International Navistar CXT MXT RXT TerraStar Truck Workshop Repair Service Manual PDF - MINTXTOPES.zip
This complete service and repair manual for International/Navistar Trucks—covering the CXT, MXT, RXT, and TerraStar models—comes with full Electrical Wiring Diagrams and delivers every technical detail needed to service, troubleshoot, fix, and rebuild these vehicles to the same standard as a professional technician.
Inside the International/Navistar Trucks CXT, MXT, RXT, and TerraStar workshop service and repair manual, you'll find:
* 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.
PRODUCT DETAILS:
Total Pages: 5,560 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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TABLE OF CONTENTS
0000001602 - Exhaust Aftertreatment System with SCR EPA 10 (Supersedes S07005), Revision 10....1
toc....3
Summary of Changes....3
1. Description....9
1.1. Theory of Operation....15
Aftertreatment regeneration burns soot to ash when excess soot buildup occurs. For regeneration to occur, the Engine Control Module (ECM) must detect a DPF restriction by monitoring temperature and pressure sensors.....15
1.2. Switchback / Horizontal....16
1.3. Vertical / Vertical....17
1.4. In-Line....18
2. General Service Information....19
2.1. Exhaust Aftertreatment System Modifications....20
2.2. Gaskets and Fasteners....21
2.3. Diesel Particulate Filter (DPF) Indexing....21
2.4. DPF and DOC Cleaning....21
2.5. DPF General Inspection....22
DPF Inspection Points....23
2.6. DOC General Inspection....26
DOC Inspection Points....26
2.7. DPF / DOC Thread Repair....30
12 MM Thread Replacement....30
14 MM Thread Replacement....34
2.8. DOC and DPF Reuse Guidelines....38
General Information....38
Diesel Oxidation Catalyst (DOC) Inlet / Outlet – Melted....39
Diesel Oxidation Catalyst (DOC) Inlet – Face Plugged....40
Diesel Particulate Filter (DPF) Inlet / Outlet – New....41
Diesel Particulate Filter (DPF) Inlet – Good but Dirty (1)....42
Diesel Particulate Filter (DPF) Inlet – Good but Dirty (2)....43
Diesel Particulate Filter (DPF) Inlet – Clean....44
Diesel Particulate Filter (DPF) Inlet – Gouged....45
Diesel Particulate Filter (DPF) Inlet – Ash....46
Diesel Particulate Filter (DPF) Inlet – Dark Soot Rings....47
Diesel Particulate Filter (DPF) Outlet – Soot Stains....48
Diesel Particulate Filter (DPF) Outlet – Burn Marks from Welding Process....49
Diesel Particulate Filter (DPF) Outlet – Excessive Soot Stains ....50
Diesel Particulate Filter (DPF) Outlet – Face Cracked....51
Diesel Particulate Filter (DPF) Outlet – Coolant Staining....52
Diesel Particulate Filter (DPF) Outlet – Melted....53
2.9. Decomposition Reactor Tube Cleaning....54
2.10. Diesel Exhaust Fluid (DEF) Dosing Valve cleaning....55
2.11. DEF Supply Module Filter Inspection....57
2.12. Diesel Exhaust Fluid (DEF) System Contamination....59
2.13. DEF System Decontamination Procedure....62
2.14. Diesel Exhaust Fluid (DEF) Refractometer Tool....63
Using the DEF Refractometer....63
DEF Refractometer Maintenance....65
2.15. Diesel Exhaust Fluid (DEF) Dosing System Reuse Guidelines....66
2.16. Diesel Exhaust Fluid (DEF) Tank Draining....69
3. Switchback / Horizontal....70
3.1. Cummins ISX15 and ISB6.7 or Navistar® N13, N9, and N10 Engines....70
Switchback / Horizontal – Removal....70
Switchback / Horizontal – Installation....72
Diesel Exhaust Fluid (DEF) Dosing Valve – Removal....73
Diesel Exhaust Fluid (DEF) Dosing Valve – Installation....74
Decomposition Reactor Tube – Removal....75
Decomposition Reactor Tube – Installation....76
Aftertreatment Assembly Mounting Bracket – Removal....77
Diesel Particulate Filter (DPF) and Selective Catalyst Reduction (SCR) Assembly Mounting Bracket – Installation....78
Selective Catalyst Reduction (SCR) NOx Out Sensor Module – Removal....79
Selective Catalyst Reduction (SCR) NOx Out Sensor Module – Installation....79
Selective Catalyst Reduction (SCR) NOx Out Sensor – Removal....81
Selective Catalyst Reduction (SCR) NOx Out Sensor – Installation....81
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor Module – Removal (If Equipped)....82
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor Module – Installation (If Equipped)....82
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor – Removal (If Equipped)....83
Selective Catalyst Reduction (SCR) Ammonia (NH3) Sensor – Installation (If Equipped)....83
Selective Catalyst Reduction (SCR) Temperature Sensors and Module – Removal....84
Selective Catalyst Reduction (SCR) Temperature Sensors and Module – Installation....84
(DPF) Temperature Sensors and Module – Removal....86
Diesel Particulate Filter (DPF) Temperature Sensors and Module– Installation....86
Diesel Particulate Filter (DPF) Pressure Sensor Module – Removal....88
Diesel Particulate Filter (DPF) Pressure Sensor Module – Installation....89
Diesel Particulate Filter (DPF) High Pressure Tube – Removal....90
Diesel Particulate Filter (DPF) High Pressure Tube – Installation....90
Diesel Particulate Filter (DPF) Low Pressure Tube – Removal....91
Diesel Particulate Filter (DPF) Low Pressure Tube – Installation....91
4. Vertical / Vertical ....92
4.1. Navistar® N13 Engine....92
Vertical / Vertical....92
Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) Heat Shield – Removal....93
Diesel Particulate Filter (DPF) or Selective Catalyst Reduction (SCR) Heat Shield – Installation....93
Power Distribution Module (PDM) – Removal....94
Power Distribution Module (PDM) – Installation....94
Aftertreatment Control Module (ACM) – Removal....95
Aftertreatment Control Module (ACM) – Installation....95
5. In–Line....96
5.1. Cummins ISB6.7 or Navistar® N9 and N10 Engines....96
In-Line....96
6. Diesel Exhaust Fluid (DEF) System....97
6.1. Cummins ISX15 and ISB6.7 or Navistar® N13, N9, and N10 Engines....97
Diesel Exhaust Fluid (DEF) Tank – Removal....97
Diesel Exhaust Fluid (DEF) Tank – Installation....100
Power Distribution Module (PDM) – Removal....101
Power Distribution Module (PDM) – Installation....101
Diesel Exhaust Fluid (DEF) Tank Wiring Harness – Removal....102
Diesel Exhaust Fluid (DEF) Tank Wiring Harness – Installation....105
Diesel Exhaust Fluid (DEF) Tank Lines – Removal....106
Diesel Exhaust Fluid (DEF) Tank Lines – Installation....108
Diesel Exhaust Fluid (DEF) Supply Module – Removal....109
Diesel Exhaust Fluid (DEF) Supply Module – Installation....110
Diesel Exhaust Fluid (DEF) Supply Module Filter – Removal....111
Diesel Exhaust Fluid (DEF) Supply Module Filter – Installation....111
Aftertreatment Control Module (ACM) – Removal....112
Aftertreatment Control Module (ACM) – Installation....113
Diesel Exhaust Fluid (DEF) Tank Bracket – Removal....114
Diesel Exhaust Fluid (DEF) Tank Bracket – Installation....115
Diesel Exhaust Fluid (DEF) Tank Pickup Assembly – Removal....116
Diesel Exhaust Fluid (DEF) Tank Pickup Assembly – Installation....117
Diesel Exhaust Fluid (DEF) Tank Heater Valve – Removal....118
Diesel Exhaust Fluid (DEF) Tank Heater Valve – Installation....119
Diesel Exhaust Fluid (DEF) Pressure Line and Coolant Lines – Removal....120
Diesel Exhaust Fluid (DEF) Pressure Line and Coolant Lines – Installation....122
Diesel Exhaust Fluid (DEF) System....123
7. Acronym List....124
tables....20
Table 2Minimum Clearance Between Exhaust System Components and Other Chassis Components.....20
Table 32Acronym List.....124
Table 33Torque Chart.....125
0000002322 - DuraStar and TerraStar Cab Service Manual (Supersedes S16026) Service Manual....126
toc....128
Summary of Changes....128
1. DESCRIPTION....140
1.1. Standard Cab, Extended Cab and Crew Cab....140
1.2. VEHICLE IDENTIFICATION NUMBER (VIN) TAG LOCATION....141
1.3. ELECTRIC WINDSHIELD WIPERS....142
1.4. WINDSHIELD WASHER....143
2. OPERATION....146
2.1. Electric Windshield Wipers....146
2.2. WINDSHIELD WASHER....146
3. MAINTENANCE....147
3.1. Windshield Washer....147
4. REMOVE....148
4.1. ONE PIECE ENCAPSULATED WINDSHIELD....148
Remove One Piece Encapsulated Windshield on Standard Cab, Extended Cab and Crew Cab for all Models....148
4.2. REAR WINDOW GLASS ON VEHICLES WITHOUT VAN BODY....154
Remove Rear Window Glass on Vehicles without Van Body on Standard Cab, Extended Cab and Crew Cab for all Models....154
4.3. REAR WINDOW GLASS ON VEHICLES WITH VAN BODY....157
Remove Rear Window Glass on Vehicles with Van Body on Standard Cab, Extended Cab and Crew Cab for all Models....157
4.4. HOOD SEAL....165
Remove Hood Seal on Standard Cab, Extended Cab and Crew Cab for All Models....165
4.5. SUNSHADE....166
Remove Sunshade on Standard Cab, Extended Cab and Crew Cab for all Models....166
4.6. SUN VISOR AND CLIP....166
Remove Sun Visor and Clip on Standard Cab, Extended Cab and Crew Cab for all Models....166
4.7. IGNITION SWITCH AND IGNITION SWITCH CYLINDER....168
Remove Ignition Switch on Standard Cab, Extended Cab and Crew Cab for all Models....169
Remove Ignition Switch Cylinder on Standard Cab, Extended Cab and Crew Cab for all Models....171
4.8. INSTRUMENT PANEL....173
Remove Instrument Panel on Standard Cab, Extended Cab and Crew Cab for all Models....173
4.9. CAB DOORS....177
Remove Front Cab Door on Standard Cab, Extended Cab and Crew Cab for all Models....177
Remove Rear Cab Door on Crew Cab for All Models....181
4.10. Cab Door Hinge....186
Remove Front Cab Door Hinge on Standard Cab, Extended Cab and Crew Cab for all Models....186
Remove Rear Cab Door Hinge on Crew Cab for all Models....187
4.11. CAB DOOR STRIKER PIN....189
Remove Front Cab Door Striker Pin on Standard Cab, Extended Cab and Crew Cab for All Models....189
Remove Rear Cab Door Striker Pin on Crew Cab for all Models....190
4.12. CAB DOOR CHECK BRACKET....191
Remove Front Cab Door Check Bracket on Standard Cab, Extended Cab and Crew Cab for all Models....191
Remove Crew Cab rear Door Check Bracket on Crew Cab for all Models....192
4.13. CAB DOOR CHECK LINK....192
Remove Front Cab Door Check Link on Standard Cab, Extended Cab and Crew Cab for all Models....192
Remove Rear Door Check Link on Crew Cab for all Models....193
4.14. CAB DOOR TRIM PANEL....195
Remove Front Cab Door Trim Panel with Electric Door Window and Locks on Standard Cab, Extended Cab and Crew Cab for all Models....195
Remove Front Cab Door Trim Panel with Manual Door Window and Locks on Standard Cab, Extended Cab and Crew Cab for all Models....197
Remove Crew Cab Rear Cab Door Trim Panel with Electric Door Window and Locks on Crew Cab for all Models....199
Remove Crew Cab Rear Cab Door Trim Panel with Manual Door Window and Locks on Crew Cab for all Models....201
4.15. CAB DOOR INNER DOOR PANEL WATER SHIELD....203
Remove Front Cab Door Inner Panel Water Shield on Standard Cab, Extended Cab and Crew Cab for all Models....203
Remove Rear Cab Door Inner Panel Water Shield on Crew Cab for all Models....205
4.16. CAB DOOR WINDOW SLIDE BLOCK....206
Remove Front Cab Door Window Slide Block on Standard Cab, Extended Cab and Crew Cab for all Models....206
Remove Rear Cab Door Window Slide Block on Crew Cab for all Models....207
4.17. CAB DOOR GLASS....209
Remove Front Cab Door Glass on Standard Cab, Extended Cab and Crew Cab for all Models....209
Remove Rear Cab Door Glass on Crew Cab for all Models....213
4.18. MODULAR DOOR HARDWARE ASSEMBLY....217
Remove Front Cab Door Modular Door Hardware Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....217
Remove Rear Cab Door Modular Door Hardware Assembly on Crew Cab for all Models....221
4.19. CAB DOOR VENT WINDOW....224
Remove Front Cab Door Vent Window on Standard Cab, Extended Cab and Crew Cab for all Models....224
4.20. CAB DOOR VENT WINDOW HINGE....225
Remove Front Cab Door Vent Window Hinge on Standard Cab, Extended Cab and Crew Cab for all Models....225
4.21. CAB DOOR VENT WINDOW SEAL....227
Remove Front Cab Door Vent Window Seal on Standard Cab, Extended Cab and Crew Cab for all Models....227
4.22. CAB DOOR LOCK CYLINDER....227
Remove Cab Door Lock Cylinder on Front Cab Door of Standard Cab or Extended Cab Models and on Front and Rear Cab Doors of Crew Cab Models....227
4.23. CAB DOOR WINDOW ELECTRIC MOTOR....229
Remove Front Cab Door Window Electric Motor on Standard Cab, Extended Cab and Crew Cab for all Models....229
Remove Rear Cab Door Window Electric Motor on Crew Cab for all Models....230
4.24. CAB DOOR WINDOW REGULATOR ARM ASSEMBLY....231
Remove Front Cab Door Window Regulator Arm Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....231
Remove Rear Cab Door Window Regulator Arm Assembly on Crew Cab for all Models....235
4.25. OUTER CAB DOOR HANDLE....236
Remove Front Cab Door Outer Cab Door Handle on Standard Cab, Extended Cab and Crew Cab for all Models....236
Remove Rear Cab Door Outer Cab Door Handle on Crew Cab for all Models....240
4.26. CAB DOOR LATCH....241
Remove Front Cab Door Latch on Standard Cab, Extended Cab and Crew Cab for all Models....241
Remove Rear Cab Door Latch on Crew Cab for all Models....243
4.27. INNER CAB DOOR HANDLE....244
Remove Front Cab Door Inner Cab Door Handle on Standard Cab, Extended Cab and Crew Cab for all Models....244
Remove Rear Cab Door Inner Cab Door Handle on Crew Cab for all Models....246
4.28. CAB DOOR WINDOW RUN CHANNELS....247
Remove Front Cab Door Window Run Channels on Standard Cab, Extended Cab and Crew Cab for all Models....247
Remove Rear Cab Door Window Run Channels on Crew Cab for all Models....250
4.29. CAB DOOR ELECTRIC WINDOW AND DOOR LOCK SWITCH....251
Remove Front Cab Door Electric Window and Door Lock Switch on Standard Cab, Extended Cab and Crew Cab for all Models....251
Remove Rear Cab Door Electric Window and Door Lock Switch on Crew Cab for all Models....252
4.30. CAB DOOR ELECTRIC MIRROR SWITCH....253
Remove Front Cab Door Electric Mirror Switch on Standard Cab, Extended Cab and Crew Cab for all Models....253
4.31. SEATS....254
Remove Passenger Bucket Seat on Standard Cab, Extended Cab and Crew Cab for all Models....254
Remove Fixed Passenger Seat on Standard Cab, Extended Cab and Crew Cab for all Models....256
Remove Two Man Fixed Bench Seat without Tool Box on Standard Cab, Extended Cab and Crew Cab for all Models....258
Remove Two Man Fixed Bench Seat with Tool Box on Standard Cab, Extended Cab and Crew Cab for all Models....258
Remove Full Width Rear Bench Seat on Extended Cab and Crew Cab for all Models....258
4.32. CAB DOOR OPENING SCUFF PLATE AND SEAT BELT RETRACTOR COVER....260
Remove Cab Door Opening Scuff Plate and Seat Belt Retractor Cover on Standard Cab, Extended Cab and Crew Cab for all Models....260
4.33. EXTENDED CAB BUNK/STORAGE UNIT....261
Remove Bunk/Storage Unit on Extended Cab for all Models....261
4.34. SIDE AND CORNER INTERIOR TRIM PANEL....262
Remove Side and Corner Interior Trim Panel on Standard Cab for all Models....262
Remove Side and Corner Interior Trim Panel on Extended Cab for all Models....263
Remove Side and Corner Interior Trim Panel on Crew Cab for all Models....264
4.35. Extended Cab Rear Side Window....266
Remove Rear Side Window on Extended Cab for all Models....266
Remove Rear Side Window Latch from Rear Side Window on Extended Cab for all Models....268
4.36. REAR INTERIOR TRIM PANEL....269
Remove Rear Interior Trim Panel on Standard Cab, Extended Cab and Crew Cab for all Models....269
4.37. HEADER CONSOLE PANEL....269
Remove Header Console Panel on Standard Cab, Extended Cab and Crew Cab for all Models....269
4.38. HEADLINER TRIM PANEL....273
Remove Headliner Trim Panel on Standard Cab for all Models....273
Remove Front Headliner Trim Panel on Extended Cab for all Models....274
Remove Rear Headliner Trim Panel on Extended Cab for all Models....276
Remove Front Headliner Trim Panel on Crew Cab for all Models....276
Remove Rear Headliner Trim Panel on Crew Cab for all Models....279
4.39. Crew Cab B - Pillar Trim Panel....280
Remove B - Pillar Trim Panel on Crew Cab for all Models....280
4.40. Cab Door Opening Weather Seals....280
Remove Front Cab Door Opening Weather Seals on Standard Cab, Extended Cab and Crew Cab for all Models....280
Remove Rear Cab Door Opening Weather Seals on Crew Cab for all Models....281
4.41. WINDSHIELD WIPER ARM AND BLADE ASSEMBLY....282
Remove Windshield Wiper Arm and Blade Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....282
4.42. CAB COWL TRAY....283
Remove Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models before September 2000....283
Remove Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models after September 2000....285
Remove Cab Cowl Tray on Standard Cab, Extended Cab and Crew Cab for all Models after February 2002....287
4.43. WINDSHIELD WIPER ASSEMBLY....289
Remove Windshield Wiper Assembly on Standard Cab, Extended Cab and Crew Cab for all Models....289
4.44. ELECTRIC WINDSHIELD WIPER MOTOR....291
Remove Electric Windshield Wiper Motor on Standard Cab, Extended Cab and Crew Cab for all Models....291
4.45. WINDSHIELD WASHER BOTTLE AND/OR PUMP MOTOR....293
Remove Windshield Washer Bottle and/or Pump Motor on Standard Cab, Extended Cab and Crew Cab for all Models....293