Authorized Field Change
AFC 12910
Date: November 2012
Subject File: ENGINE
Subject: Exhaust Gas Recirculation (EGR) Valve Replacement
Model: PayStar®, ProStar®, WorkStar®, and TranStar®
Start Date: 04 February 2011 End Date: 23 June 2011
Engine Family: MaxxForce® 11 and 13

DESCRIPTION
This AFC describes the procedure for EGR valve replacement on vehicles marked with AFC 12910.

PARTS INFORMATION
Table 1.

Parts Information

Part Number

Description

Quantity

7092735C91
*3007671C96
*3007670C96

Kit, EGR Valve
EGR Inlet tube (Inner)
EGR Inlet tube (Outer)

1
1
1

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

1

WARNING: Read all safety instructions in the “Safety Information” section of the Engine
Service Manual or Engine Diagnostic Manual to prevent personal injury or death.

WARNING: To prevent personal injury or death, shift transmission to park or neutral, set
parking brake, and block wheels before doing diagnostic or service procedures.

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 VALVE REPLACEMENT PROCEDURE
1. Turn vehicle wheels to right and remove engine cover. Refer to Engine Cover Removal procedure in the
MaxxForce® 11 and MaxxForce® 13 EGR Cooler Resource Center.
2. Using Coolant Management Tool (KL5007NAV), drain cooling system. Refer to TSI 12–12–01.

AFC–12910

2

EGR VALVE REPLACEMENT PROCEDURE (CONT.)
3. Disconnect Engine Coolant Temperature sensor 1 (ECT1) (Figure 1, Item 2).

Figure 1.

Engine Coolant Temperature (ECT) Sensor.
1. Engine harness
2. ECT1 sensor

4. Disconnect EGR valve engine harness connector (Figure 2, Item 2).

Figure 2.

EGR Valve Engine Harness Connector.
1. Engine harness
2. EGR valve engine harness connector

3

AFC–12910

EGR VALVE REPLACEMENT PROCEDURE (CONT.)
5. Cut and remove wire tie (Figure 3, Item 1) near EGR valve electrical connector (Figure 3, Item 2).

Figure 3.

EGR Valve Electrical Connector.
1. Wire tie
2. EGR valve electrical connector

6. Remove engine harness guide (Figure 4, Item 1) from bolt (Figure 4, Item 2).

Figure 4.

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

AFC–12910

4

EGR VALVE REPLACEMENT PROCEDURE (CONT.)
7. Remove engine harness guide (Figure 5, Item 1) from bolt (Figure 5, Item 2).

Figure 5.

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

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

Figure 6.

Cab Heater Supply Tube Brackets.
1. Cab heater supply tube brackets
2. EGR cooler

5

AFC–12910

EGR VALVE REPLACEMENT PROCEDURE (CONT.)
9. Disconnect cab heat tube (Figure 7, Item 1) from heat tube nipple (Figure 7, Item 2) on coolant manifold.

Figure 7.

Cab Heat Tube.
1. Cab heat tube
2. Heat tube nipple

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

Figure 8.

Coolant Manifold.
1. HCI coolant supply tube nut
2. Coolant manifold

AFC–12910

6

EGR VALVE REPLACEMENT 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.

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

Figure 9.

HCI Fuel Supply Line.
1. HCI fuel inlet nut
2. HCI fuel supply line

7

AFC–12910

EGR VALVE REPLACEMENT PROCEDURE (CONT.)
12. Remove HCI coolant outlet tube (Figure 10, Item 1).
13. Remove two HCI bolts (Figure 10, Item 2), and remove HCI from thermal management valve housing.

Figure 10.

HCI Fuel Inlet.
1. HCI coolant outlet tube
2. HCI bolt (2)

14. Discard HCI bolts and gasket (Figure 11, Item 1).
15. Place cap (Figure 11, Item 2) on thermal management valve housing port.

Figure 11.

Thermal Management Valve Housing Port.
1. HCI bolt hole and gasket location
2. Thermal management valve housing port cap

AFC–12910

8

EGR VALVE REPLACEMENT PROCEDURE (CONT.)
16. Remove EGR inlet tube heat shield (Figure 12, Item 1), remove one heat-resistant bolt
(Figure 12, Item 2),and remove three bolts (Figure 12, Item 3).

Figure 12.

EGR Inlet Tube Heat Shield.
1. EGR inlet tube heat shield
2. Heat-resistant bolt
3. Bolt (3)

9

AFC–12910

EGR VALVE REPLACEMENT PROCEDURE (CONT.)
NOTE: Place drip pan under truck to prevent coolant from leaking on ground.
17. Remove coolant manifold (Figure 13, Item 1), remove two bolts (Figure 13, Item 2), and one stud bolt
(Figure 12, Item 3).

Figure 13.

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

AFC–12910

10

EGR VALVE REPLACEMENT PROCEDURE (CONT.)
CAUTION: To prevent engine damage, extension tubes should be handled with care.

18. Remove EGR inlet tube (Figure 14, Item 1), and remove four heat-resistant bolts and two gaskets
(Figure 14, Item 2). Discard bolts and gaskets.

Figure 14.

EGR Inlet Tube (Outside).
1. EGR inlet tube (outside)
2. Heat-resistant bolt (4) and gasket (2)

11

AFC–12910

EGR VALVE REPLACEMENT PROCEDURE (CONT.)
19. Remove EGR inlet tube (Figure 15, Item 1), remove two heat-resistant bolts and gasket
(Figure 15, Item 2), and remove two heat-resistant bolts and gasket (Figure 15, Item 3). Discard bolts
and gaskets.

Figure 15.

EGR Inlet Tube (Inside).
1. EGR inlet tube (inside)
2. Heat-resistant bolt (2) and gasket
3. Heat-resistant bolt (2) and gasket

AFC–12910

12

EGR VALVE REPLACEMENT PROCEDURE (CONT.)
20. Place cap on rear exhaust manifold outlet (Figure 16, Item 1).

Figure 16.

Rear Exhaust Manifold Outlet.
1. Rear exhaust manifold outlet cap

21. Remove EGR valve coolant supply tube nut (Figure 17, Item 1) and position tube away from valve
(Figure 17, Item 2).

Figure 17.

EGR Valve.
1. EGR valve coolant supply tube nut
2. EGR valve

13

AFC–12910

EGR VALVE REPLACEMENT PROCEDURE (CONT.)
22. Remove EGR heat shield (Figure 18, Item 1) and remove two bolts (Figure 18, Item 2).

Figure 18.

EGR Heat Shield.
1. EGR heat shield
2. Bolt (2)

AFC–12910

14

EGR VALVE REPLACEMENT PROCEDURE (CONT.)
23. Remove nine heat-resistant bolts (Figure 19, Item 3) and the EGR valve (Figure 19, Item 3). Position EGR
valve coolant return tube assembly (Figure 19, Item 2) out of the way.

Figure 19.

EGR Valve.
1.
2.
3.
4.

EGR valve
EGR valve coolant return tube assembly
Heat-resistant bolt (9)
EGR valve coolant supply tube (previously removed)

NOTE: Discard gasket after removal of the EGR valve.

15

AFC–12910

EGR VALVE REPLACEMENT PROCEDURE (CONT.)
24. Inspect High-Temp (HT) EGR cooler inlet for damage (Figure 20, Item 1). If HT EGR cooler is damaged,
replace HT cooler per HT EGR Cooler Replacement procedure in the MaxxForce® 11 and MaxxForce® 13
EGR Cooler Resource Center.

Figure 20.

High-Temp (HT) EGR Cooler Inlet.
1. HT EGR cooler inlet damage

NOTE: EGR cooler inlet may have internal rust due to condensation (Figure 21). This condensation or
rust is normal and does not require replacement of high-temp EGR cooler.

Figure 21.

EGR Cooler Inlet.
1. EGR cooler inlet internal rust

AFC–12910

16

EGR VALVE INSTALLATION INSTRUCTIONS
1. Install EGR valve (Figure 22, Item 1) with nine new M8 x 30 heat-resistant bolts (Figure 22, Item 3) and
finger tighten. Install EGR valve coolant return tube assembly (Figure 22, Item 2).
NOTE: Use new gasket when replacing EGR valve.

Figure 22.

EGR Valve.
1.