SB-10044439-1772

Authorized Field Change
AFC 12905
Date: June 2012
Subject File: ENGINE
Subject: Removal and Replacement of the MaxxForce® 11 and MaxxForce® 13 EGR Inlet Tubes
Model: LoneStar®, PayStar®, ProStar®, TransStar®, and WorkStar®
Start Date: 01 June 2011 End Date: 21 October 2011
Engine Family: MaxxForce® 11 and MaxxForce® 13

DESCRIPTION
EGR inlet tubes for certain MaxxForce® 11 and MaxxForce® 13 engines can crack during vehicle operation,
causing progressive engine damage up to and including engine harness. This AFC describes a repair
procedure to replace EGR inlet tubes for all affected engines and to replace EGR valve if damaged.

PARTS INFORMATION
Table 1

Parts Information

Part Number
3007670C95

EGR Inlet Tube

Quantity
1

3007671C95

EGR Inlet Tube

1

3007672C94

EGR Valve (if necessary)

1

Table 2

Description

Equipment Required

Part Number

Description

KL5007NAV

Quantity
1

Coolant Management Tool

Tools Required
Table 3

Tool Information
Description

Tool Number / Type

Torque Wrench

⅜ in, ¼ in

Ratchet Wrench

⅜ in, ½ in, 10 mm, 12 mm

Socket

¼ in drive 7 mm, ¼ in drive 8 mm, ⅜ in drive 10 mm,
⅜ in drive 13 mm, ⅜ in drive 14 mm, ½ in drive 36 mm

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

1

PARTS INFORMATION (CONT.)
Table 3

Tool Information (cont.)

Socket Deep Well

⅜ in drive 11/16 in, ⅜ in drive 10 mm, ⅜ in drive ⅜ in,
⅜ in drive 13 mm, ⅜ in drive 15 mm

Extension

½ in drive 6 in, ⅜ in drive 12 in, ⅜ in drive 10 in, ⅜ in
drive 6 in, ⅜ in drive 3 in.

Combination Open End Wrenches

1-¼ in, 1-1/16 in, 10 mm, 12 mm, 13 mm, 14 mm, 17
mm, 18 mm

Crow’s Foot

⅜ in drive ⅞ in, ⅜ in drive 10 mm , ⅜ in drive 13 mm,
⅜ in drive 14 mm, ⅜ in drive 17 mm

Swivel Socket

⅜ in drive 10 mm, ⅜ in drive 13 mm

Blue Point Trim Removal Tool

#YA331

Pliers

-

Telescopic Magnet

-

Angle Pick

-

Allen Socket

⅜ in drive 6 mm

AFC–12905

2

PARTS INFORMATION (CONT.)

WARNING – Park vehicle on hard flat surface, turn the engine off, set the parking brake, and
block the wheels to prevent the vehicle from moving in both directions. Failure to do so may result
in property damage, personal injury, and/or death.

WARNING – If the vehicle must be raised, do not work under the vehicle supported only by
jacks. Jacks can slip or fall over, potentially resulting in property damage, personal injury, and/or
death.

WARNING – Always wear safe eye protection when performing vehicle maintenance. Failure
to do so may result in serious eye injury.

WARNING – Keep flames or sparks away from vehicle and do not smoke while servicing
the vehicle’s batteries. Batteries expel explosive gases. Failure to do so may result in property
damage, personal injury, and/or death.

WARNING – Remove the ground cable from the negative terminal of the battery box before
disconnecting any electrical components. Always connect the ground cable last. Failure to do so
may result in property damage, personal injury, and/or death.

EGR INLET TUBE REPLACEMENT AND EGR VALVE INSPECTION
PROCEDURE
1. Read and follow all safety precautions listed above.
2. Turn vehicle wheels to right and remove engine cover. Refer to Engine Cover Removal procedure in the
MaxxForce® 11 / MaxxForce® 13 EGR Cooler Resource Center.
3. Using Coolant Management Tool (KL5007NAV), drain cooling system. Refer to TSI 12–12–01.

3

AFC–12905

EGR INLET TUBE REPLACEMENT AND EGR VALVE INSPECTION PROCEDURE
(CONT.)
4. Disconnect engine coolant temperature (ECT) sensor (2) (Figure 1).

Figure 1

Engine Coolant Temperature Sensor
1. Engine Harness
2. Engine Coolant Temperature Sensor

5. Disconnect EGR valve engine harness connector (2) (Figure 2).

Figure 2

EGR Valve Engine Harness Connector
1. Engine Harness
2. EGR Valve Engine Harness Connector

AFC–12905

4

EGR INLET TUBE REPLACEMENT AND EGR VALVE INSPECTION PROCEDURE
(CONT.)
6. Cut and remove wire tie (1) near EGR valve electrical connector (2) (Figure 3).

Figure 3

EGR Valve Electrical Connector
1. Wire Tie
2. EGR Valve Electrical Connector

7. Remove engine harness guide (1) from bolt (2) (Figure 4).

Figure 4

Engine Harness Guide
1. Engine Harness Guide
2. Bolt (Not shown, located behind engine harness guide)

5

AFC–12905

EGR INLET TUBE REPLACEMENT AND EGR VALVE INSPECTION PROCEDURE
(CONT.)
8. Remove engine harness guide (1) from bolt (2) (Figure 5).

Figure 5

Engine Harness Guide
1. Engine Harness Guide
2. Bolt
3. Engine Harness

9. Remove cab heater supply tube support brackets (1) from EGR cooler (2) (Figure 6).

Figure 6

Cab Heater Supply Tube Brackets
1. Cab Heater Supply Tube Brackets
2. EGR Cooler

AFC–12905

6

EGR INLET TUBE REPLACEMENT AND EGR VALVE INSPECTION PROCEDURE
(CONT.)
10. Disconnect cab heat tube (1) from heat tube nipple (2) on coolant manifold (Figure 7).

Figure 7

Cab Heat Tube
1. Cab Heat Tube
2. Heat Tube Nipple

11. Remove hydrocarbon injector (HCI) coolant supply tube nut (1) from coolant manifold (2) (Figure 8).

Figure 8

Coolant Manifold
1. HCI Coolant Supply Tube Nut
2. Coolant Manifold

7

AFC–12905

EGR INLET TUBE REPLACEMENT AND EGR VALVE INSPECTION PROCEDURE
(CONT.)
CAUTION – To prevent component damage, do not bend fuel supply line.

CAUTION – To prevent component damage, do not drop hydrocarbon injector onto a hard surface.
The HCI Nozzle tip is easily damaged. If this happens, replace the injector.

12. Remove and cap HCI fuel supply line (2) and inlet nut (1) (Figure 9).

Figure 9

HCI Fuel Supply Line
1. HCI Fuel Inlet Nut
2. HCI Fuel Supply Line

AFC–12905

8

EGR INLET TUBE REPLACEMENT AND EGR VALVE INSPECTION PROCEDURE
(CONT.)
13. Remove HCI coolant outlet tube (1) (Figure 10).

Figure 10

HCI Fuel Inlet
1. HCI Coolant Outlet Tube
2. HCI Bolts (2)

14. Remove two HCI bolts (2), and remove HCI from thermal management valve housing (Figure 10).
15. Discard HCI bolts and gasket (1) (Figure 11).
16. Place cap (2) on thermal management valve housing port (Figure 11).

Figure 11

Thermal Management Valve Housing Port
1. HCI Bolts and Gasket
2. Thermal Management Valve Housing Port

9

AFC–12905

EGR INLET TUBE REPLACEMENT AND EGR VALVE INSPECTION PROCEDURE
(CONT.)
17. Remove EGR inlet tube heat shield (1), remove one heat-resistant bolt (2), and remove three M8 x
12 bolts (3) (Figure 12).

Figure 12

EGR Inlet Tube Heat Shield
1. EGR Inlet Tube Heat Shield
2. Heat-resistant Bolt
3. Bolts (3)

NOTE – Place drip pan under truck to prevent coolant from leaking on ground.

AFC–12905

10

EGR INLET TUBE REPLACEMENT AND EGR VALVE INSPECTION PROCEDURE
(CONT.)
18. Remove coolant manifold (1), remove two bolts (2), and one stud bolt (3) (Figure 13).

Figure 13

Coolant Manifold
1. Coolant Manifold
2. Bolt (2)
3. Stud Bolt

CAUTION – To prevent engine damage, extension tubes should be handled with care.

11

AFC–12905

EGR INLET TUBE REPLACEMENT AND EGR VALVE INSPECTION PROCEDURE
(CONT.)
19. Remove EGR inlet tube (1), and remove and discard four heat-resistant bolts (2) (Figure 14).

Figure 14

EGR Inlet Tube (Outside)
1. EGR Inlet Tube (Outside)
2. Heat-resistant bolt (4)

20. Remove EGR inlet tubes (1), remove and discard two heat-resistant bolts (2), and remove and discard
two heat-resistant bolts (3) (Figure 15).

Figure 15

EGR Inlet Tube (Inside)
1. EGR Inlet Tube (Inside)
2. Heat-resistant Bolt (2)
3. Heat-resistant Bolt (2)

AFC–12905

12

EGR INLET TUBE REPLACEMENT AND EGR VALVE INSPECTION PROCEDURE
(CONT.)
21. Place cap on rear exhaust manifold outlet (1) (Figure 16).

Figure 16

Rear Exhaust Manifold Outlet Cap

22. Inspect EGR valve for a cracked or broken shaft and damaged or missing parts. Make sure all six screws
are present and shaft is not cracked or broken (Figure 17). If EGR valve flap screw is missing, or shaft is
cracked or broken, replace EGR valve. If EGR valve is replaced, check high-temp EGR cooler for damage
and replace, if necessary. Charge EGR cooler repair to Regular 01 Warranty, not to AFC.
If EGR valve is not damaged, proceed to step 7 of EGR Valve Installation Instructions in this AFC.

Figure 17

EGR Valve Missing Screw and Cracked Shaft
1. Missing Screw and Cracked Shaft

13

AFC–12905

EGR INLET TUBE REPLACEMENT AND EGR VALVE INSPECTION PROCEDURE
(CONT.)
23. Remove the EGR valve coolant supply tube nut (1) and position the coolant supply tube away from
the EGR valve (2) (Figure 18).

Figure 18

EGR Valve
1. EGR Valve Coolant Supply Tube Nut
2. EGR Valve

24. Remove EGR heat shield (1) and remove two bolts (2) (Figure 19).

Figure 19

EGR Heat Shield
1. EGR Heat Shield
2. Bolts (2)

AFC–12905

14