SB-10043719-5737

Authorized Field Change
AFC 11934
Date: February 2012
Subject File: ENGINE / CAB
Subject: Heater Supply Pipe Change / Grease Application for Exhaust Gas Recirculation (EGR) Valve /
HVAC Front Inside Module Drain Repair
Model: For Grease Application for EGR Valve Repair– Specific engine serial numbers within the following
date range
Start Date: 03/01/2011 End Date: 09/15/2011
Engine Family: MaxxForce® 11 and 13
Model: For Heater Supply Pipe Change – TransStar® and ProStar® (Springfield Assembly Plant)
Start Date: 01/10/2011 End Date: 06/27/2011
Model: TransStar® and ProStar® (Garland Assembly Plant)
Start Date: 12/02/2010 End Date: 06/29/2011
Model: ProStar® (Escobedo Assembly Plant)
Start Date: 11/30/2010 End Date: 07/05/2011
Model: For HVAC Front Inside Module Drain Repair – TranStar®, ProStar®, and LoneStar® equipped with
Feature 0016WCT – Heater and Air Conditioner (Blend-Air)
Start Date: 01/19/2011 End Date: 09/13/2011

DESCRIPTION
FOR GREASE APPLICATION FOR EGR VALVE
EGR Valves for certain MaxxForce® 11 and 13 engines were produced without grease and could fail
prematurely. This AFC describes a repair procedure to install grease in the EGR valve for all affected engines.
The repair will involve drilling small hole in the EGR housing, injecting 18 cc of grease with a syringe, and
sealing the hole with a rivet and RTV sealant.

FOR HEATER SUPPLY PIPE CHANGE
Vehicle Population: Certain vehicles repaired before 12/01/2011 under AFC 10924 or AFC 10926, or vehicles
built after these AFCs with the single-piece pipe per the date ranges above are included in this campaign.
NOTE: Vehicles that have NOT been repaired under AFC 10924 or 10926 will be repaired under those two
revised AFCs. Those procedures will include the new three-piece heater pipe.

© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

1

DESCRIPTION (CONT.)
Certain TransStar® and ProStar® vehicles built with MaxxForce® 11 or 13 2010-emission engines may
experience leaks in the single-piece water pipe. The purpose of this AFC is to replace the single-piece water
pipe with the three-piece water pipe on certain TransStar® and ProStar® models.

FOR HVAC FRONT INSIDE MODULE DRAIN REPAIR
The HVAC drain valve is being held open. When the blower motor is on, this causes the moisture not to drain.
The following are the causes:
1. The HVAC module floor seal interferes with the drain tube and forces it open or closed.
Condensate inside the module does not properly drain and instead is pulled into the blower motor.
2. The floor seal is mis-positioned or damaged during HVAC module installation.

PARTS INFORMATION
Table 1

Parts Information – For Grease Application for EGR Valve Repair

Part Number
3016337C91

Table 2

Description
Grease Application on EGR Valve Kit

1

Blind rivet

1

Cotton swab

2

Drill bit assembly

1

Drill jig

1

Jig bolt

1

M8 x 25 heat-resistant bolt

1

RTV sealant

1

Spacer assembly

1

Syringe assembly

1

Syringe tip

1

Instruction Sheet

1

Parts Information – For Heater Supply Pipe Repair

Part Number
8000932R91
Table 3

Quantity

Description
Three-piece water pipe kit

Quantity
1

Parts Information – For HVAC Front Inside Module Drain Repair

Part Number
8000934R91

AFC–11934

Description

Quantity
1

Sealant

2

PROCEDURE
WARNING – To prevent vehicle damage, personal injury or death, park the vehicle on a flat,
level surface. Make sure the engine ignition is in the off position, and the transmission is in neutral
or in the park position, if the vehicle is equipped with an automatic transmission. Set the parking
brake, block the wheels to prevent the vehicle from moving in both directions, and disconnect the
batteries at the negative terminal before doing any service procedures on the vehicle.

WARNING – To prevent personal injury or death, remove ground cable from negative terminal
of main battery before disconnecting electrical components. Always connect ground cable last.

WARNING – To prevent personal injury or death, always wear safe eye protection when
performing vehicle maintenance.

WARNING – To prevent personal injury or death, make sure that the engine has cooled before
removing components.

WARNING – To prevent personal injury or death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing
and rags contaminated with engine fluids.

3

AFC–11934

SERVICE PROCEDURE FOR GREASE APPLICATION FOR EGR VALVE
REPAIR
1. Park vehicle on a flat surface, shift transmission to park or neutral, set parking brake, and block wheels to
prevent the vehicle from moving in both directions.
2. Raise hood assembly. Flip down bumper on ProStar®+ models.
3. Drain the coolant using the Navistar Coolant Management tool.
4. Remove engine housing cover. (NOTE: It may be necessary to remove trim panels on some models
and trim levels.) On ProStar® and TransStar® models with the deluxe interior, removal of the driver and
passenger seat and floor mats is necessary.
5. Remove coolant manifold (rear of EGR) according to removal procedure in the “Exhaust Gas Recirculation
(EGR) System” section of the EGES-465 Engine Service Manual.
NOTE – Save all fasteners and seals for reuse.

Figure 1

EGR Valve
1. M8 x 25 heat resistant bolt
2. EGR part number and serial number location
3. EGR heat shield

6. Push EGR heat shield as far inboard as possible to allow room to work.
7. Thoroughly clean EGR part number and serial number surface with brake cleaner or equivalent.
8. Remove only one M8 x 25 heat resistant bolt from EGR inlet tube flange. Discard bolt.

AFC–11934

4

SERVICE PROCEDURE FOR GREASE APPLICATION FOR EGR VALVE REPAIR
(CONT.)

Figure 2

Drill Jig
1.
2.
3.
4.

Drill jig
Push direction
Jig bolt
Jig drill hole

9. Place drill jig onto EGR housing and install jig bolt finger tight.
10. Push drill jig in the direction as shown and tighten jig bolt to 18 lb-ft (24 N•m).

Figure 3

Drill Hole to Proper Depth

5

AFC–11934

SERVICE PROCEDURE FOR GREASE APPLICATION FOR EGR VALVE REPAIR
(CONT.)
11. Drill through the hole in the drill jig to the mounted stop collar.
12. Continue to rotate the drill bit while removing.
13. Remove jig bolt and jig. Save jig bolt.

Figure 4

Syringe Assembly

14. Remove protective cover from end of syringe assembly by rotating counterclockwise.

Figure 5

Syringe Tip

AFC–11934

6

SERVICE PROCEDURE FOR GREASE APPLICATION FOR EGR VALVE REPAIR
(CONT.)
15. Install syringe tip onto syringe assembly end by rotating clockwise.

Figure 6

Inject Grease into EGR Housing

16. Insert syringe tip fully into drilled hole.
17. Slowly inject 0.3 fl oz (9 cc) of grease by pressing plunger.
18. Wait 30 seconds to allow grease to settle.

Figure 7

Empty Syringe

7

AFC–11934

SERVICE PROCEDURE FOR GREASE APPLICATION FOR EGR VALVE REPAIR
(CONT.)
19. Inject remaining 0.3 fl oz (9 cc) of grease.
NOTE – Some grease may squeeze out of the hole. Wipe off excess if this occurs.
20. Remove syringe assembly with tip and discard.

Figure 8

Clean Drilled Hole

21. Insert one of the cotton swabs to full depth of cotton end while rotating.
22. Continue to rotate in the same direction while removing.
23. Repeat with second cotton swab.

AFC–11934

8

SERVICE PROCEDURE FOR GREASE APPLICATION FOR EGR VALVE REPAIR
(CONT.)

Figure 9

EGR Housing Surface

24. Apply brake cleaner or equivalent to a clean shop towel and wipe EGR housing surface clean of any grease.

Figure 10

EGR Housing Surface Height Difference

NOTE – Due to the difference in height between the as-cast and machined surfaces of the EGR
housing, it will be necessary to use a spacer to install the blind rivet.

9

AFC–11934

SERVICE PROCEDURE FOR GREASE APPLICATION FOR EGR VALVE REPAIR
(CONT.)

Figure 11

Jig Bolt

25. Reinstall the jig bolt in the EGR housing to where there is approximately 1.0 in. (26 mm) of thread left
above the exhaust flange.

Figure 12

Rivet Gun and Rivet/Spacer Assembly

26. Install blind rivet into spacer assembly.
27. Install blind rivet/spacer assembly into locally obtained rivet gun. Use the appropriate rivet guide on the
rivet gun for rivet supplied in the kit.

AFC–11934

10

SERVICE PROCEDURE FOR GREASE APPLICATION FOR EGR VALVE REPAIR
(CONT.)
NOTE – Always wear safety glasses when using a rivet gun.

Figure 13

Rivet/Spacer Assembly Positioned in the Rivet Gun