28. Using the rivet gun to hold the rivet/spacer assembly, apply RTV sealant around the diameter of the
blind rivet shank as shown.

Figure 14

Tether Rivet/Spacer Assembly to Jig Bolt

29. After coating the blind rivet with RTV sealant, insert the blind rivet/spacer assembly into the drilled hole.
Position tether wire on rivet/spacer assembly in such a way where the wire can be tied to the jig bolt.

11

AFC–11934

SERVICE PROCEDURE FOR GREASE APPLICATION FOR EGR VALVE REPAIR
(CONT.)
30. Tie the tether wire of the blind rivet/spacer assembly around the jig bolt to retain the spacer when the
mandrel on the blind rivet breaks off.
31. Squeeze riveter handles until rivet stem pulls free from the blind rivet. Tether wire should keep spacer
assembly attached to jig bolt.

Figure 15

Blind Rivet Installed

32. Remove spacer assembly and jig bolt from EGR valve and discard.

Figure 16

AFC–11934

Rivet Filled with RTV

12

SERVICE PROCEDURE FOR GREASE APPLICATION FOR EGR VALVE REPAIR
(CONT.)
33. Apply a small amount of RTV sealant to remaining hole. Additional RTV sealant over the head of the blind
rivet is acceptable and does not need to be removed.
34. Install new M8 x 25 heat-resistant bolt to EGR inlet tube flange and tighten to 18 lb-ft (24 N•m).
35. Install coolant manifold (rear of EGR) according to installation procedure in the “Exhaust Gas Recirculation
(EGR) System” section of the EGES-465 Engine Service Manual.

13

AFC–11934

SERVICE PROCEDURE FOR HEATER SUPPLY PIPE CHANGE
1. From inside cab, locate EGR crossover pipe (coolant manifold) (See Figure 17, page 14) at the rear of
the engine.

Figure 17

EGR Crossover Pipe (Rear of Engine)
1. EGR crossover pipe (coolant manifold)
2. M18 fitting

2. Remove the single-piece water pipe at the flare fitting end leaving the brass fitting in place in the EGR
crossover. NOTE: Hold the brass fitting with a wrench when removing the flare fitting as this is an O-ring
seal. The torque on the O-ring fitting should be maintained at 15 to 18 ft-lb (20-25 N•m). The torque on the
flare nut should be 44-55 ft-lb (60-75 N•m). Remove the two fasteners holding the pipe to the EGR cooler
housing. Disconnect the front end of the single-piece water pipe from the heater supply hose.
NOTE – When installing threaded fittings note whether the fitting is supplied with sealant applied to the
threads. If no sealant is present, apply sealant during installation.
3. Install new heater supply hose, as follows (See Figure 18, page 15).

AFC–11934

14

SERVICE PROCEDURE FOR HEATER SUPPLY PIPE CHANGE (CONT.)

Figure 18

Three-Piece Heater Supply Hose
1. Top of engine-side of heater pipe
2. 15 in. (380 mm) section of 0.75 in. (19 mm) heater hose (supplied hose may need to
be trimmed to 15 in. (380 mm))
3. Flare-side of heater pipe
4. 2 x Mubea #27 clamps

4. Remove the nipple or shut-off valve from the single-piece pipe and install the nipple or shut-off valve to the
new heater supply pipe BEFORE installing on the engine (See Figure 19, page 16).

15

AFC–11934

SERVICE PROCEDURE FOR HEATER SUPPLY PIPE CHANGE (CONT.)

Figure 19

Adding Nipple to Assembly Heater Front Supply Pipe

5. Add the 15 in. (380 mm) hose section onto the rear end of the curved pipe that mounts to top of the
engine BEFORE installing on engine. Use P80® lubricant on hose and pipe for assembly. Install hose
approximately 1 in. over the raised flare on the pipe.
6. Add the Mubea #27 clamp to the step 5 assembly.
7. Install step 6 assembly onto engine and fasten down using the 2 M6 hex flange nuts (See Figure 20,
page 17) that were removed in step 2.

AFC–11934

16

SERVICE PROCEDURE FOR HEATER SUPPLY PIPE CHANGE (CONT.)

Figure 20

Attaching Supply Heater Pipe to Engine

8. Install the rear pipe and hand-tighten the flare nut on the heater pipe. The tube should align up with the top
engine heater pipe and torque to 44-55 lb-ft (60-75 N•m) (See Figure 21, page 17) while holding the brass
fitting in the EGR crossover pipe with a back-up wrench.

Figure 21

Aligning Heater Supply Tube

9. Add the Mubea clamp #27 to the hose and attach the hose end to step 13 assembly using P80.
10. Review the procedure and verify that all connections are tight and properly secured.
11. Inspect the front heater return hose to make sure the hose on the elbow is not contacting the cowl drain.

17

AFC–11934

SERVICE PROCEDURE FOR HEATER SUPPLY PIPE CHANGE (CONT.)
12. If the hose or elbow is contacting the cowl drain, slide the hose down farther on the metal tube to gain
clearance.
13. Refill the cooling system using the Navistar Coolant Management Tool.
14. Start engine and check for coolant leaks.
15. Stop engine.

AFC–11934

18

SERVICE PROCEDURE FOR HVAC FRONT INSIDE MODULE DRAIN
REPAIR
1. Remove the kick panel and scuff panel on the passenger side of the truck (See Figure 22, page 19).

Figure 22

Removing Kick and Scuff Panels

2. Detach and pull back the center console to expose the floor mat (See Figure 23, page 19).

Figure 23

Removing Center Console

3. Pull the floor mat away from the drain area (See Figure 24, page 20).

19

AFC–11934

SERVICE PROCEDURE FOR HVAC FRONT INSIDE MODULE DRAIN REPAIR (CONT.)

Figure 24

Pulling Floor Mat away from Drain Area

4. Removal of drain seal.
a. In the engine compartment on the firewall, loosen the lower mounting nuts from area shown (See
Figure 25, page 20).

Figure 25

Loosening Mounting Nuts
1. Outboard Nut next to HVAC TXV
2. Inboard Nut next to HVAC TXV

b. Back the nuts off the studs until the end of the nut is approximately flush with the end of the stud
(do not remove completely).

AFC–11934

20

SERVICE PROCEDURE FOR HVAC FRONT INSIDE MODULE DRAIN REPAIR (CONT.)
c.

With the mounting nuts loosened, gently pull the HVAC unit rearward to expose the drain seal for
easier removal (See Figure 26, page 21) and (See Figure 27, page 21). Remove the foam seal and
not the rubber drain valve (See Figure 28, page 22).

Figure 26

Pulling HVAC Unit Rearward

Figure 27

Typical Condition of the Foam Seal after Removal

21

AFC–11934

SERVICE PROCEDURE FOR HVAC FRONT INSIDE MODULE DRAIN REPAIR (CONT.)

Figure 28

Rubber Drain Valve
1. Foam Seal
2. Rubber Drain Valve

5. Tighten the HVAC module mounting nuts (See Figure 25, page 20).
6. Using a thin piece of cardboard / credit card, place the cardboard between the floor and the HVAC module.
a. Push the cardboard halfway under the HVAC module.
b. Continue this operation for all sides of the drain. This will make sure the drain valve is not caught.
c.

Slide the cardboard / credit card from the firewall side completely under the HVAC housing to ensure it
is not folded under. You will be able to see the drain valve end as you slide the cardboard / credit card
under the module between HVAC Module and Floor (See Figure 29, page 23).

AFC–11934

22

SERVICE PROCEDURE FOR HVAC FRONT INSIDE MODULE DRAIN REPAIR (CONT.)

Figure 29

Placing Cardboard Between HVAC Module and Floor

7. Use sealant (p/n 8000934R91) to seal the HVAC unit to the floor. Make sure not to force excessive
sealant into the gap (See Figure 30, page 23).

Figure 30

Sealing HVAC unit to the Floor

8. Reposition the floor mat in place.
9. Do the following to test the blower motor:
a. Turn the ignition key to the On position.
b. Turn the control on high blower speed.

23

AFC–11934

SERVICE PROCEDURE FOR HVAC FRONT INSIDE MODULE DRAIN REPAIR (CONT.)
c.

If the blower turns on, go to each blower speed and verify that the blower is operational. If the blower
is operational, go to step 10.

d. If the blower does not turn on or has limited airflow, locate the Linear Power Module (LPM) behind the
passenger-side kick panel (See Figure 31, page 24) and do the following:

Figure 31

Locating the LPM
• Black wire on the two-cavity connector.
• White heavy ground wire on the 6-way connector.

e. Use a 12-gauge jumper harness to place the jumper across these two wires (See Figure 32, page 25).

AFC–11934

24

SERVICE PROCEDURE FOR HVAC FRONT INSIDE MODULE DRAIN REPAIR (CONT.)

Figure 32

Using 12-gauge Jumper Harness
1. Jumper wire on the two-cavity connector and on the 6-way connector.
2. 12-gauge jumper harness

f.

The blower motor should operate.

g. Remove the jumper wire.
h. Turn the key off and then back on to verify the blower motor works.
10. Reassemble the center console.
11. Install engine cover and any trim panels removed earlier. On ProStar® and TransStar® models with deluxe
interior, install the driver and passenger seats and floor mats. For all other models, install passenger
seat (if it was removed).
Table 4

Labor Information
Description

Operation No.

Time

A40-11934-1

Three-piece heater hose installation, EGR
Valve Re-Greasing, and HVAC Front Inside
Module Drain Repair – ProStar®, LoneStar®,
and TransStar®(deluxe interior)

3.2 hrs.

A40-11934-2

Three-piece heater hose installation, EGR
Valve Re-Greasing, and HVAC Front Inside
Module Drain Repair – TransStar® (standard
interior)

2.6 hrs.

ADMINISTRATIVE PROCEDURE
Expense is to be charged to Warranty. Claims are to be submitted in the normal manner, making reference to
Authorized Field Change Number G-11934.

25

AFC–11934

It is important that the coding be completed properly to assist in processing the warranty claim. Complete
instructions will be found in the Warranty Manual, Section 7–1. Special attention should be given to Items 39
through 44.
To assure this important improvement is made in a timely manner, all claims for G-11934 activity must be
submitted by February 28, 2013 or within the normal warranty period for the vehicle, if after February 28, 2013.

AFC–11934

26