This DuraStar exhaust aftertreatment service manual, publication 0000001602 Revision 7, documents the Exhaust Aftertreatment System with DPF and SCR for International trucks. It covers DPF and DOC inspection, cleaning and reuse guidelines plus diesel exhaust fluid (DEF) system service.
Official document details
| Brand | International Trucks (Navistar) |
| Model coverage | 9900, DuraStar, LoneStar, PayStar, ProStar+, TerraStar, TranStar, WorkStar |
| System / Group | 4000 Series (DuraStar) / Aftertreatment Troubleshooting |
| Publication no. | 0000001602 |
| Year / Revision | Revision 7, October 2014 |
| Pages | 165 |
| File size | 19.2 MB |
| Format | |
| Language | English |
Inside the DuraStar exhaust aftertreatment
- Theory of operation and exhaust system layouts
- DPF and DOC general inspection points
- DPF/DOC thread repair (12 mm and 14 mm)
- DOC and DPF reuse guidelines
- DEF dosing valve cleaning and supply module filter
- DEF system contamination and decontamination
Published by Navistar in October 2014 as Revision 7, the manual first shows the many exhaust layouts, from single horizontal and vertical to switchback, in-line and dual-vertical arrangements, so the right variation is identified before any wrench is turned. General service information warns against unlawful tampering and covers gasket and fastener rules, filter indexing, and detailed diesel particulate filter and diesel oxidation catalyst inspection points with photographic reuse guidelines for soot, ash, cracks and melting. The diesel exhaust fluid sections add decomposition reactor tube cleaning, dosing valve cleaning, supply-module filter inspection, and full contamination identification and decontamination procedures. Component replacement steps give real torque values, such as 35 to 37 lb-ft on filter mount bolts and 28 to 30 lb-ft on the V-clamp nut, keyed to figure and item numbers.
Applicable truck models
The manual applies to 9900, DuraStar, LoneStar, PayStar, ProStar+, TerraStar, TranStar and WorkStar with MaxxForce DT/7/9/10/11/13/15 and Cummins ISX15, ISB or Navistar N9/N10/N13 engines. The acceptable DEF concentration specification is 32.5 ± 1.5%. Verify coverage against your VIN and build sheet on the International Trucks website.
Who needs the DuraStar exhaust aftertreatment
Emissions and driveability technicians use this manual to inspect and reuse DPF and DOC canisters, clean the DEF dosing valve, and diagnose contaminated DEF before replacing aftertreatment hardware on International trucks.
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