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Authorized Field Change

AFC 11913R Date: July, 2011 Subject File: ELECTRICAL

Subject: Nuisance Air Control Valve Diagnostic Codes on Certain Vehicles with MaxxForce 11/13 Engines
Model: PayStar Start Date: March 4, 2010 End Date: March 30, 2011 Model: WorkStar Start Date: March 4, 2010 End Date: March 30, 2011 Model: TransStar Start Date: March 4, 2010 End Date: March 30, 2011 Model: ProStar Start Date: March 4, 2010 End Date: March 30, 2011 Engine Family: MaxxForce 11 Engine Family: MaxxForce 13

DESCRIPTION
Revision 1, 07/25/2011Added note to Parts Information table for obtaining epoxy through direct ship program. This AFC applies to certain PayStar, WorkStar, TranStar, and ProStar trucks built with a MaxxForce 11 or 13, 2010 Emission Compliant Engine from March 4, 2010 to March 30, 2011. Air Control Valve (ACV) diagnostic codes can be caused by connector vibration, loose terminals, or terminal fretting. The following procedure is intended to tighten the terminal connectors and secure the harness to prevent setting nuisance ACV Diagnostic Trouble Codes (DTCs).

PARTS INFORMATION
Table 1 Parts Information Part Number Acquire locally* Acquire locally* Loctite E-50CR (epoxy) Dielectric Grease Description Quantity As needed As needed

*If you are unable to obtain the epoxy or grease locally, the below options may be obtained through the direct ship program. LOC1079593, E-50CR(TM)HYSOL(R) Adhesive 400 ml LOC1079594, E-50CR(TM)HYSOL(R) Adhesive 50 ml LOC218312, Dual Cartridge Manual Applicator LOC606052, 200/400 ML SQ Mix Nozzle 5.3 LOC720228, Dual Cartridge Manual Applicator LOC778273, 50 ML SQ Mix Nozzle 16 Element

Copyright 2011 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

PROCEDURE
WARNING To prevent vehicle damage, personal injury, or death, park the vehicle on a at, level surface. Make sure the engine ignition is in the off position, and the transmission is in the neutral or park position (if the vehicle is equipped with an automatic transmission). Set the parking brake, block the wheels to prevent the vehicle from moving in both directions, and disconnect the batteries at the negative terminal before doing any service procedures on the vehicle.

WARNING To prevent personal injury or death, remove ground cable from negative terminal of main battery before disconnecting electrical components. Always connect ground cable last.

WARNING To prevent personal injury or death, make sure that the engine has cooled before removing components.

WARNING To prevent personal injury or death, always wear safe eye protection when performing vehicle maintenance.

WARNING To prevent personal injury or death, do not let engine uids stay on your skin. Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine uids.

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PROCEDURE (CONT.)
1. Repair the ACV connections (Figure 1) as follows: A. Remove the connector insert (Figure 2). B. Remove one terminal at a time and tighten the pin individually (Figure 3), before reinstalling that terminal. C. After all terminals are tightened, reinstall the connector insert; then, carefully add dielectric grease to the connector terminals. Use enough grease to coat the terminals, and do not allow grease to get on the outside of the connector body.

Figure 1

Location of air control valve and connector 1. Air control valve connector 2. Air control valve 3. Front of engine

Figure 2

Removing the connector insert

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PROCEDURE (CONT.)

Figure 3

Tightening the ACV terminals

2. Reinstall the connector and test drive the vehicle to insure the terminals have been tightened properly. A 2to3 mile test drive should be sufcient. If any of the following ACV related, active DTCs (Table 2) are set during the test drive, one or more connector terminals are still too loose. Repeat Step 1 to make sure that the terminals are making good contact. Then, repeat this step (Step 2). If no ACV related, active DTCs are set during the test drive, proceed to Step 3.

Table 2

ACV Related Diagnostic Trouble Codes SPN 102 1173 1188 1189 5541 5542 5543

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PROCEDURE (CONT.)
3. In order to secure the ACV connection, Loctite E-50CR epoxy must be applied to the connector body to prevent it from loosening. A. Disconnect the connector from the ACV. B. Thoroughly clean the ACV connector body surface. C. Apply epoxy around the entire outer shell of the connector body (Figure 4). Be sure not to get any epoxy onto the terminals. D. Install the harness into the ACV connector, and push in the red lock.

Figure 4 Applying epoxy to the connector shell 4. Once the connector is installed and the epoxy is allowed to set, secure the harness with zip ties in the three locations as shown in Figure 5.

Figure 5

Three zip tie locations

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Operation number must appear on all claims. Table 3 Labor Information Description Repair ACV Connections Time 0.6 hrs

Operation No. A40-11913-1 Warranty Claims

Expense is to be charged to Warranty. Claims are to be submitted in the normal manner, making reference to Authorized Field Change Number G-11913 It is important that the coding be completed properly to assist in processing the warranty claim. Complete instructions will be found in the Warranty Manual, Section 7-1. Special attention should be given to Items 39 through 44. To assure this important improvement is made in a timely manner, all claims for G-11913 activity must be submitted by July 31, 2012 or within the normal warranty period for the vehicle, if after July 31, 2012.

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