NHTSA ID Number: 10115471
Manufacturer Communication Number: IK1201250
TSB/Document Date: 2017-08-16
Summary
EGR Valve Command Faults
IK1201250 MaxxForce 7 EGR Valve Command Faults
Page 1 of 5
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Title : MaxxForce 7 EGR Valve Command Faults
Applies To : 2010-2013 MaxxForce 7
CHANGE LOG
03/26/2015 - Edited to not diagnose "inactive" codes
02/25/2015 - Added warnings for stopping the Output State Tests before engine operation.
12/19/2014 - Initial Article Release 2013 OBD Calibration to Address Concern (PRS24***)
DESCRIPTION
This document will guide the user through necessary steps to properly diagnose Exhaust Gas Recirculation Valve (EGRV) faults. Note,
after extended periods of down time during freezing ambient temperatures the EGRV may not cycle properly causing diagnostic trouble
codes to become active. The DTCs may go "Inactive" or "Healing" after engine warm up.
Customer Interim Relief: Warm up engine, cycle key five times. Fault codes should become "inactive" or "healing" allowing for vehicle
operation.
SYMPTOMS
Diagnostic Trouble Codes:
DTC/Light
Description
Status
SPN 27 FMI 7
SPN 2791 FMI 7
SPN 2659 FMI 10
EGRP Does Not Agree with Commanded Position
Pending/Active/Healing
EGR Valve Unable to Achieve Commanded Position Pending/Active/Healing
EGR Slow Response Fault
Pending/Active/Healing
Customer Observations or Concerns:
Malfunction Indicator Lamp (MIL), when active
SPECIAL TOOLS / SOFTWARE
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 4/2/2015
IK1201250 MaxxForce 7 EGR Valve Command Faults
Tool Description
Tool Number
ServiceMaxx
EGR Valve Puller
Flat Bladed Screw Driver and Pick
ZTSE6010
Locally
Comments
Page 2 of 5
Instructions
Tools Resource Center
SERVICE PARTS INFORMATION
Kit Description
Part Number
Quantity
Notes
Required
VALVE ASSY EGR W/ O-RINGS
1881385C94
1
RING O 2-140 2.62 X 56.82ID
1881383C1
1
RING O 2-226 3.53 X 50.39 ID
1881384C1
2
DIAGNOSTIC STEPS
Step Action
Vehicle Health Report
1
Yes. STEP 2
Generate Vehicle Health Report and Upload to Navistar
's System, update the ECM No. Release to the customer. If this DTC
is a repeat offender for this truck continue
calibration if required.
with; STEP 2
Was the DTC Pending/Active/Healing?
Step Action
2
Decision
Decision
Verify valve operation.
Yes. STEP 3
In ServiceMaxx perform Output State High & Low Test 5 times. Monitor EGRV
movement.
Does EGRD & EGRP match movements?
No. STEP 4
ATTENTION
THE OUTPUT STATE TESTS MUST BE STOPPED BY HITTING
ON THE MENU BAR OF SERVICEMAXX BEFORE
OPERATING THE ENGINE. THE TESTS WILL CONTINUE TO RUN IN THE BACKGROUND AND WILL CAUSE IMPROPER
OPERATION OF ENIGNE COMPONENTS WITH FALSE DTCS.
Step Action
3
Decision
Review vehicle warranty history.
Yes. Gather previous repair information
and review. Continue to STEP 4
Search vehicle history and solicit any history from the customer.
Has the unit been in the dealer recently for a similar issue?
No and the calibration required update.
Release to customer
No but calibration was uptodate.
STEP 4
Step Action
Verify valve wiring integrity.
4
Decision
Yes. Repair, if no other issues are found
release unit
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IK1201250 MaxxForce 7 EGR Valve Command Faults
Page 3 of 5
No and EGRV operates at this time.
Release to customer
See Diagnostic Manual EGED 0000001681 and follow step based diagnostics for
the EGR valve wiring harness.
Were any faults found?
Step Action
5
Decision
Inspect EGR valve operation.
Yes. STEP 6
See REPAIR STEPS section below for valve operation.
Did this solve the problem?
No. STEP 7
Step Action
6
No and EGRV operates at this time
but as a repeat offender.
STEP 7
No and EGRV remains Inoperable.
STEP 5
Decision
Road test the vehicle.
Yes. Release to customer
Did the fault codes remain inactive?
No. STEP 7
Step Action
Manually free valve.
Remove the EGR Valve per 0000002383.
Decision
Yes. Replace the ORings 1881383C1
[Quantity 1] and 1881384C1 [Quantity 2]
then follow the Installation Procedure per
0000002383; STEP 8
NOTE: Loosening the valve and soaking the mixing housing with penetrating
lubricant may be required to free the valve.
7
Once carbon deposits are removed cleaned off carbon deposits, cycle the
valve using the Output State High/Low Test in ServiceMaxx. Monitor the valves
physical movement.
No. Rreplace the valve assembly
1881385C94 following the Installation
Procedure per
Service Manual 0000002383 and ensure
the new valve cycles properly; STEP 8
Does the valve move properly?
Step Action
Road test the vehicle.
8
Did the fault codes remain inactive?
Decision
Yes. Release to customer
No. If the valve was not replaced, replace
it at this time. Otherwise reevaluate
condition and double check diagnostics. If
issue can not be resolved, open a case
file with Navistar's Technical Support
Team.
REPAIR STEPS
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IK1201250 MaxxForce 7 EGR Valve Command Faults
Page 4 of 5
Figure 1: 2010-2013 MaxxForce 7 EGR
Valve
Item 1: DC Motor
Item 2: T-30 Torx Screws (4)
Item 3: M6 X 20 bolts (3)
Item 4: Inspection Cover
Item 5: Manifold Mixer
1. Remove EGR Valve Inspection Cover (Figure 1, Item 4) by gently pulling the two cover clips on both sides of the valve outward; then
gently pry up on the cover.
Figure 2: 2010-2013 MaxxForce 7 EGR Valve Inspection
Item 1: Cam
Item 2: Pivot Shaft Yoke
2. Use a small hammer and soft punch to tap the top of the EGR Valve Pivot Shaft Yoke (see Figure 2, Item 2).
3. Run the Output State High and Low Test 5-10 times and monitor valves movements with the cover off.
ATTENTION
THE OUTPUT STATE TESTS MUST BE STOPPED BY HITTING
ON THE MENU BAR OF SERVICEMAXX BEFORE
OPERATING THE ENGINE. THE TESTS WILL CONTINUE TO RUN IN THE BACKGROUND AND WILL CAUSE IMPROPER
OPERATION OF ENIGNE COMPONENTS WITH FALSE DTCS.
4. Run the Air Management Test in ServiceMaxx and Monitor valves movement and if any codes come active. Return to STEP 5
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 4/2/2015
IK1201250 MaxxForce 7 EGR Valve Command Faults
Page 5 of 5
WARRANTY INFORMATION
Warranty Claim Coding:
Group: 12000 - ENGINE
Noun: 716 - REPROGRAM ENGINE - CALIBRATION
Group: 12000 - ENGINE
Noun: 893 - VALVE, EGR
Standard Repair Times:
Step
Description
Chassis
SRT Link
Hours
Step 1
Engine, Program
ALL
A12-3510X
0.4
Step 2
Electronic Engine Control Systems
Diagnostics
ALL
A12-2053A
0.7
Step 3
EGR Valve, Diagnostics
CE
T-Time
0.7
Step 3
EGR Valve, Diagnostics
4100
TTime
0.7
Step 3
EGR Valve, Diagnostics
4300
TTime
0.7
Step 5
Road Test and Snapshot Perform
ALL
A12-2052A
0.4
Step 6
EGR Valve, Replace
CE/BE
GY12-6893X
1.5
Step 6
EGR Valve, Replace
4300/4400
KL12-6893X
1.5
Step 6
EGR Valve, Replace
TERMINAL TRACTOR TT12-6893X
1.3
Step 6
EGR Valve, Replace
AC BUS
V126893X
1.6
Step 6
EGR Valve, Replace
TERRASTAR
TS12-6893X
1.6
OTHER RESOURCES
Master Service Information Site
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Copyright © 2015 Navistar, Inc.
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 4/2/2015
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TSB/Document ID: IK1201250
Replacement Service Bulletin Number:
MFR Communication Date: 2015-03-26
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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