AFC 12917: Deaeration Tank Hose Rerouting. Study Guide TMT Course Code: 8438

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1 AFC 12917: Deaeration Tank Hose Rerouting Study Guide TMT Course Code: 8438

2 2013 Navistar, Inc Navistar Drive, Lisle, IL All rights reserved. No part of this publication may be duplicated or stored in an information retrieval system without the express written permission of Navistar, Inc.

3 Table of Contents Course Navigation... 3 Description of Repair... 3 Deaeration Tank Hose Re-Route Procedure... 4 Step 1: Prepare the Vehicle for Service... 4 Step 2: Coolant Management Tool Setup... 4 Step 3: Draining the Deaeration Tank... 5 Step 4: Component Removal... 5 Step 5: Component Installation... 5 Step 6: MIN Level Indicator... 6 Step 7: Refill the Cooling System... 7 Step 8: Check for Leaks... 8 Step 9: Verify Coolant Level... 8 Deaeration Tank Cap Replacement Procedure... 8 Step 1: Remove Clamp and Cap... 8 Step 2: Install Cap and Clamp... 8 Step 3: Before Returning the Vehicle to Service... 8 Updating ECM Parameters... 8 Step 1: Update ECM Parameters... 8 Conclusion... 9

4 Introduction Welcome to the Navistar Training Course for AFC 12917: Deaeration Tank Hose Rerouting. If you have questions or concerns regarding the playback of this program, please contact Navistar Service Education by submitting a case file (Dealer Personnel); or by calling THE INFORMATION PROVIDED WITHIN THIS COURSE IS FOR TRAINING PURPOSES ONLY. ALWAYS CONSULT THE LATEST SERVICE, DIAGNOSTIC, AND TOOL INFORMATION, LOCATED ON NAVISTAR S SERVICE PORTAL, PRIOR TO PERFORMING SERVICE ON NAVISTAR ENGINES, VEHICLES, AND EQUIPMENT. Course Navigation Navigation of this course may be done using the three buttons near the bottom center of your screen. Clicking the "Pause/Play/Continue" Button while the course is playing will pause or play the course content. At the end of each section this button will flash red, indicating that you must click it to continue the course. Clicking the "Previous" Button will return you to the previous section for review of information. Clicking the Next Button will advance you to the next section in the course. It is recommended to avoid using the "Next" button to ensure all course content may be viewed. Description of Repair The purpose of AFC is to correct an issue on 2010 model year 11 and 13 Liter engines, built between September 1st, 2010 and July 10th On these engines, the Low-coolant Warning Lamp is disabled in the ECM. When enabled, the original routing of the Deaeration Tank hoses may cause false illumination of the Low Coolant Warning Lamp. To correct this issue, the Deaeration Tank hoses must be re-routed, and the ECM must be updated.

Deaeration Tank Hose Re-Route Procedure Step 1: Prepare the Vehicle for Service Before performing this procedure the vehicle must be parked on a level surface with the transmission shifted to park or

Step 2: Coolant Management Tool Setup ALWAYS MAKE SURE THE ENGINE HAS COOLED BEFORE SERVICING THE COOLING SYSTEM. FAILURE TO DO SO MAY RESULT IN PROPERTY DAMAGE, PERSONAL INJURY, AND/OR DEATH.

5 Deaeration Tank Hose Re-Route Procedure Step 1: Prepare the Vehicle for Service Before performing this procedure the vehicle must be parked on a level surface with the transmission shifted to park or neutral. The parking brake must be engaged and the wheels chocked. The hood will need to be opened and the front bumper should be flipped forward. Step 2: Coolant Management Tool Setup ALWAYS MAKE SURE THE ENGINE HAS COOLED BEFORE SERVICING THE COOLING SYSTEM. FAILURE TO DO SO MAY RESULT IN PROPERTY DAMAGE, PERSONAL INJURY, AND/OR DEATH. To facilitate performing this portion of the AFC, use the Coolant Management Tool to drain the coolant from the Cooling System until the coolant level is at or below the Coolant Level Sensor. Ensure the engine has cooled and slowly remove the pressure cap from the Deaeration Tank. Turn the Coolant Management Tool tank valve to DRAIN VEHICLE. Next, attach the Coolant Management Tool hose to the quick-disconnect fitting on the bottom of the radiator assembly. Install the Cap Adapter, KL5004NAV, onto the Deaeration tank and attach the Pressure Module, KL5006NAV, to the Cap Adapter.

6 Step 3: Draining the Deaeration Tank After installing the components of the Coolant Management Tool on the vehicle, connect shop air to the Pressure Module. Open the valve on the Pressure Module and allow coolant to drain from the system until the level is below the Coolant Level Sensor. IF THE SYSTEM IS NOT DRAINING, ENSURE THE COOLANT MANAGEMENT TOOL TANK VALVE IS SET TO DRAIN VEHICLE. When the coolant is at or below the Coolant Level Sensor, close the valve on the Pressure adapter and turn the valve on the Coolant Management Tool from DRAIN VEHICLE to CLOSED. After you have finished draining the system, remove the Pressure Module from the Coolant Management Tool adapter. Step 4: Component Removal Next, remove the clamp and hose from the fitting located on top of the High Temperature Radiator. Cut the cable tie straps securing the coolant pipe in place and remove the plastic trim retainers securing the coolant pipe to the Deaeration Tank. Remove the clamp securing the coolant pipe and hose at the top of the Deaeration tank. Remove and discard the coolant pipe and hose and restore the lower trim retainer and the tie straps. Remove the clamp and hose from the Low Temperature Radiator. Remove the clamp and hose from the backside of the Deaeration Tank. Discard the hose and clamp. Step 5: Component Installation Install the cap and clamp supplied with the kit to the fitting on the Deaeration Tank. Do not reuse the old clamp. Insert the end of the formed T-hose through the recirculation seal and install the hose and clamp onto the Low Temperature Radiator. Turn the fitting on top of the High Temperature Radiator to align with the single formed hose fitting end. Install the vertical portion of the T-hose onto the fitting located on top of the High Temperature Radiator. Install the hose and clamp onto the fitting on the backside of the Deaeration Tank.

If the distance measures approximately 1 and 1/4 inches (32mm) adding the new label is not required. MIN Line is too low and requires installation of the new MIN Label.

7 Step 6: MIN Level Indicator On the Deaeration Tank, measure the distance between the coolant MIN and MAX level lines. If the space between the lines measures about 2 inches (51 mm) the label with the new coolant MIN indication will need to be installed. If the distance measures approximately 1 and 1/4 inches (32mm) adding the new label is not required. MIN Line is too low and requires installation of the new MIN Label. MIN Line is in correct location and does not require a new Label. If adding the label is necessary, first clean the surface of the Deaeration Tank and then install new the new coolant MIN label as shown here. Ensure the MIN indicator is approximately 1 and 1/4 inches (32 mm) below the MAX line. After completing the new Deaeration Tank hose installation, refill the cooling system to the MIN level line on the Deaeration Tank.

8 Step 7: Refill the Cooling System With the Coolant Management Tool's tank valve in the CLOSED position connect the Vacuum Module, KL5005NAV to the Cap Adapter. Turn the blue Vent Valve to the closed position and connect shop air to the Vacuum Module. Direct the clear exhaust hose from the Vacuum Module into the drain pan to collect all coolant mist emitted while refilling the Cooling System. Open the black Air Valve on the Vacuum Module and allow the Coolant Management Tool to draw inhg (68-85 kpa) of vacuum, as represented on the gauge by the green zone. NEVER ALLOW THE COOLANT MANAGEMENT TOOL S TANK TO COMPLETELY EMPTY WHILE FILLING THE COOLING SYSTEM. FAILURE TO MAINTAIN AN ADEQUATE SUPPLY OF COOLANT IN THE COOLANT MANAGEMENT TOOL COULD ALLOW AIR TO ENTER THE COOLING SYSTEM. Once the gauge reading on the Vacuum Module reaches the green zone, turn the tank valve to the FILL VEHICLE position. Allow the Coolant Management Tool to fill the Cooling System until the coolant has slightly passed the MIN level indicator. When the coolant reaches the desired level, turn the tank valve to the CLOSED position. WHEN THE BLUE VALVE ON THE VACUUM MODULE IS OPENED TO RELEASE THE VACUUM ON THE COOLING SYSTEM, THE COOLANT LEVEL WILL DROP. IT MAY BE NECESSARY TO ADD COOLANT TO THE DEAERATION TANK TO FILL THE SYSTEM TO THE PROPER LEVEL. Close the black air valve, and open the blue vent valve on the Vacuum Module to release the vacuum placed on the Cooling System. Then, disconnect the Vacuum Module and remove the Cap Adapter. Remove the hose from the quick-disconnect fitting at the bottom of the radiator assembly. Top-off Deaeration Tank to achieve the proper coolant level and then reinstall the cap on the Deaeration Tank.

9 Step 8: Check for Leaks DUE TO AN INCREASE IN COOLANT TEMPERATURE AFTER RUNNING THE ENGINE, THE DEAERATION TANK MAY BE UNDER PRESSURE. USE EXTREME CAUTION WHEN REMOVING THE DEAERATION TANK CAP. FAILURE TO DO SO MAY RESULT IN PROPERTY DAMAGE, PERSONAL INJURY, AND/OR DEATH. Run the engine for 10 to 15 minutes and check for any leaks from the Cooling System. Step 9: Verify Coolant Level After running the vehicle, check the coolant level one last time and top-off as needed. Deaeration Tank Cap Replacement Procedure Step 1: Remove Clamp and Cap Start by removing and discarding the cap and clamp attached to the port on the top / back of the deaeration tank. Step 2: Install Cap and Clamp Now install a new cap on the deaeration tank port and secure it into place using a new clamp. Step 3: Before Returning the Vehicle to Service Before returning the vehicle to service be sure to remove the drain pan, close and properly secure the hood, and remove the wheel chocks. Step 1: Update ECM Parameters Updating ECM Parameters COMPLETION OF THIS REPAIR REQUIRES UPDATING THE ECM, AS WELL AS REPORTING THE UPDATE TO THE NAVISTAR DATABASE. UPDATING MUST BE PERFORMED BY A CERTIFIED TECHNICIAN.

10 To update the ECM begin by downloading the parameter template for " Coolant Level Low Protection Light - Red MaxxForce 11 and 13" to your desktop. Refer to "IK AFC Deaeration Tank Hose Re-Route Engine Parameter Download Instructions" for instruction and a link to download the template. Now launch ServiceMaxx and log in if prompted. In ServiceMaxx select "Open Template" under the File dropdown. Locate and select the file you just downloaded to your desktop, " Coolant Level Low Protection Light - Red MaxxForce 11 and 13." Verify parameter " Coolant Level Low Protection Light - Red MaxxForce 11 and 13" is in right-side window of ServiceMaxx and click the "Program Engine" button. Open NETS and use the "GET" function to obtain engine information, then select "SEND" to update the parameter history in the Navistar database. Conclusion This Concludes the Navistar training course for AFC 12917, Deaeration Tank Hose Re-Route. Thank you for your participation.

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