2010 EPA 2013 HD-OBD N13 with SCR Diagnostics for

2010 EPA 2013 HD-OBD N13 with SCR Diagnostics for technicians

Study Guide

Course Code: 8356

1 2010 EPA 2013 HD-OBD N13 with SCR Diagnostics for technicians| Study Guide

©2014 Navistar, Inc. 2701 Navistar Drive, Lisle, IL 60532.

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.

2010 EPA 2013 HD-OBD N13 with SCR Diagnostics for technicians• © 2014 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.


Table of Contents Introduction .................................................................................................................................................. 2

Objectives ..................................................................................................................................................... 3

Guided Practice ............................................................................................................................................. 3

FMI Hierarchy ................................................................................................................................................ 4

Exercise 1 ...................................................................................................................................................... 7

Exercise 2 ...................................................................................................................................................... 8

Exercise 3 .................................................................................................................................................... 16

CONCLUSION ............................................................................................................................................... 20

Introduction Welcome to the Navistar training course for 2010 EPA 2013 HD-OBD N13 with SCR Diagnostics for technicians. This course is intended to introduce technicians to the Navistar N13 Step-Based Diagnostic procedures.

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 1-800-365-0088.

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.

2010 EPA 2013 HD-OBD N13 with SCR Diagnostics for technicians • © 2014 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.


Objectives Navistar’s 2010 EPA 2013 HD-OBD N13 with SCR step-based diagnostics are designed to aid technicians in diagnosing faults. Upon completion of this course, the student will be able to:

• Utilize the Failure Mode Indicator Hierarchy to identify which fault codes should be diagnosed first.

• Use Navistar’s N13 Step-Based Diagnostic manual. • Use Navistar special tools to diagnose and service N13 engine systems. • Test Selective Catalytic Reduction components for proper operation. • Utilize the Navistar EZ-Tech launcher.

Guided Practice The customer's complaint is that the Malfunction Indicator Lamp is on, and the vehicles power has been limited. The dashboard also displays the "STOP ENGINE" message. Take a look at the repair order labeled Guided Practice in the back of this guide.

To begin diagnosing the customer's complaint, the vehicle needs to be checked for Diagnostic Trouble Codes (DTCs). First connect the USB-Link to the vehicle’s Data Link Connector (DLC). Next turn the EZ-Tech on along with the ignition switch.



The EZ-Tech launcher displays a collection of DTCs from all of the vehicles modules, and the modules they are stored in. Next the EZ-Tech needs to be connected to the vehicle, Click the "CONFIGURE" button to select the interface cable you are using. Next select the appropriate cable from the "ADAPTER SELECTION" drop down menu. The EZ-Tech will remember the last cable selected.

After automatically generating a health report, the launcher displays the DTCs from all modules on the vehicle's network. Because multiple fault codes can be set at once, a hierarchy is used to determine which fault to diagnose first based on the Failure Mode Indicator (FMI).

FMI Hierarchy

The FMI Hierarchy defines the FMI into three categories, Circuit, Component, and System faults. When more than one FMI is present, first diagnose "Circuit" FMIs, secondly, diagnose "Component" FMIs, and finally, diagnose "System" FMIs. Occasionally Component FMIs (2, 13, 14) may need to be diagnosed first, for the most up to date information use the appropriate Engine Diagnostic Manual found in the service portal.

A. Circuit FMI: 3, 4, 5, and 19. These FMI direct diagnostics to specific circuit failures. B. Component FMI: 2, 7, 11, 13, and 14. These FMI direct diagnostics towards a monitored system

component failure, and other components associated with the operation of a system. C. System FMI: 0, 1, 10, 15, 16, 17, 18, 20, 21, and 31. These FMI direct diagnostics to a loss of

efficiency and performance in the monitored system. Some FMIs are an indication of higher emissions being produced.

If you would like more information on the FMI Hierarchy, refer to the Service Portal.

When there are multiple codes on the same FMI level, start with the one closest to the top of the DTC list.

Always use the service information on Service Portal when available in order to ensure you are using the most up to date information available.



SPN 1761 FMI 19 - Diesel Exhaust Fluid Tank Level Temperature (DEFTLT) not Detected on J1939 is the first fault with a circuit FMI. To view the diagnostic procedure for this fault code, open the Diagnostic Manual. When you click the service manual icon, there will be an option to use service manuals saved on the EZ-Tech, or service manuals on Service Portal. Always use the service information on Service Portal when available in order to ensure you are using the most up to date information available. The Diagnostic Manual will display the steps that should be taken to diagnose a fault, and the order they should be completed in. In the web based course, you must click the Action for each step; once the diagnostic step has been completed a Decision must be made. The decision you select will guide you to the step which should be completed next.

Many diagnostic processes require electrical diagnosis. Harnesses and connectors must be inspected for corrosion and damage. Even if the harnesses in question are visually free of damage, further electrical testing may still be required. Navistar offers special “Breakout harnesses” which aid technicians in electrical testing.

After unplugging the connector, inspect each half of the connector. Use the Diagnostic Manual to view the required actions for this step. If the terminals are not damaged continue to step 2, if they are damaged continue with the repair information in the lower right hand corner of step 1.



Next check the voltage to the Diesel Exhaust Fluid Tank Level Temperature (DEFTLT) sensor module. In order to complete these diagnostic steps, a Digital Multimeter (DMM) ZTSE4357 will be needed along with Breakout Harness 18-124-01. Connect the DEFTLT Breakout Harness to the sensor module connector and measure the voltage between pin-3 and pin-4. If the voltage reading is within .5 volt of battery voltage continue on to step 4. If the voltage is not within .5 volts of battery voltage go to step 3.

Next check the voltage between pin-4 and ground using Breakout Harness 18-124-01 and Digital Multi Meter ZTSE4357. If the voltage from pin-4 to ground is within .5 volts of battery voltage follow repair information in the upper right corner of step 3 in the diagnostic manual. If the voltage is not within .5 volts of battery voltage follow the repair information in the lower right corner of step 3. Since the voltage in the course is low between the DEFTLT sensor module connector pin-4 and the switched ignition relay pin-87, repair the open or high resistance of this circuit and retest for this fault. After repairing a fault, retest for the fault code to ensure the issue has been resolved.

The wire that was repaired in this example supplies power to multiple Selective Catalytic Reduction (SCR) system sensors. The benefit of utilizing the FMI hierarchy is that repairing the wire not only fixed the fault we were diagnosing, but also remedied the other fault codes which were present in the ECM. For more information on wire repair please refer to iKNow article IK0800269 titled proper wire repair.


https://evalue.internationaldelivers.com/service/service_info/aspPageRef.aspx?pageid=93


Exercise 1 The customer's complaint is that the Malfunction Indicator Lamp is on. Take a look at the repair order labeled Exercise 1 in the back of this guide.

To begin diagnosing the customer's complaint, the vehicle needs to be checked for Diagnostic Trouble Codes (DTCs). First connect the USB-Link to the DLC. Next turn the EZ-Tech on along with the ignition switch. Then use the FMI hierarchy to select which code to diagnose first. Remember, if there are multiple codes on the same FMI level, start with the one closest to the top of the DTC list.

Is the DTC list free of the fault codes listed in step 1 of the diagnostic procedure for fault code SPN 1761 FMI 18? If yes continue to step 2, if no follow the repair instructions in the lower right corner of step 1.

Next check to see if the Diesel Exhaust Fluid (DEF) tank and lines are free of damage and not leaking. If none of the lines have DEF residue on them continue on to step 3. If any of the lines are damaged or leaking follow the repair instructions in the lower right corner of step 2.



Check the DEF gauge and tank to verify the DEF level. If the DEF level is low fill the DEF tank with the appropriate diesel exhaust fluid. After the tank has been filled retest for SPN 1761 FMI 18. If the DEF level is above a half tank continue on to step 4.

Exercise 2 The customer's complaint is that the Malfunction Indicator Lamp is on, and the vehicles power has been limited. Take a look at the repair order labeled Exercise 2 in the back of this guide.

To begin diagnosing the customer's complaint, the vehicle needs to be checked for Diagnostic Trouble Codes (DTCs). First connect the USB-Link to the DLC. Next turn the EZ-Tech on along with the ignition switch. Then use the FMI hierarchy to select which code to diagnose first. Remember, if there are multiple codes on the same FMI level, start with the one closest to the top of the DTC list.

Is the DTC list free of the fault codes listed in step 1 of the diagnostic procedure for fault code SPN 3362 FMI 31? If yes continue to step 2, if no follow the instructions listed in the bottom right corner of step 1.




Inspect the tank and lines for damage and leaks. If the tank and lines are in good condition, continue on to step 3, if not, follow the instructions listed in the bottom right corner of step 2.

Is the DTC list free of the fault codes listed in step 3 of the diagnostic procedure for fault code SPN 3362 FMI 31? If the fault codes listed in step 3 are not present in the DTC list then continue to step 4, If the fault codes listed in step 3 are present in the DTC list then follow the repair information listed in the lower right corner of step 3.

Is the DTC list free of the fault codes listed in step 4 of the diagnostic procedure for fault code SPN 3362 FMI 31? If the fault codes listed in step 4 are not present in the DTC list then continue to step 5, If the fault codes listed in step 4 are present in the DTC list then follow the repair information listed in the lower right corner of step 4.

Inspect the DEF Suction and Return Lines for proper routing. If the DEF Suction and Return lines are not reversed between the DEF supply module and the DEF tank then continue to step 6. If the DEF Suction and Return lines are reversed between the DEF supply module and the DEF tank then follow the repair information listed in the lower right corner of step 5.



Are the DEF tank, DEF supply module, and DEF doser valve lines and connections in good condition? Does air flow freely through the DEF suction line? If the DEF tank, DEF supply module, or DEF doser valve lines are not damaged or leaking continue to step 7. If the DEF tank, DEF supply module, or DEF doser valve lines are damaged or leaking follow the repair information listed in the lower right corner of step 6.

Inspect DEF supply module suction line for restrictions. If air flows freely through the suction line clean the DEF supply module and retest for fault code SPN 3362 FMI 31. If air does not flow freely through the suction line follow repair information in the lower right corner of step 7.

DEF Supply Module Cleaning

Do not disconnect vehicle batteries, DEF supply module 12-way connector, or any DEF lines until the DEF dosing system has completed the purge cycle. Wait at least five minutes after Key OFF for the DEF dosing system to complete the purge cycle.



Inspect the DEF supply module housing for cracks or leaks. If the DEF supply module housing is in good condition then continue to step 2. If the DEF supply module housing is not in good condition follow the repair information in the lower left corner of step 1.

Inspect the connections at the DEF supply module, with the ignition switch in the off position disconnect the DEF supply module 12-way connector and inspect connector and DEF supply module terminals. If the DEF supply module connector, harness, and terminals are clean and undamaged continue on to step 3. If the DEF supply module connector, harness, and terminals are

Inspect the DEF supply module filter cap and fluid fittings for white DEF deposits. If the DEF supply module filter cap or fluid fittings have white DEF deposits on them follow the repair information in the lower right corner of step 3. If the DEF supply module filter cap or fluid fittings do not have white DEF deposits on them continue on to step 4.

Remove and inspect DEF supply module fluid fittings for cracks or damage. If the DEF supply module fluid fittings are in good condition continue on to step 5. If the DEF supply module fluid fittings are not in good condition follow the repair information in the lower right corner of step 4.



Use a rubber-tipped blow gun, blow air through the threaded side of the fitting onto a sheet of paper, then inspect the paper for debris that has been blown out of the fitting. If there was debris In the DEF supply module suction fitting continue follow the repair information in the upper right corner of step 5. If there wasn’t any debris in the DEF supply module suction fitting continue to step 6.

Use a rubber-tipped blow gun, blow air through the threaded side of the return line fitting and the Non-threaded side of the pressure line fitting onto a sheet of paper. Inspect the paper for debris that has been blown out of the fittings. If debris was present in the fittings follow the repair information in the upper right corner of step 6. If there was no debris present in the fittings continue on to step 7.

Inspect the DEF Supply Module filter cap for cracks and damage. If the DEF supply module filter cap is not broken continue on to step 8. If the DEF supply module filter cap is broken follow the repair instructions in the lower right hand corner of step 7.



A Refractometer displays the concentration of certain chemicals by limiting a colored area. The edge of the colored area is the measured concentration. Place a sample of DEF from the tank on a Refractometer. Next check the DEF quality. If it is then continue on with step 9, if the DEF’s urea concentration is not within specification then follow the repair information in the lower right corner of step 8.

Next re-install the DEF supply module fluid fittings using new O-rings and torque them to the proper specification. Then fill the DEF supply module cleaner bottle (18-200-01-01) with water and connect it to the supply module inlet connector. Now open ServiceMaxx™ to start the DEF Doser Pump Override Test. Lightly squeeze the DEF supply module cleaner bottle to push the water into the DEF supply module, until the module starts to draw water on its own. If the DEF supply module does draw water from the

Do not disconnect vehicle batteries, DEF supply module 12-way connector, or any DEF lines until the DEF dosing system has completed the purge cycle. Wait at least five minutes after Key OFF for the DEF dosing system to complete the purge cycle.



bottle continue on to step 10. If the DEF supply module does not draw water from the bottle follow the repair information in the lower right corner of step 9.

Now that the supply module has been cleaned, install a new DEF supply module filter and then complete the DEF Doser Valve (DEFDV) spray test. Since the DEF doser override test initial checks have already been completed, continue to the DEFDV preparatory steps.

First connect the Vacuum Module (KL5005NAV) of the Coolant Management Tool to draw vacuum on the cooling system. Then open the Vacuum Module’s air valve, and allow vacuum to build until the gauge reads 20 to 25 inHg (inches of mercury).

To prevent contaminating the SCR system, use compressed air and warm water to clean any white deposits and debris from the mating area of the DEFDV and the Decomposition Tube. To complete the test you will need the DEF Dosing Injector Spray Test Kit (18-559-01). Next, the coolant lines must be removed and immediately plugged. After plugging the coolant lines, you can now open the blue vent valve on the Vacuum Module to release the vacuum from the cooling system.

To prevent personal injury or death, allow the engine to cool before removing components.

To prevent personal injury or death, wear safety glasses with side shields.



Now disconnect and plug the DEFDV pressure line and electrical connector. Next remove the DEFDV from the decomposition tube and ensure the gasket is removed as well. Then connect the DEFDV Harness Extension and DEFDV Pressure Line Extension.

With the DEF doser valve placed in a graduated cylinder for the test, click the EZ-Tech in the Toolbar to open ServiceMaxx so we can start the test. Using the Navistar EZ-Tech Launcher, click on the ServiceMaxx icon to open the program.

To prevent damage to the SCR system, remove the DEF dosing nozzle from the exhaust pipe and place it in a graduated cylinder before the test is run.

Low battery voltage can cause the dosing volume to be low. Verify the batteries are fully charged before beginning this test.

Verify the DEF tank is full before beginning this procedure.



The DEF Doser Pump Override Test is an aftertreatment test that is performed with the key on and the engine off. Once ServiceMaxx has opened, navigate to the test by clicking the “TESTS” tab in the menu bar and selecting “KEY ON ENGINE OFF (KOEO) AFTERTREATMENT TESTS”. From the list of tests, select the “DEF DOSER PUMP OVERRIDE TEST” to open the test session then click the “BEGIN TEST” button to initiate the test.

Monitor the DEFDV spray pattern during the test. If the spray pattern is not even or is denser on one side, then follow the DEFDV cleaning procedure to clean the DEF doser valve.

Now that the DEF supply module is clean, and the DEF doser valve is spraying the correct amount of DEF, the next step is to retest for SPN 3362 FMI31.

Exercise 3 The customer's complaint is that the Malfunction Indicator Lamp is on, and the vehicles power has been limited. The dashboard also displays the "STOP ENGINE" message. Take a look at the repair order labeled Exercise 3 in the back of this guide.

To begin diagnosing the customer's complaint, the vehicle needs to be checked for Diagnostic Trouble Codes (DTCs). First connect the USB-Link to the DLC. Next turn the EZ-Tech on along with the ignition switch.

The DEFDV spray pattern should be a fine mist. If larger drops, dripping, or a non-symmetrical spray pattern is present, stop the test and clean the DEFDV tip. After cleaning is completed, restart the test.

After each test, measure the DEF in the graduated cylinder. Refer to Navistar’s Service Portal for instructions regarding results outside of the specification.



Is the DTC list free of the fault codes listed in step 1 of the diagnostic procedure for fault code SPN 5298 FMI 17? If yes continue to step 2, if no follow the repair instructions in the lower right corner of step 1.

Inspect the exhaust system between the turbocharger outlet and DOC inlet. If the exhaust system between the turbocharger outlet and the DOC inlet appears to be in good condition and sealed continue on to step 3. If the exhaust system between the turbocharger outlet and the DOC inlet appears to be damaged or leaking, then follow the repair instructions in the lower right corner of step 2.

Next inspect the Aftertreatment Fuel Shutoff Valve (AFTSV) for leakage. In order to test the AFTSV for leakage, remove the AFT Fuel Shutoff Valve Leak Test. First connect the Vacuum Module (KL5005NAV) of the Coolant Management Tool to draw a vacuum on the cooling system. Open the air valve on the Vacuum Module and allow the system to build 20 to 25 inHg.




Next unplug the electrical connector on the Aftertreatment Fuel Injector (AFTFI). Next remove the grey clips from the engine to unclip the AFTFI Electrical Harness. For the next few steps, multiple Special Tools will be needed; you’ll need the Air and Fuel Cap and Plug Kit (ZTSE 4891) and the Aftertreatment injector Test Kit (12-599-01).

The next step is to remove the AFTFI fuel supply line and immediately install the cap. Next remove and plug the coolant lines on the AFTFI. Now open the blue vent valve on the Vacuum Module to release the vacuum from the cooling system. Ensure the old seals on the coolant fittings are removed before continuing. Next the AFTFI can be removed from the turbocharger exhaust outlet pipe, and the AFTFI Block-off Plate and bolts can be installed onto the turbocharger exhaust outlet pipe. After connecting the AFTFI Harness Extension and the AFTFI Fuel Supply Extension Line to the Aftertreatment Fuel injector connect them to the vehicle. Once the AFTFI is in a graduated cylinder for the test, open ServiceMaxx to start the test.

The AFT Fuel Shutoff Valve Leak Test is an aftertreatment test that is performed with the engine running at operating temperature. Click the “TESTS” tab in the menu bar, and then select “KEY ON ENGINE RUNNING (KOER) AFTERTREATMENT TESTS”. From the list of tests, select the “AFT Fuel Dosing Test” to open the test session. Next select the second field under the “Value” heading, and then select “AFT Fuel Shutoff Valve Leak Test”. Now click “BEGIN TEST” to start the test, if the start of the test needs to be delayed, the “DELAY TIME” slider can be used to delay the start of the test. Once the test is complete, record the results. If the amount of fuel dispensed is outside of the specification, replace the Aftertreatment Fuel Shutoff Valve.

To prevent personal injury or death, wear safety glasses with side shields.

The engine must be at operating temperature before performing this test.

Remove the AFT Fuel Injector from the exhaust pipe and place it in the vessel or jar before the test is run to avoid SCR system damage.



Inspect the Aftertreatment Fuel Injector (AFTFI) for fuel? If the AFTFI is dry and free of fuel then continue to step 5. If the AFTFI is not dry or free of fuel then follow the repair information in the bottom right corner of step 4.

The next test is the AFT Fuel Injector Leak Test. The preparatory steps are the same as the steps for the last test that was performed. Since the AFTFI is already in a graduated cylinder, open ServiceMaxx to start the test. The AFT Fuel Injector Leak Test is started in the same session as the previous test, but you must specify that you would like to perform the AFT Fuel Injector Leak Test. Click the second field under the “VALUE” heading to open a drop down menu, and then select “AFT Fuel Injector Leak Test”. After the test is complete, record the results. If the AFTFI is dry and free of fuel then continue to step 5, if the AFTFI is not dry or is soaked with fuel follow the repair information in the lower right hand corner of step 4.

The last test that needs to be done is the AFT Dosing System Test. The preparatory steps are the same as the steps for the last test that was performed. Since the AFTFI is already in a graduated cylinder, open ServiceMaxx to start the test. The AFT Dosing System Test is started in the same session as the previous test, but you must specify that you would like to perform the AFT Dosing System Test. Click the second field under the “VALUE” heading to open the drop down menu, and then select the “AFT Dosing System Test”. After the test is completed, record the results. If the amount of fuel dispensed meets the specification follow the repair information in the upper right hand corner of step 5. If the amount of fuel dispensed is below specification then replace the Aftertreatment Fuel Shutoff Valve. After installing the new AFTFI, retest for SPN 5298 FMI 17.

If needed the start of the test may be delayed. To delay the start of the test use the “DELAY TIME” slider can be used so that the test does not start right away.



CONCLUSION Congratulations! You’ve used step based diagnostics to complete all three exercises. This concludes the Navistar training course for 2010 EPA 2013 HD-OBD N13 with SCR Diagnostics for technicians.

Thank you for your participation.











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2010 EPA 2013 HD-OBD N13 with SCR Diagnostics for