This DuraStar cooling system manual (publication S12038, January 2011) is the factory radiator and cooling package service section for International DuraStar vehicles. It covers component descriptions plus coolant drain, pressure test and fill procedures.
Official document details
| Brand | International Trucks (Navistar) |
| Model coverage | International DuraStar (4000 Series) |
| System / Group | Radiator & Cooling System |
| Publication no. | S12038 |
| Year / Revision | January 2011 |
| Pages | 47 |
| File size | 0.8 MB |
| Format | |
| Language | English |
What the DuraStar cooling system manual covers
- Description — surge tank, fan shroud and fan drive
- A/C condenser and radiator/charge air cooler assembly
- Cross-member and transmission oil cooler
- Coolant drain, pressure test and fill procedures
- Splash panel and surge tank service
- Fan and fan drive, fan shroud and radiator hose
- Cooling package removal and torque chart
Publication S12038 introduces the KL5007NAV Coolant Management Tool for draining and refilling without air pockets, lists torque values in N·m and lbf-ft, and refers technicians to S09016 for hood and grille removal before pulling the charge air cooler and cooling package.
Applicable truck models
This section applies to the International DuraStar (4000 Series) medium-duty truck. Confirm your radiator and engine package before service. Brand details are on the International Trucks official website.
Who needs this DuraStar cooling system manual
Medium-duty truck technicians and fleet shops use this factory section to replace radiators, surge tanks and hoses and to bleed the system correctly. It is written for trained professionals.
The manual is built around safe pressure handling: never pressurise the system beyond the radiator cap rating, and gravity-drain instead of pressurising if a leak is already present. The KL5007NAV tool speeds refills and cuts air pockets, while the Y-strainer screen on the tank valve should be checked for debris. Remember the hood, bumper and charge air cooler must come off first to pull the full cooling package, so budget time accordingly.
The full PDF is available in the DiagTechPro manuals library — a free account is required to download. Each listing shows the exact publication number so you can match the document to your VIN and build date before downloading.
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