoroughly with clean rag.

Figure 39 Oil filter cover

1. High-pressure turbocharger2. Oil filter cover3. Oil filter housing4. Air intake duct

3. Remove the oil filter and cover as a unit. Discard the O-ring.

4. Dispose of the oil filter according to local regulations.

5. Install new O-ring onto the oil filter cover.

6. Using clean engine oil, lubricate the circumference of thenew oil filter cover O-ring as well as the inside and outsidediameters of the seal on the bottom of the oil filter.

7. Install new oil filter and oil filter cover into oil filter housing.Tighten to 30 lb·ft (40 N·m).

8. Put a drain pan under the oil pan drain plug, remove the oilpan drain plug, and drain the oil.

9. Inspect the oil pan drain plug O-ring. If it is free of defects,it can be reused. Replace if required.

10. Lubricate the oil pan drain plug O-ring with clean engine oiland put the O-ring onto the drain plug.

11. Install the oil pan drain plug and tighten to 55 lb·ft (75 N·m).

12. Dispose of oil according to applicable local regulations.

CAUTION: To prevent engine damage, do not overfill with oil.

13. Add engine oil with the correct oil viscosity and formulation.API CJ-4 oil is recommended but CI-4 is allowable. Use ofCI-4 oils will reduce Diesel Particulate Filter (DPF) cleaning

Page 82




interval; see Maintenance Schedule . Add oil through theengine oil fill tube.

Figure 40 Oil level gauge (typical)

14. Check the oil level gauge. Oil level must be within thecrosshatched operating range.

15. Start the engine and run at low idle.

16. Run the engine at various speeds for 2 minutes to fill the oilpassages. Shut off the engine. Check for leaks, especiallyaround the oil filter cap and the oil pan drain plug.

17. Shut down the engine for 5 minutes to allow the oil to returnto the oil pan.

CAUTION: To prevent engine damage, do not overfill with oil.

18. Recheck oil level and add oil to bring oil level within the upperhalf of the crosshatched operating range on gauge.

RESETTING CHANGE ENGINE OIL SERVICE INTERVALMESSAGE

Reset the Service Interval Message (change engine oil) per thefollowing procedure or using ServiceMaxx™ software:

1. If not already done, set the parking brake.

2. Turn ignition switch to ON.

3. Turn cruise ON.

4. Turn cruise OFF.

5. Turn cruise ON.

6. Very rapidly push the Resume switch four times and thenhold down on the fifth time for 4 seconds.

7. The Change Oil message should clear.

8. The operation from the time the cruise is turned ON for thesecond time to the fifth activation of the resume switch musttake place within 6 seconds. If you fail to reset the message,repeat the process.

Page 83


Service Procedures (cont.)FUEL FILTER

Service Interval: At oil change or maximum of: 25,000 miles(40,000 km), 12 months, 1,100 hours, 4,200 gallons (16,000liters) of fuel, or whichever comes first.

NOTE: Change the fuel filter before recommended serviceinterval if the Fuel Filter text message is illuminated.

NOTE: If fuel has more than average impurities, shortenservice intervals.


WARNING: To prevent personal injury or death, storediesel fuel properly in an approved container designed forand clearly marked DIESEL FUEL.

CAUTION: To prevent engine damage, do not add fuel to thefuel filter housing; this can add contaminants to the fuel.

Figure 41 Fuel filter assembly

1. Fuel filter cover2. Fuel filter element3. Fuel filter housing4. Water drain valve5. Fuel strainer

1. Set the parking brake and shift the transmission to park orneutral.

Page 84



FUEL FILTER (cont.)

WARNING: To prevent personal injury or death, makesure the engine has cooled before removing components.

2. Turn ignition switch to OFF and allow engine to cool beforeremoving components.

WARNING: To prevent personal injury or death, wearsafety glasses with side shields. Limit compressed airpressure to 30 psi (207 kPa).

CAUTION: To prevent engine damage, clean area around fuelfilter housing before removing fuel filter cover This will protectthe open fuel filter housing from contaminants falling into thehousing. If contaminants do fall in, remove them and blow outfuel filter housing with compressed air before installing a newfilter element. Contaminants reaching high-pressure fuel systemcomponents may cause component failure.

3. Clean engine compartment components in the area of thefuel filter housing using compressed air, before removingthe fuel filter cover. Also, wipe the fuel filter cover cleanto prevent contaminants from entering the fuel system.Contaminants may cause engine failure.

4. Loosen the fuel filter cover counterclockwise 3 1/2 turns tovent the fuel filter housing and drain the fuel back to the fueltank.

5. From under the vehicle, attach a hose to the end of thewater-in-fuel drain valve.

6. Put a suitable container under the hose from the water drainvalve.

7. Open water drain valve and drain the fuel filter assembly.

8. Close water drain valve.

9. Recycle or dispose of fuel according to applicableregulations.

10. Loosen and remove the fuel filter cover and element. Donot unplug the engine wiring harness connector to increaseaccess to fuel filter. This may result in a damaged connector.

11. Remove the fuel filter cover from the fuel filter element byholding the element vertically and pushing up on the cover.The cover will snap off the fuel filter element. Dispose of thefuel filter element according to applicable regulations.

12. Remove the O-ring from the fuel filter cover. Discard O-ring.

13. Coat a new O-ring for the fuel filter cover with clean dieselfuel and install onto the fuel filter cover.

14. Attach the fuel filter cover to the fuel filter element by pushingthe fuel filter cover onto the fuel filter element. The fuel filtercover will snap onto the fuel filter element.

Page 85



FUEL FILTER (cont.)

15. Coat the threads of the fuel filter cover with clean diesel fuel.

16. Install the fuel filter element with cover into the fuel filterhousing. Slowly submerse the fuel filter element into the fuelfilter housing until fuel filter cover is ready to be secured tothe fuel filter housing.

17. Secure the fuel filter cover and element to the fuel filterhousing by turning the fuel filter cover clockwise untilfinger-tight.

CAUTION: To prevent engine damage, tighten fuel cover on fuelfilter assembly.

18. Tighten the fuel filter cover to 18 lb·ft (25 N·m).

19. Prime the fuel system before starting the vehicle. SeePriming the Fuel System (page 52).

COOLANT FILTER (IF EQUIPPED)

Service Interval: At engine oil change

Perform the following steps when changing the coolant filter. Figure 42 Typical mounting location of coolant filter

1. Navistar® N13 diesel engine2. Coolant filter3. Low-pressure charge-air-cooler (side mounted)4. Frame rail

Page 86



COOLANT FILTER (IF EQUIPPED) (cont.)


WARNING: To prevent personal injury or death, makesure the engine has cooled before removing components.

NOTE: It is recommended to use coolant filter WF2077 whenchanging the coolant filter. The coolant filter should bechanged with every oil change.

1. Loosen and retighten coolant tank pressure cap to relievecooling system pressure. Turn both shutoff valve handlesperpendicular to coolant filter hoses to close valves.Remove coolant filter using a filter wrench / strap. Thecoolant filter is usually mounted to the truck frame rail.

NOTE: Coolant filter header is equipped with two checkvalves to stop the flow of coolant when the filter is removed.

2. Apply a thin coat of coolant to the new filter gasket and installonto filter header.

3. Tighten until gasket touches the coolant filter header.Tighten, by hand, an additional one (1) full turn. Turn shutoff

valve handles parallel to coolant filter hoses to resumecoolant flow.

4. Top off coolant level to the COLDMAX line, if it is not alreadyat that level or higher.

FUEL STRAINER

Service Interval: Annually

NOTE: If fuel used has more than average impurities,shorter service intervals may be required.


WARNING: To prevent personal injury or death, do notsmoke and keep fuel away from flames and sparks.

Page 87



FUEL STRAINER (cont.)

Figure 43 Fuel filter and strainer

1. Fuel primer pump2. Fuel filter cover3. Fuel filter housing4. Water drain valve5. Fuel strainer cover6. Fuel strainer

1. Park vehicle on level ground, set parking brake, and shifttransmission to park or neutral.

2. Unscrew fuel strainer cover from fuel primer pump.

3. Remove and discard fuel strainer cover O-ring.

4. Remove fuel strainer.

5. Do one of the following with the fuel strainer:

• If strainer is not damaged, clean the fuel strainer withclean diesel fuel and reinstall the fuel strainer.

• If strainer is damaged, install a new fuel strainer.

6. Install a new fuel strainer cover O-ring.

7. Coat threads and O-ring on fuel strainer cover with cleandiesel fuel.

8. Install fuel strainer cover and tighten to 89 lb·in (10 N·m).

9. Prime the fuel system before starting the vehicle. SeePriming the Fuel System (page 52).

Page 88


Service Procedures (cont.)ELECTRICAL SYSTEM

Service Interval: Annually

1. Check wiring harness for cracks, rubbing, and looseconnections.

2. Check sensors for loose connections, corrosion, or cracks.

3. Check battery cables for the following conditions:

• Broken insulation

• Rubbing or chaffing

• Corroded or loose connections

4. Repair items identified.

CLEANING DIESEL PARTICULATE FILTER (DPF)

CJ-4 Engine Oil

Service Interval: 155,000 miles to 250,000 miles (250,000 km -400,000 km), 30 months or 6,000 hours. See service intervalchart (Figure 44). Clean DPF at designated service interval.Take vehicle to your International dealer for cleaning

.

CI-4 Engine Oil

Service Interval: 125,000 miles to 195,000 miles (200,000 km -312,000 km), 30 months, 6,000 hours. See service interval chart(Figure 44). Clean DPF at designated service interval. Takevehicle to your International dealer for cleaning.

Page 89



CLEANING DIESEL PARTICULATE FILTER (DPF) (cont.)

Figure 44 Service interval chart for diesel particulate filter

ENGINE VALVE LASH AND ENGINE BRAKE LASH

Service Interval: At 120,000 miles (190,000 km), at 300,000miles (480,000 km), then every 300,000 miles (480,000 km)thereafter.

For adjustment procedures, see the Navistar® N13 EngineService Manual or take vehicle to an authorized service providerfor adjustment.

SERVICE COOLING SYSTEM

Service Interval: 600,000 miles (1,100,000 km), 6 years, or12,000 hours

See Vehicle Service Publications or your authorized serviceprovider for cooling system drain and refill procedure.

WARNING: To prevent personal injury or death, makesure engine has cooled before draining coolant.

CAUTION: To prevent engine damage, engine coolant drainand refill procedure must be followed per the instructions in theVehicle Service Publications or as supplied by your dealer.

Page 90


Service Procedures (cont.)ESTIMATED REPLACEMENT OF DIESEL PARTICULATEFILTER

Service Interval: 1,200,000 miles (1,930,000 km)

Replace diesel particulate filter.

NOTE: See Vehicle Service Manual for service andmaintenance procedures for DPF.

Page 91

note:donotfollowmpgbasednormalservicevehicle note ... ·...

Documents