NAVISTAR PROSTAR COOLING WITH SCR SERVICE MANUAL

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NAVISTAR PROSTAR COOLING WITH SCR SERVICE MANUAL contains high quality images, diagrams, instructions to help you to operate, maintenance, diagnostic, and repair your machine. This document is printable, without restrictions, contains searchable text and bookmarks for easy navigation.

NAVISTAR PROSTAR COOLING WITH SCR SERVICE MANUAL includes:

• Numbered table of contents easy to use so that you can find the information you need fast.
• Detailed sub-steps expand on repair procedure information.
• Numbered instructions guide you through every repair procedure step by step.
• Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
• Notes, cautions and warnings throughout each chapter pinpoint critical information.
• Bold figure number help you quickly match illustrations with instructions.
• Detailed illustrations, drawings and photos guide you through every procedure.
• Enlarged inset helps you identify and examine parts in detail.

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TABLE OF CONTENT OF THE NAVISTAR PROSTAR COOLING WITH SCR SERVICE MANUAL

1. GENERAL DESCRIPTION……………………………………………………………………………. 1
1.1. DEAERATION TANK…………………………………………………………………………… 3
1.2. FAN SHROUD…………………………………………………………………………………. 3
1.3. A/C CONDENSER…………………………………………………………………………….. 3
1.4. TRANSMISSION OIL COOLER……………………………………………………………….. 3
1.5. RADIATOR…………………………………………………………………………………….. 3
1.6. CHARGE AIR COOLER……………………………………………………………………….. 3
1.7. LOW-TEMPERATURE RADIATOR…………………………………………………………….. 3
1.8. FAN DRIVE…………………………………………………………………………………….. 4
1.9. POWER STEERING OIL COOLER……………………………………………………………. 4
2. REMOVAL AND INSTALLATION…………………………………………………………………….. 5
2.1. COOLANT DRAIN, PRESSURE TEST, AND FILL PROCEDURES……………………………. 6
Coolant Drain Procedure – Navistar ® 11, 13, 15 and Cummins® ISX15 (Recommended). . . . . . . . 8
Pressure Test Procedure – Navistar ® 11, 13, 15, and Cummins® ISX15 (Recommended). . . . . . 10
Coolant Fill Procedure – Navistar ® 11, 13, 15 and Cummins® ISX15 (Recommended). . . . . . . . . . 11
Coolant Drain Procedure – Navistar ® 11, 13, 15, Cummins® ISX15 (Optional). . . . . . . . . . . . . . . . . . . 13
Coolant Fill Procedure – Navistar ® 11, 13, 15 (Optional)……………………………………… 14
Coolant Fill Procedure – Cummins® ISX Engines (Optional)…………………………………. 16
2.2. GRILLE……………………………………………………………………………………….. 17
Grille – Removal……………………………………………………………………………… 17
Grille – Installation……………………………………………………………………………. 17
2.3. DEAERATION TANK – NAVISTAR ® ENGINES………………………………………………. 19
Deaeration Tank Removal – Navistar ® 11, 13, 15…………………………………………….. 19
Deaeration Tank – Installation Navistar ® 11, 13, 15…………………………………………… 20
2.4. DEAERATION TANK – CUMMINS® ISX ENGINES………………………………………….. 20
Deaeration Tank Removal – Cummins® ISX15……………………………………………….. 21
Deaeration Tank Installation – Cummins® ISX15…………………………………………….. 21
2.5. A/C CONDENSER……………………………………………………………………………. 23
A/C Condenser Removal – Navistar ® 11, 13 …………………………………………………. 23
A/C Condenser Installation – Navistar ® 11 or 13 …………………………………………….. 25
A/C Condenser Removal – Navistar ® 15 Liter ……………………………………………….. 26
A/C Condenser Installation – Navistar® 15 Liter ………………………………………………. 27
A/C Condenser Removal – Cummins® ISX15 ……………………………………………….. 28
A/C Condenser Installation – Cummins® ISX15………………………………………………. 29
2.6. FAN SHROUD………………………………………………………………………………… 30
Fan Shroud Removal – Navistar ® 11, 13……………………………………………………… 30
Fan Shroud Installation – Navistar® 11, 13 Liter ………………………………………………. 35
Fan Shroud Removal – (Three-Piece Upper) Navistar® 15 …………………………………… 36
Fan Shroud Installation – (Three-Piece Upper) Navistar® 15 …………………………………. 38
Fan Shroud Removal – (Three-Piece Lower) Navistar® 15 ………………………………….. 39
Fan Shroud Installation – (Three-Piece Lower) Navistar ® 15…………………………………. 39
Fan Shroud (One-Piece) Removal – Navistar ® 15……………………………………………. 40
Fan Shroud Installation – (One-Piece) Navistar ® 15………………………………………….. 42
Fan Shroud Removal – (Two-Piece) Cummins® ISX15………………………………………. 42
Fan Shroud Installation – (Two-Piece) Cummins® ISX15…………………………………….. 47
2.7. RADIATOR FAN………………………………………………………………………………. 49
Radiator Fan Removal – Navistar ® 11, 13……………………………………………………. 49
Radiator Fan Installation – Navistar® 11, 13 ………………………………………………….. 50
Radiator Fan Removal (With Three-Piece Fan Shroud) – Navistar® 15……………………….. 51
Radiator Fan Installation (With Three-Piece Fan Shroud) – Navistar® 15……………………… 51

Radiator Fan Removal (With One-Piece Fan Shroud) – Navistar® 15…………………………. 52
Radiator Fan Installation (With One-Piece Fan Shroud) – Navistar ® 15………………………. 53
Radiator Fan Removal – Cummins® ISX15…………………………………………………… 53
Radiator Fan Installation – Cummins® ISX15………………………………………………… 53
2.8. FAN DRIVE…………………………………………………………………………………… 55
Fan Drive Removal – Navistar ® 11, 13……………………………………………………….. 55
Fan Drive Installation – Navistar ® 11, 13……………………………………………………… 56
Fan Drive Removal – Navistar® 15……………………………………………………………. 57
Fan Drive Installation – Navistar® 15………………………………………………………….. 58
Fan Drive Assembly Removal – Cummins® ISX15 (Horton)………………………………….. 58
Fan Drive Assembly Installation – Cummins® ISX15 (Horton) ……………………………….. 59
2.9. FAN BELT…………………………………………………………………………………….. 61
Fan Belt Removal – Navistar ® 11, 13…………………………………………………………. 61
Fan Belt Installation – Navistar ® 11, 13……………………………………………………….. 62
Fan Belt Removal – Navistar® 15 ……………………………………………………………. 63
Fan Belt Installation – Navistar ® 15…………………………………………………………… 64
Alternator Fan Belt Removal – Navistar ® 15 …………………………………………………. 65
Alternator Fan Belt Installation – Navistar ® 15 ……………………………………………….. 66
Fan Belt Removal – Cummins® ISX15 ………………………………………………………. 67
Fan Belt Installation – Cummins® ISX15……………………………………………………… 68
2.10. RADIATOR HOSES…………………………………………………………………………… 69
Heat Shrink Clamp – Removal……………………………………………………………….. 69
Heat Shrink Clamp – Installation……………………………………………………………… 70
Radiator Hose Removal – Navistar® 11, 13 …………………………………………………… 73
Radiator Hose Installation – Navistar® 11, 13…………………………………………………. 74
Radiator Hose Removal – Navistar ® 15 ……………………………………………………… 75
Radiator Hose Installation – Navistar ® 15…………………………………………………….. 76
Exhaust Gas Recirculation (EGR) Valve/Cooler Hose Removal – Navistar ® 15 . . . . . . . . . . . . . . . . . . 77
Exhaust Gas Recirculation (EGR) Valve/Cooler Hose Installation – Navistar® 15. . . . . . . . . . . . . . . . . 78
Radiator Hose Removal – Cummins® ISX15…………………………………………………. 80
Radiator Hose Installation – Cummins® ISX15 ………………………………………………. 82
2.11. RECIRCULATION SEALS……………………………………………………………………. 84
Recirculation Seals Removal – Navistar ® 11, 13……………………………………………… 84
Recirculation Seals Installation – Navistar ® 11, 13 …………………………………………… 84
Recirculation Seals Removal – Navistar® 15 …………………………………………………. 85
Recirculation Seals Installation – Navistar ® 15……………………………………………….. 87
2.12. CHARGE AIR COOLER………………………………………………………………………. 88
Charge Air Cooler Removal – Navistar® 11, 13, 15……………………………………………. 88
Charge Air Cooler Installation – Navistar ® 11, 13, 15…………………………………………. 89
Charge Air Cooler Removal – Cummins® ISX15……………………………………………… 89
Charge Air Cooler Installation – Cummins® ISX15…………………………………………… 93
2.13. HOOD-TILT ASSIST CYLINDER……………………………………………………………… 96
Hood-Tilt Assist Cylinder – Removal………………………………………………………….. 96
Hood-Tilt Assist Cylinder – Installation………………………………………………………… 98
2.14. LOW-TEMPERATURE RADIATOR (NAVISTAR® ENGINES ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Low-Temperature Radiator Removal – Navistar® 11, 13………………………………………. 99
Low-Temperature Radiator Installation – Navistar® 11, 13…………………………………… 101
Low-Temperature Radiator Removal – Navistar® 15…………………………………………. 102
Low-Temperature Radiator Installation – Navistar® 15……………………………………….. 105
2.15. RADIATOR ASSEMBLY…………………………………………………………………….. 108
Radiator Assembly Removal – Navistar® 11, 13……………………………………………… 108

Radiator Assembly Installation – Navistar® 11, 13……………………………………………. 110
Radiator Assembly Removal – Navistar® 15…………………………………………………. 110
Radiator Assembly Installation – Navistar® 15……………………………………………….. 112
Radiator Assembly Removal – Cummins® ISX15…………………………………………… 113
Radiator Assembly Installation – Cummins® ISX15…………………………………………. 120
2.16. RADIATOR CORE…………………………………………………………………………… 122
Radiator Core Removal – Navistar® 11, 13………………………………………………….. 123
Radiator Core Installation – Navistar® 11, 13………………………………………………… 125
Radiator Core Removal – Navistar® 15………………………………………………………. 127
Radiator Core Installation – Navistar® 15……………………………………………………. 128
Radiator Core- Removal – Cummins® ISX15 ………………………………………………. 129
Radiator Core Installation – Cummins® ISX15 ……………………………………………… 133
2.17. POWER STEERING OIL COOLER…………………………………………………………. 135
Power Steering Oil Cooler – Removal……………………………………………………….. 135
Power Steering Oil Cooler – Installation…………………………………………………….. 136
2.18. TRANSMISSION OIL COOLER (CUMMINS® ISX15 ONLY)………………………………… 137
Transmission Oil Cooler – Removal…………………………………………………………. 137
Transmission Oil Cooler – Installation……………………………………………………….. 140
TORQUE……………………………………………………………………………………………….. 140

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