2014 Navistar N13 Engine with SCR Service Repair Workshop Manual

ENGINE SERVICE MANUAL 0000003823 Navistar ® N13 with SCR Revision 1 EPA 10 - US, Canada, Mexico April 2014 ENGINE SERVICE MANUAL Navistar ® N13 with SCR Navistar, Inc. 2701 Navistar Drive, Lisle, IL 60532 USA ©2014 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

Summary of Changes Section Updated Description Engine Systems Inserted updated Engine Systems section taken from 0000002161R9 Inlet Air Heater System • Installation procedure updated to reﬂect correct installation of the IAHFI in the air intake throttle duct. Engine Electrical Added following new sections: • NOx IN sensor module • AFTPAV • AFTFI • AFTFP1 • AFTFSV Remove MAF sensor procedures. Aftertreatment System New or updated procedures: • Aftertreatment (AFT) Fuel Doser Module • Aftertreatment Purge Air Valve (AFTPAV) Assembly • Aftertreatment Fuel Injector (AFTFI) Assembly • AFTI Coolant Return Tube Assembly • AFTI Coolant Supply Tube Assembly • AFTI Fuel Tube Assembly Remove PDOC sections Change naming of “metering unit” to “AFT fuel doser module” Fuel System New or updated procedures: • Fuel Supply and Drain (Return) Lines • Fuel Filter Housing Assembly Appendix D Inserted Appendix D: Component Locator — copied from 0000002161R9

ENGINE SERVICE MANUAL I TABLE OF CONTENTS Foreword...................................................................................................................1 Service Diagnosis ........................................................................................................2 Safety Information........................................................................................................3 Engine Systems...........................................................................................................5 Mounting Engine on Stand............................................................................................53 Engine Electrical.........................................................................................................61 Inlet Air Heater System...............................................................................................107 Aftertreatment System................................................................................................119 Exhaust Back Pressure Control.....................................................................................143 Turbochargers..........................................................................................................157 Air Compressor and Power Steering...............................................................................207 Fuel System.............................................................................................................221 Oil Cooler, Filter Housing, and Crankcase Ventilation..........................................................277 Exhaust Gas Recirculation (EGR) System.........................................................................295 Air Intake Throttle Duct and Exhaust Manifold...................................................................331 Front Cover, Fan Drive, Cooling System, and Related Components.........................................353 Navistar ® N13 Engine Brake by Jacobs............................................................................383 Cylinder Head, Camshaft and Valve Train.........................................................................399 Flywheel and Flywheel Housing.....................................................................................435 Oil Pan and Oil Pickup Tube.........................................................................................453 Oil Pump and Timing Gears..........................................................................................469 Power Cylinders........................................................................................................485 Crankcase and Crankshaft...........................................................................................505 Abbreviations and Acronyms........................................................................................519 Terminology.............................................................................................................525

II ENGINE SERVICE MANUAL Appendix A – Speciﬁcations.........................................................................................537 Appendix B – Torques.................................................................................................543 Appendix C – Special Service Tools................................................................................561 Appendix D: Component Locator...................................................................................577

ENGINE SERVICE MANUAL 1 Foreword Navistar, Inc. is committed to continuous research and development to improve products and introduce technological advances. Procedures, specifications, and parts defined in published technical service literature may be altered. This Engine Service Manual provides a general sequence of procedures for out-of-chassis engine overhaul (removal, inspection, and installation). For in-chassis service of parts and assemblies, the sequence may vary. NOTE: Photo illustrations identify specific parts or assemblies that support text and procedures; other areas in a photo illustration may not be exact. See vehicle manuals and Technical Service Information (TSI) bulletins for additional information. Navistar ® N13 with SCR Engine Operation and Maintenance Manual Navistar ® N13 with SCR Engine Service Manual (EPA 10) Navistar ® N13 with SCR Engine Diagnostic Manual (EPA 10) Navistar ® N13 with SCR Hard Start and No Start Diagnostics Form (EPA 10) N13 with SCR Performance Diagnostics Form (EPA 10) Navistar ® N13 with SCR Electronic Control System Diagnostics Form (EPA 10) Technical Service Literature is revised periodically. If a technical publication is ordered, the latest revision will be supplied. NOTE: To order technical service literature, contact your International dealer. All marks are trademarks of their respective owners.

2 ENGINE SERVICE MANUAL Service Diagnosis Service diagnosis is an investigative procedure that must be followed to find and correct an engine application problem or an engine problem. If the problem is engine application, see specific vehicle manuals for further diagnostic information. If the problem is the engine, see specific Engine Diagnostic Manual for further diagnostic information. Prerequisites for Effective Diagnosis • Availability of gauges, diagnostic test equipment, and diagnostic software. • Availability of current information for engine application and engine systems. • Knowledge of the principles of operation for engine application and engine systems. • Knowledge to understand and do procedures in diagnostic and service publications. Technical Service Literature required for Effective Diagnosis • Engine Service Manual • Engine Diagnostic Manual • Diagnostics Forms • Electronic Control Systems Diagnostics Forms • Service Bulletins

ENGINE SERVICE MANUAL 3 Safety Information This manual provides general and specific maintenance procedures essential for reliable engine operation and your safety. Since many variations in procedures, tools, and service parts are involved, advice for all possible safety conditions and hazards cannot be stated. Read safety instructions before doing any service and test procedures for the engine or vehicle. See related application manuals for more information. Obey Safety Instructions, Warnings, Cautions, and Notes in this manual. Not following warnings, cautions, and notes can lead to injury, death or damage to the engine or vehicle. Safety Terminology Three terms are used to stress your safety and safe operation of the engine: Warning, Caution, and Note Warning: A warning describes actions necessary to prevent or eliminate conditions, hazards, and unsafe practices that can cause personal injury or death. Caution: A caution describes actions necessary to prevent or eliminate conditions that can cause damage to the engine or vehicle. Note: A note describes actions necessary for correct, efficient engine operation. Safety Instructions Work Area • Keep work area clean, dry, and organized. • Keep tools and parts off the floor. • Make sure the work area is ventilated and well lit. • Make sure a First Aid Kit is available. Safety Equipment • Use correct lifting devices. • Use safety blocks and stands. Protective Measures • Wear protective safety glasses and shoes. • Wear correct hearing protection. • Wear cotton work clothing. • Wear sleeved heat protective gloves. • Do not wear rings, watches or other jewelry. • Restrain long hair. Vehicle • Shift transmission to park or neutral, set parking brake, and block wheels before doing diagnostic or service procedures. • Clear the area before starting the engine. Engine • The engine should be operated or serviced only by qualified individuals. • Provide necessary ventilation when operating engine in a closed area. • Keep combustible material away from engine exhaust system and exhaust manifolds. • Install all shields, guards, and access covers before operating engine. • Do not run engine with unprotected air inlets or exhaust openings. If unavoidable for service reasons, put protective screens over all openings before servicing engine. • Shut engine off and relieve all pressure in the system before removing panels, housing covers, and caps. • If an engine is not safe to operate, tag the engine and ignition key. Fire Prevention • Make sure charged fire extinguishers are in the work area. NOTE: Check the classification of each fire extinguisher to ensure that the following fire types can be extinguished. 1. Type A — Wood, paper, textiles, and rubbish 2. Type B — Flammable liquids 3. Type C — Electrical equipment Batteries • Always disconnect the main negative battery cable first. • Always connect the main negative battery cable last. • Avoid leaning over batteries.

4 ENGINE SERVICE MANUAL • Protect your eyes. • Do not expose batteries to flames or sparks. • Do not smoke in workplace. Compressed Air • Use an OSHA approved blow gun rated at 207 kPa (30 psi). • Limit air pressure to 207 kPa (30 psi). • Wear safety glasses or goggles. • Wear hearing protection. • Use shielding to protect others in the work area. • Do not direct compressed air at body or clothing. Tools • Make sure all tools are in good condition. • Make sure all standard electrical tools are grounded. • Check for frayed or damaged power cords before using power tools. Fluids Under Pressure • Use extreme caution when working on systems under pressure. • Follow approved procedures only. Fuel • Do not over fill the fuel tank. Over fill creates a fire hazard. • Do not smoke in the work area. • Do not refuel the tank when the engine is running. Removal of Tools, Parts, and Equipment • Reinstall all safety guards, shields, and covers after servicing the engine. • Make sure all tools, parts, and service equipment are removed from the engine and vehicle after all work is done.

2014 Navistar N13 Engine with SCR Service Repair Workshop Manual

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