Authorized Field Change
AFC 13903
Date: October 2013
Subject File: Engine
Subject: Inspection of Air Control Valve (ACV) Connector / Engine Harness Connection for proper plug
orientation and corrosion.
Model: LoneStar®, PayStar®, ProStar® , TranStar®, and WorkStar®
Start Date: 03 April 2012 End Date: 31 May 2012
Engine Family: MaxxForce® 11 and 13

DESCRIPTION
This AFC applies to certain vehicles with air control valve (ACV) 3015646C91. Some ACV connectors were
produced with plugs installed backwards in empty connector cavities. This condition could permit water
intrusion, which may short the terminals and lead to ACV failure. This repair involves inspecting the ACV
harness connection for corrosion. If no corrosion is present, the plug orientation in the ACV connector will be
corrected to establish a tight seal. If corrosion is present, the ACV will be replaced and a splice kit will be
installed on the main engine harness.
This AFC is applicable only to vehicles marked in International® Service PortalSM with AFC 13903.

CAUTION: Failure to perform this repair before any other service activity that may expose the
connector to coolant, water, or other fluid may result in damage to engine.

PARTS INFORMATION
Table 1.

Tools Required
Description

Tool Number / Type

Yellow paint marker

Obtain locally

Tape measure

Obtain locally

Permanent marker

Obtain locally

Wire cutters

Obtain locally

Soldering tool

Obtain locally

Heat gun

Obtain locally

© 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

1

PARTS INFORMATION (CONT.)
Table 1.

Tools Required (cont.)
Description

Tool Number / Type

Terminal Release Tool

TX126870202 (49304)

Small flathead screwdriver

Obtain locally

Complex pick tool

Obtain locally

Table 2.

A40-13903-3: Install New ACV Kit and Higher Level ACV Kit

Part Number

Description

Quantity

3015646C91

Air Control Valve Kit (Includes Tie Straps)

1

3017826C91
Obtain locally

ACV Higher Level Kit Assembly
Wire loom tape

1
1

Table 3.

3017826C91: Kit Contents

Part Number

Description

Quantity

3017820C1
ES20000-1
4328077R1
2421001903

Jumper Harness
50 mm Heatshrink Tubing Raychem

1
7

Instruction Sheet
160 mm x 19 mm Flex Wrap Federal Mogul

1
1

1800009C1

Harness M6 - M8 Zip Tie Retainer

1

1847046C1

Tie Straps

6

Table 4.

A40-13903-2: Reverse Cavity Plugs Only

Part Number

Description

Quantity

291207C1

Tie Strap, 10 pack

1

1831730C1

Dielectric Grease, ¼ oz tube

1

AFC–13903

2

SERVICE PROCEDURE
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 personal injury and / or death.

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.

3

AFC–13903

SERVICE PROCEDURE (CONT.)
Inspection of the ACV harness in this AFC can lead to three independent labor operations:
•

A40-13903-1 Inspection only: Yellow paint dot present, rework already performed.

•

A40-13903-2 Inspect for corrosion and reverse cavity plugs only.

•

A40-13903-3 Inspect for corrosion and install new ACV kit and higher level ACV kit.

The condition of the ACV connector will determine which operation to perform. Completion of only one is
necessary.

Figure 1.

AFC 13903 Document Logic Flow Chart.

The flow chart (Figure 1) maps the steps leading to all three outcomes to ease navigation of the document.

AFC–13903

4

SERVICE PROCEDURE (CONT.)
1. Bring truck into shop and park on flat surface.
2. Shift transmission to Park or Neutral, set parking brake, and block wheels.
3. Unlatch and open hood.

Figure 2.

ACV Connector on Sensor Harness.
1. ACV connector

4. Locate ACV connector (Figure 2, Item 1) on sensor harness secured to coolant control valve (CCV)
near front on passenger side of engine.

5

AFC–13903

SERVICE PROCEDURE (CONT.)

Figure 3.

Marked ACV Connector.

5. Inspect base of connector for presence of yellow paint dot (Figure 3).
a. If yellow paint dot is present, proceed to Step 54.
b. If no yellow paint dot is present, proceed to Step 6.
NOTE: If yellow paint dot is present, labor operation A40–13903–1 (Inspect ACV connector for yellow
paint dot) is complete.
6. Disconnect battery.
7. Slide red tab, press release tab, and disconnect harness.

AFC–13903

6

SERVICE PROCEDURE (CONT.)

Figure 4.

Engine Harness Connector.

Figure 5.

ACV Harness Connector.

8. Inspect both sides of connector for corrosion (Figures 4 and 5).
a. If corrosion is present, proceed to Step 20 and finish labor operation A40–13903–3, install new ACV
kit and higher level ACV kit.
b. If no corrosion is present, proceed to Step 9 and finish labor operation A40–13903–2, reverse cavity
plugs.

7

AFC–13903

SERVICE PROCEDURE (CONT.)
NOTE: Steps 9 through 19 cover the remainder of labor operation A40–13903–2 (Inspect for corrosion
and reverse cavity plugs only). Steps 20 through 51 cover the remainder of labor operataion
A40–13903–3 (Inspect for corrosion and install new ACV kit and higher level ACV kit).

Figure 6.

ACV Connector Plugs.
1. Incorrectly installed plugs
2. Correctly installed plugs

9. Inspect plugs in ACV connector to determine if they have been inserted backwards (Figure 6).
a. If plugs are installed correctly (Figure 6, Item 2), reconnect mating ends of connector, re-latch red
lock button, and proceed to Step 52.
b. If installed incorrectly (Figure 6, Item 1), proceed to Step 10.
NOTE: Incorrectly installed plugs may cause corrosion due to moisture intrusion.

Figure 7.

Terminal Release Tool.

AFC–13903

8

SERVICE PROCEDURE (CONT.)

Figure 8.

Plug Removal.

10. Locate each small rectangular hole inside ACV connector that corresponds each incorrectly installed
plug (Figure 7). Using terminal release tool, gently push plastic plug out end of connector (Figure 8).
Repeat for remaining plugs.

Figure 9.

Setting TPA Lock to Pre-Locked Position.
1. Pre-locked TPA

9

AFC–13903

SERVICE PROCEDURE (CONT.)
11. Using complex pick tool, gently pull terminal position assurance (TPA) lock upward into pre-locked position
(Figure 9, Item 1). TPA lock will move approximately 0.1 in (2.5 mm). TPA lock should click once and
remain in connector housing.
NOTE: TPA lock should not be removed from connector. If TPA lock is completely removed, place lock
back into connector in its pre-locked position.

Figure 10.

Plug Reinsertion.
1. Barbed tooth pointing outward

12. Reinsert plugs with square end first and barbed tooth facing outward (Figure 10, Item 1). Gently push
plugs into connector, leaving approximately ⅛ inch (3.175 mm) protruding.

AFC–13903

10

SERVICE PROCEDURE (CONT.)

Figure 11.

Plug Seating.
1. Plug seating

13. Using a small flathead screwdriver, gently push each plug into locked position (Figure 11, Item 1). Plugs
will click when fully inserted.
NOTE: If excessive force is needed to insert plug, make sure it is correctly aligned to connector block
before proceeding.

Figure 12.

Setting TPA Lock to Locked Position.
1. Locked TPA lock

11

AFC–13903

SERVICE PROCEDURE (CONT.)
14. Using complex pick tool, gently press TPA surface to snap back into locked position (Figure 12, Item 1).
15. Verify that no plugs were pushed out of connector during rework.

Figure 13.

AFC–13903

Dielectric Grease.

12