NHTSA ID Number: 10115367
Manufacturer Communication Number: IK1200739
TSB/Document Date: 2017-08-16
Summary
EGR Valve Diagnostics
IK1200739 Big Bore EGR Valve Diagnostics
Page 1 of 4
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IK1200739
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Title : Big Bore EGR Valve Diagnostics
Applies To : 2010 Emissions MaxxForce 11 & 13 Liter Engines, MaxxForce 15
CHANGE LOG
2015/05/27: Added note to step 3 in Diagnostic Steps when Fault 27-7 is present without 274
2015/05/11: Fixed link to Actuator Test
2015/04/30: Reordered steps for checking ECM software level. Inserted link to Actuator Test and removed graphs. Removed
N13 references
2015/04/10: Updated 15L EGR valve kit part number
DESCRIPTION
This document provides users with Exhaust Gas Recirculation (EGR) Valve diagnostics and repair information for the three most likely fault
codes. It covers all 2010 and newer MaxxForce 11, 13 and 15.
To the Top
SYMPTOMS
Diagnostic Trouble Codes & Dashboard Indicator Lights:
Fault
Description
SPN 27 FMI 4
EGRP Signal Out of Range Low
SPN 27 FMI 7
EGRP Does Not Agree With Commanded Position
SPN 2659 FMI20
EGR High Flow Rate Detected
To the Top
PARTS
Kit Description
Part Number
Qty Notes
Kit, EGR Valve
7092735C94
1
2010-2013 MaxxForce 11/13 ONLY
Kit, Harness Repair*
2513174C91
1
ONLY if necessary
7096462C1
1
ONLY if necessary
Kit, EGR Valve
3016004C92
1
20112012 MaxxForce 15
Gasket, EGR Valve
3006736C2
2
MaxxForce 15 EGRV Gaskets
*Harness Installation Kit Instructions Click Here
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IK1200739 Big Bore EGR Valve Diagnostics
Page 2 of 4
To the Top
DIAGNOSTICS
• If faults 27-4 and 27-7 are both present, diagnose the 274 fault first.
• There are two diagnostic sectionsproceed to the section respective to fault code.
• If NO EGR Valve Faults are present DO NOT replace the EGR Valve. No repairs are required for the EGR
system.
Diagnostic Steps when Fault 27-4 is present:
Step Action
Check the vehicle build date.
1
Decision
Yes: Continue to Step 2.
No: Continue to Step 3.
Was the vehicle built BEFORE 07/01/2012?
Step Action
Check the warranty history to determine if an updated pigtail, 3017846C91 or
2513174C91, has already been installed.
2
Does vehicle history show previous installation?
Step Action
Clear all faults with EST.
Run EGR Valve Actuator Test in ServiceMaxx.
Decision
Yes: Continue to Step 3.
No: Replace the EGR Valve wiring
pigtail with
PN : 2513174C91. Apply dielectric
grease on the new terminals.
Continue to Step 3.
Decision
Yes: Release the vehicle to the
customer.
3
Did the Actuator test pass?
No: Replace EGR Valve.
Diagnostic Steps when Fault 27-7 is present without 27-4:
Step Action
Check for active fault codes
Decision
Yes: Continue to Step 2.
1
• Using EST (Electronic Service Tool), Check the EST DTC list for fault codes.
No: Continue to Step 3.
Does the Vehicle have a 2659-20 Present?
Step Action
Perform Visual inspection of the EGR Valve.
• Remove Exhaust Manifold Bellows tubes to view EGR Valve.
• Remove EGR valve.
2
Is the EGR Valve damaged (i.e. broken shaft and/ or butterfly plate) ?
Decision
Yes: Replace the EGR Valve and
continue to Step 5.
Note: For 2010 EPA MaxxForce
11/13 and vehicle built BEFORE
07/01/2012, replace the EGR
Valve wiring pigtail with splice kit.
Apply dielectric grease on the new
terminals.
No: Continue to Step 3.
Step
3
Action
Verify ECM Calibration.
For 11L and 15L,check the Scorecard on Service Portal. If the scorecard shows current,
then the vehicle has the latest version of the calibration.
For 13L, Check the vehicle’s ECM calibration ID (i.e. OEFXATMB) in ServiceMaxx™
vehicle information section of default session. Are the 5th and 6th digits in ECM
calibration ID "AT" or above (ie "AT" or "AU")?
Decision
Yes: Replace the EGR Valve. After
repairs are complete, retest for SPN
27 FMI 7 and(or) SPN 2659 FMI 20.
Note: For 2010 EPA MaxxForce
11/13 and vehicle built BEFORE
07/01/2012, replace the EGR Valve
wiring pigtail with splice kit. Apply
Is the ECM calibration current or at level "AT" or above?
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IK1200739 Big Bore EGR Valve Diagnostics
Page 3 of 4
dielectric grease on the new
terminals.
No: Update ECM calibration, then
continue to Step 4.
Step Action
Decision
Yes: Reinstall EGR Valve if
necessary. Retest for SPN 27 FMI
7 and(or) SPN 2659 FMI 20.
After performing all tests, if no
problem is found, verify that each
step was completed correctly and
the proper decision was made.
Open Tech Services case file if
needed.
Perform EGR Valve Actuator Test.
Does EGR Valve Actuator test pass?
4
No: Replace EGR Valve. After
repairs are complete, retest for
SPN 27 FMI 7 and(or) SPN 2659
FMI 20.
Note: For 2010 EPA MaxxForce
11/13 and vehicle built BEFORE
07/01/2012, replace the EGR
Valve wiring pigtail with splice kit.
Apply dielectric grease on the new
terminals.
REPAIR PROCEDURE
See the Service Manual (direct link to EGRV) for EGR Valve installation and removal.
To the Top
WARRANTY INFORMATION
Special Requirements:
• PocketMaxx or EZTech Health Report with Fault Codes is required for warranty reimbursement, per WPL13-009G.
EGR VALVE REPLACEMENT:
Warranty Claim Coding:
Group: 12000 - Engine
Noun:
893 - Valve, EGR
Standard Repair Times:
Time
SRT
Chassis Model
Engine Model
2.8
N12-6893U
7600
MaxxForce 11/13
2.8
Q12-6893U
8600
MaxxForce 11/13
2.9
R12-6893U
ProStar
MaxxForce 11/13
2.5
R12-6893O
ProStar
MaxxForce 15
2.8
T12-6893U
5000
MaxxForce 11/13
2.5
S12-6893O
LoneStar
MaxxForce 15
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IK1200739 Big Bore EGR Valve Diagnostics
Page 4 of 4
2.5
TC12-6893
CAT CT660
MaxxForce 15
3.8
TC12-6893U
CAT CT660
MaxxForce 11/13
ECM CALIBRATION:
Warranty Claim Coding:
Group: 12000 - Engine
Noun: 716 - Reprogram Engine Calibration
Standard Repair Times:
Time
SRT
Chassis Model
0.5
A12-3510U
All
Engine Model
MaxxForce 11/13
EGR Valve Actuator Test :
Time
SRT
Chassis Model
0.1
TTime
All
Engine Model
All
EGR Valve Pigtail Replacement :
Time
SRT
Chassis Model
0.2
A08-2001A
All
Engine Model
All
Engine Cover Removal and Installation
(Use only if EGR Valve Pigtail is repaired, not for use on EGR Valve Replacement)
Time
SRT
Chassis Model
Engine Model
0.8
A16-7555A
ProStar
MaxxForce 11/13
0.8
T- Time
All
MaxxForce 11/13
To the Top
OTHER RESOURCES
2010 MaxxForce 11/13 Resource Center (IK1200548)
2010 MaxxForce 11/13 Diagnostic Manual
2010 MaxxForce 11/13 Service Manual
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Feedback Information
Hide Details
Viewed:
22259
Helpful:
370
Not Helpful: 95
Staff
ID
Client
ID
DY00012
Comments
You received the following feedback From: dy00012 - Brandon Wesselius Email Address: [email protected] Job Classification: SE008, Service
Technician Dealer: ALTRUCK INTL TRUCK CENTR Feedback: Step 2 with code 27-4 present and step 3 without code 27-4 both have the decision missing
when article is printed.
Created
Date
6/1/2015
8:40:59 AM
Copyright © 2015 Navistar
, Inc.
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TSB/Document ID: IK1200739
Replacement Service Bulletin Number:
MFR Communication Date: 2015-05-27
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:GAS RECIRCULATION VALVE (EGR VALVE)
MFR Component System:
MFR Component Subsystem:
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