2010 EPA 2013 HD-OBD N13 With SCR Diagnostics For Technicians

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.
2010 EPA 2013 HD-OBD N13 with SCR Diagnostics for technicians| Study Guide 2
Table of Contents
Introduction .................................................................................................................................................. 2
Objectives ..................................................................................................................................................... 3
Guided Practice ............................................................................................................................................. 3
FMI Hierarchy................................................................................................................................................ 4
Exercise 1 ...................................................................................................................................................... 7
Exercise 2 ...................................................................................................................................................... 8
Exercise 3 .................................................................................................................................................... 16
CONCLUSION............................................................................................................................................... 20
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.
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.
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.
respective owners.
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
When there are multiple codes on the same FMI level, start with the one closest to the top of
the DTC list.
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.
Always use the service information on Service Portal when available in order to ensure you are
using the most up to date information available.
respective owners.
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.
respective owners.
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.
respective owners.
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.
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.
respective owners.
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
limited. Take a look at the repair order labeled Exercise 2 in the back of this guide.
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.
respective owners.
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.
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.
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
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.
respective owners.
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.
respective owners.
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.
respective owners.
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.
respective owners.
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
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.
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
respective owners.
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.
To prevent personal injury or death, allow the engine to cool before removing components.
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 personal injury or death, wear safety glasses with side shields.
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.
respective owners.
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.
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.
Low battery voltage can cause the dosing volume to be low. Verify the batteries are fully
charged before beginning this test.
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.
Verify the DEF tank is full before beginning this procedure.
respective owners.
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.
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.
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.
After each test, measure the DEF in the graduated cylinder. Refer to Navistar’s Service Portal
for instructions regarding results outside of the specification.
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
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.
switch.
respective owners.
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.
respective owners.
To prevent personal injury or death, wear safety glasses with side shields.
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 engine must be at operating temperature before performing this test.
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.
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.
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.
respective owners.
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.
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.
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.
respective owners.
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.
respective owners.
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.
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.
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.
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.
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respective owners.

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2010 EPA 2013 HD-OBD N13 with SCR

Diagnostics for technicians

Course Code: 8356

©2014 Navistar, Inc.

All rights reserved.

No part of this publication may be duplicated

Many diagnostic processes require electrical diagnosis. Harnesses

DEF Supply Module Cleaning

A Refractometer displays the concentration of certain

Verify the DEF tank is full before beginning this procedure.

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

Thank you for your participation.

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