IK1200739 Service Bulletin/Repair Instructions

IK1200739 ­ EGR Valve Diagnostics
Page 1 of 4
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CANADA, COLOMBIA, UNITED

STATES, PUERTO RICO
Document

ID:
IK1200739
Availability:
ISIS, FleetISIS
Revision:
12
Major System:
ENGINES
Created:
3/16/2012
Current

Language:
English
Last

Modified:
6/9/2014
Other

Languages:
NONE
Author:
David

Smith
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Title : EGR Valve Diagnostics

Applies To : 2010 Emissions MaxxForce 11 & 13 Liter Engines, N13 SCR Engine, MaxxForce 15
CHANGE LOG

DO NOT delete the Change Log.
Updated : 06/06/2014 Added MaxxForce 15L information.

05/16/2014 : Changed EGR Valve Pigtail Part Number. 03/27/2014 : Adjusted Title 03/21/2014 - Added diagnostic step to 27­4,

added EGR Valve Generation Identification steps, added change log, updated part number. 04/11/2014 Added N13 SCR Part

number and warning to not interchange with 2010 MaxxForce 11/13 EGR Valve. Adjusted Diagnostics to reflect N13 SCR

Engine, Moved Health Report Requirement statement to warranty section of the article.



Description

• ECM shows an active or inactive SPN 27 FMI 7 or SPN 27 FMI 4

• Check for any Open MIN's, AFC's, and Managed Repairs Prior to starting this document.
• If NO EGR Valve Faults are present DO NOT replace the EGR Valve no repairs are required for the EGR

system.
Symptoms

• Check Engine Light On

• EGR Valve Component / Circuit Fault Code
Possible Diagnostic Trouble Codes

SPN
FMI
MODULE
DESCRIPTION
27

27
7

4
ECM

ECM
EGRP does not agree with Commanded Position

EGRP Signal Out of Range Low
Parts Information

• MaxxForce 11/13 : 7092735C93 (5010696C92 if 7092735C93 is not available) KIT, EGR VALVE

• MaxxForce 11/13 : If Necessary : Assembled Harness Repair Kit Part Number : 3017846C91(includes ECT1

connector discard ECT1 connector if not needed) / Harness Tape : 7096462C1 : Qty 1 (If not on hand)

• Harness Installation Kit Instructions Click Here
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/1/2014
IK1200739 ­ EGR Valve Diagnostics
Page 2 of 4
• N13 SCR Engine : EGR Valve : 2512163C92 (Pigtail Attached to the EGR valve)(Do Not Interchange with MaxxForce

11/13 Non­SCR Engine)

• MaxxForce 15 : EGR Valve : 3008008C92 ; EGR Valve Gaskets : 3006736C2 x 2 (if needed)
Resolution
• If faults 27-4 (Table 1) and 27-7 (Table 2) are both present you will need to diagnose the 27-4 fault first.

• 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:

Diagnostic Steps (Table 1)
YES
NO
1. Check Service Portal and see if the

vehicle qualifies for Managed Repair :

2010 Emissions MF11/13 EGR Valve

Follow Managed Repair : 2010 Emissions

Inspection Guidelines. Does the vehicle

MF11/13 EGR Valve Inspection Guidelines

qualify for the managed repair? (If N13

SCR Engine,or MaxxForce 15 go to

step 4)

2. Verify Generation of EGR Valve : Is it

an Old Generation EGR Valve? (See Serial

Number Identification process Below)

3. Check the vehicle build date

• Was the vehicle built BEFORE

07/01/2012?
4. Clear all faults with EST.

5. Run EGR Valve Actuator Test in

ServiceMaxx.
Continue to Step

2
Replace the EGR Valve
Continue to Step 3
Replace the EGR Valve wiring pigtail with

PN : 3017846C91 . Apply dielectric grease on

the new terminals.
Continue to Step 4
Release the vehicle to the customer
Replace EGR Valve
• Did the Actuator test pass?
Diagnostic Steps when Fault 27-7 is present:

Diagnostic Steps (Table 2)
YES
NO
1. Check Service Portal and see if the vehicle

qualifies for Managed Repair 2010 Emissions

MF11/13 EGR Valve Inspection Guidelines. Follow Managed Repair : 2010 Emissions MF11/13 Continue to

Does the vehicle qualify for the managed

EGR Valve Inspection Guidelines

Step 2

repair? (N13 SCR Engine, or MaxxForce 15

go to Step 2)
Replace the EGR Valve

2. Clear all faults with EST.

3. Run EGR Valve Actuator Test in

ServiceMaxx.

• Does Fault 27-7 return?
• If the vehicle was built BEFORE 07/01/2012

(Disregard this information for N13 SCR

Engine, and MaxxForce 15) you will also

need to replace the EGR Valve wiring pigtail

with splice kit PN : 3017846C91. Apply

dielectric grease on the new terminals.
Release the

vehicle to

the customer
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IK1200739 ­ EGR Valve Diagnostics
Page 3 of 4
Serial Number Identification Process shown below:
The generation of the valve can be identified by the serial number ( the 6 digit code highlighted in the red box in

the picture above) if it starts with 1 it is considered to be an old valve (On 2010 Emissions MF11/13 only. NOT SCR

equipped vehicles). If the serial number starts with a 2 it is a newer generation valve.

Note : If it starts with a 0 and has part number 5010697R1 stamped on it the EGR Valve is a New Generation. If it

starts with a 0 and has part number 3008449C1 as illustrated above then it is an Old Generation EGR Valve.
Warranty Claim Submission

Requirement : Include the Serial Number of the failed and new EGR Valve in the subsequent warranty claim "CCC"

and the "Failed Serial #" fields (See Photo Below).

• Requirement :. Be sure the replacement EGR Valve Serial # starts with a 2(Serial Number location shown below.

Disregard for N13 SCR Engine, and MaxxForce 15

• Requirement : Use PocketMaxx or an EZ-Tech to generate a Health Report which is now required for warranty

reimbursement per WPL13-009G. The Health Report will include DTC's and will link you to the Fault Code Action

Plan.

•
Labor Times and Warranty Information For EGR Valve Replacement :

• Group Description: 12000

• Noun Description: 893

• Standard Repair Time:

Time
SRT
2.8
N12-6893U
2.8
Chassis Model
Engine Model
7600
MaxxForce 11/13
8600
MaxxForce 11/13
Q12-6893U
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IK1200739 ­ EGR Valve Diagnostics
Page 4 of 4
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
2.5
TC12-6893
CAT CT660
MaxxForce 15
3.8
TC12-6893U
CAT CT660
MaxxForce 11/13
Labor Times For EGR Valve Actuator Test :

Time
SRT
0.3
T­Time
Chassis Model

All
Engine Model

All
Labor Times For EGR Valve Pigtail Replacement :

Time
SRT
0.2
A08-2001A
Chassis Model

All
Engine Model

All
Labor Time For 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
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Feedback Information

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Staff

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Comments
You received the following feedback From: U00SMO2 ­ Steve Olejniczak Email Address: steve.olejniczak@navistar.com Job

U00SMO2 Classification: SE006, Service Foreman Dealer: NAVISTAR-TSC SPRINGFIELD Feedback: The click here for the harness

installation instructions does not work
Created

Date

7/1/2014

8:20:05 AM
Copyright © 2014 Navistar, Inc.
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