Instruction Sheet

Cold Weather Kit

A NAVISTAR COMPANY 1171963R1

Application Fitting, M10 x 1.0 37 1

degree flare
International® MaxxForce® 11 and 13 Diesel Engines
Harness assembly, 1
sensor
Purpose
Hose assembly, air 1
Relocation of the Engine Retarder Controller, Boost supply
Control Solenoid (BCS) Valve and the installation of Hose, wastegate (BCS 1
the insulated breather to prevent freezing during cold output)
weather operation.
Hose, wastegate (BCS 1
supply)
Kit Contents
Instruction sheet 1
Description Quantity Nut, M6 x 1.0 hex flange 1
Bolt, hex flange M8 x 3 Nut, M8 x 1.25 hex 1
75mm flange
Bolt, M10 x 165 1 Screw, Torx M5 x 18mm 2
Bolt, M6 x 12 2 Support assembly, 1
Bolt, M8 x 25 hex flange 1 bracket with clips

Bolt, M8 x 55 hex flange 2 Support assembly, 1

exhaust brake valve
Bolt, stud M8 x 45 x 15 1
Support assembly, 1
Brake assembly, 1 wastegate valve
exhaust
Tube assembly, exhaust 1
Breather insulator 1 brake pressure sensor
Clamp, crimp 4 Tube assembly, exhaust 1
Clamp, single cushioned 1 brake valve
Clamp, tube 1 Washer, Parker 2
853009-10
Clip, strap lock 4
Wastegate valve air 1
DMR 114 Profile clamp 1 supply (banjo) fitting
DMR 119 Profile clamp 1
Extension assembly 1

1
© 2008 Navistar, Inc.
Procedure 7. Remove P-clamps from driver’s side of sensor
harness assembly and save for installation to new
Removal harness assembly.
8. Disconnect yellow wire harness jumper for
WARNING: To prevent personal injury or retarder control and black wire harness jumper for
death, read all safety instructions in the “Safety EGR actuator from sensor harness assembly and
Information” section of EGES 415-1 Service save for installation to new harness assembly.
Manual.

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: To prevent personal injury or

death, make sure the engine has cooled before
removing components.

WARNING: To prevent personal injury

or death, remove ground cable from negative
terminal of main battery before disconnecting
or connecting electrical components. Always
connect ground cable last. Figure 1 BCS valve hoses
1. Remove ground cable from negative terminal of 1. Wastegate hose (BCS supply)
batteries. 2. Wastegate hose (BCS output)
2. Remove engine cover. 3. Vent hose (if equipped)

3. Remove both inner fenders from vehicle.

4. Remove air cleaner and inlet pipe. CAUTION: To prevent engine damage, take care
when handling the Boost Control Solenoid (BCS)
5. Remove Engine Control Module (ECM) and valve. The valve is made of plastic and the ports are
electronic control unit bracket. See “Engine easily damaged.
Electrical” section of EGES 415-1 Engine Service
Manual. 9. Remove three hose clamps and disconnect three
hoses (if equipped) from BCS valve.
NOTE: To remove the sensor harness assembly,
some of the chassis harness tie straps must be cut. 10. Discard hose clamps.
Chassis harness will not need to be removed. 11. Cut crimp clamp, disconnect and discard
6. Remove sensor harness assembly. See “Engine wastegate hose (BCS output) from wastegate
Electrical” section of EGES 415-1 Engine Service actuator.
Manual.

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Removal (cont.)
14. Remove tie straps retaining wastegate hose (BCS
supply) to bracket on left side of engine.

Figure 2 BCS valve

1. M5 x 12 hex bolt (2)
2. BCS valve
Figure 4 Wastegate hose (BCS supply) and air
supply hose assembly
12. Remove two M5 x 12 hex bolts and two M5 1. Wastegate hose (BCS supply)
washers. Discard bolts and save washers for 2. Banjo bolt
installation. 3. 90 degree quick disconnect; air supply hose
assembly
13. Remove BCS valve and save for installation.

15. Remove banjo bolt and disconnect wastegate

hose (BCS supply) from air fitting. Discard
washers and save banjo bolt for installation.
16. Discard wastegate hose (BCS supply).
17. Disconnect air supply hose assembly from 90
degree quick disconnect.

Figure 3 Tie straps

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Removal (cont.)
19. Loosen exhaust brake valve tube assembly
threaded fitting (2, Figure 6) at retarder control
and disconnect exhaust brake valve tube
assembly.
NOTE: It is not necessary to disconnect the exhaust
brake valve tube assembly from the exhaust brake
assembly actuator; this will be replaced with new
assembly.
20. Remove clips and threaded fittings from exhaust
brake valve tube assembly. Save clips and fittings
for installation.

Figure 5 Exhaust brake pressure sensor tube

assembly connection at retarder control
1. Retarder control
2. 10 x 1.35 seal (2)
3. Size 6 hollow screw
4. Exhaust brake valve tube assembly threaded fitting
5. Ring union

18. Remove size 6 hollow screw and disconnect ring

union from retarder control. Discard two 10 x 1.35
seals.
Figure 7 Air supply hose assembly connection
to retarder control
1. Retarder control
2. Air supply hose assembly threaded fitting
3. M8 x 55 bolt (2)

21. Loosen air supply hose assembly threaded fitting

at retarder control and disconnect air supply hose
assembly.
22. Remove two M8 x 55 hex bolts and retarder
control. Discard bolts.

Figure 6 Exhaust brake valve tube assembly

connections
1. Clip
2. Threaded fitting (with O-ring)
3. Male end (part of exhaust brake valve tube assembly)
4. Exhaust brake valve tube assembly

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Removal (cont.)
25. Remove clips and threaded fittings from air
supply hose assembly. Save clips and fittings for
installation and discard air supply hose assembly.

Figure 8 Air supply hose assembly

1. Exhaust Gas Recirculation (EGR) control valve
2. Air supply hose assembly

Figure 10 Turbo exhaust pipe

23. Loosen air supply hose assembly fitting nut and 1. M10 x 20 hex bolt
disconnect air supply hose assembly from EGR 2. Turbo exhaust pipe
control valve. 3. DMR 119 profile clamp
24. Remove air supply hose assembly from engine.
26. Remove M10 x 20 hex bolt from turbo exhaust
pipe and save for installation.
27. Loosen DMR 119 profile clamp, remove turbo
exhaust pipe and position aside. Discard profile
clamp.

Figure 9 Air supply hose assembly connections

1. Clip
2. Threaded fitting (with O-ring)
3. Male end (part of air supply hose assembly)
4. Air supply hose assembly

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Removal (cont.)
NOTE: It is not necessary to disconnect the exhaust
brake valve tube assembly from the exhaust brake
assembly actuator; this will be replaced with new
assembly.
29. Loosen DMR 114 profile clamp and remove
exhaust brake assembly. Discard profile clamp
and exhaust brake assembly.

Figure 11 Exhaust brake pressure sensor tube

assembly connection at exhaust brake assembly
1. Exhaust brake pressure sensor tube fitting nut
2. Straight union
3. DMR 114 profile clamp
4. Exhaust brake pressure sensor tube assembly
5. Exhaust brake assembly

Figure 13 Exhaust brake pressure sensor tube

28. Loosen exhaust brake pressure sensor tube fitting assembly
nut from straight union and disconnect exhaust
1. Starter shield bolt
brake pressure sensor tube assembly.
2. Exhaust brake pressure sensor tube assembly

30. Remove starter shield bolt and save for

installation.

Figure 12 Exhaust brake assembly

1. Exhaust brake assembly
2. DMR 114 profile clamp
3. Straight union

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Removal (cont.)

Figure 14 Exhaust brake pressure sensor tube Figure 16 EGR control valve and bolts
assembly and P-clamp
1. EGR control valve
1. P-clamp 2. M8 x 50 hex bolt (3)
2. Exhaust brake pressure sensor tube assembly

33. Remove and discard three M8 x 50 hex bolts from

31. Remove and discard exhaust brake pressure EGR control valve.
sensor tube assembly and P-clamp from engine.

Figure 17 Breather outlet tube and heater

Figure 15 M10 x 160 hex bolt assembly
1. Clamp
2. Breather outlet tube and heater assembly
32. Remove and discard M10 x 160 hex bolt nearest
high pressure turbocharger from High Pressure
Charge Air Cooler (HPCAC). 34. Release clamp and disconnect breather outlet
tube and heater assembly from cyclone breather.

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Removal (cont.)

Figure 18 Middle tube assembly connection to Figure 20 Upper tube assembly

cyclone breather
1. Clamp
36. Release clamps and disconnect upper tube
2. Middle tube assembly
assembly from service breather assembly.

35. Release clamp and disconnect middle tube

assembly from cyclone breather.

Figure 21 Service breather assembly

1. M8 x 35 hex bolt (6)
2. Service breather assembly
Figure 19 Cyclone breather housing insulation
(if equipped)
37. Remove six M8 x 35 hex bolts and service
breather assembly and save for installation.
NOTE: If cyclone breather has housing insulation,
then unsnap, remove, and discard insulation.

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Installation

Figure 24 Exhaust brake valve support

assembly
Figure 22 Starter shield bolt
1. M8 x 35 bolt
1. Starter shield bolt 2. M8 x 1.25 nut
2. Extension assembly 3. M8 x 45 x 15 stud bolt
4. Exhaust brake valve support assembly
5. M8 x 25 bolt
1. Install starter shield bolt with new extension
assembly. Tighten to 31 N·m (23 lbf·ft).
3. Install new M8 x 45 x 15 stud bolt to engine and
tighten to 31 N·m (23 lbf·ft).

Figure 23 Breather insulator

Figure 25 Service breather assembly

2. Install new breather insulator to service breather
assembly. Release Velcro® tabs and open top of 1. M8 x 35 hex bolt (5)
breather insulator to expose bolt holes. 2. Service breather assembly

4. Loosely install service breather assembly and five

M8 x 35 hex bolts.

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Installation (cont.)
5. Install new exhaust brake valve support assembly 9. Connect breather outlet tube and heater assembly
(4, Figure 24) using new M8 x 25 bolt and one to cyclone breather and engage clamp.
reused M8 x 35 bolt from breather assembly.
Tighten all service breather and exhaust brake
valve support assembly M8 bolts to 31 N·m (23
lbf·ft).
6. Install new M8 x 1.25 nut to M8 x 45 x 15 stud bolt
and tighten to 31 N·m (23 lbf·ft).
7. Connect middle tube assembly to cyclone
breather and engage clamp.
8. Close top of breather insulator and secure
Velcro® tabs.

Figure 27 Wastegate valve support assembly

1. M8 x 75 bolt (3)
2. Wastegate valve support assembly

10. Install new wastegate valve support assembly and

three new M8 x 75 bolts on EGR control valve.
Tighten bolts to 31 N·m (23 lbf·ft).
CAUTION: To prevent engine damage, take care
when handling the Boost Control Solenoid (BCS)
Figure 26 Breather outlet tube and heater valve. The valve is made of plastic and the ports are
assembly easily damaged.

1. Clamp 11. Position new crimp clamps on new wastegate

2. Breather outlet tube and heater assembly hoses (BCS supply and output) and connect
hoses to BCS valve. Be sure the wastegate
hoses (BCS supply and output) are pushed all
NOTE: After installing breather outlet tube, make sure the way down to the base of the BCS valve and
tube is free of any kinks or obstructions. the crimp clamps are touching the valve.

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Installation (cont.)
13. Install BCS valve to wastegate valve support
assembly using two new M5 x 18 Torx® screws
and two reused M5 washers. Tighten screws to
5.7 N·m (50 lbf·in).

Figure 28 Crimping tool

12. Using correct crimping tool, crimp wastegate hose

(BCS supply and output) crimp clamps.
Figure 30 Support bracket assembly
1. Support bracket assembly
2. M6 x 1.0 hex nut
3. Single cushioned clamp
4. M10 x 165 bolt

14. Install new support bracket assembly with clips

and M10 x 165 bolt to HPCAC. Tighten bolt to 62
N·m (45 lbf·ft).
15. Attach breather inlet tube assembly to support
bracket assembly using new single cushioned
clamp and new M6 x 1.0 hex nut. Tighten hex nut
to 13 N·m (114 lbf·in).

Figure 29 BCS valve

1. Crimp clamp (2)
2. Wastegate hose (BCS supply)
3. BCS valve
4. Wastegate hose (BCS output)
5. M5 x 18 Torx® screw (2)

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Installation (cont.)
19. Install new exhaust brake valve tube assembly
to exhaust brake assembly actuator and tighten
fitting nut to 17 N·m (15 lbf·ft).

Figure 31 Exhaust brake assembly

1. Exhaust brake assembly
2. Exhaust brake valve tube assembly
3. M6 x 12 bolt
Figure 32 Turbo exhaust pipe
4. Exhaust brake pressure sensor tube assembly
5. DMR 114 profile clamp 1. M10 x 20 hex bolt
2. Turbo exhaust pipe
3. DMR 119 profile clamp
NOTE: There are two alignment notches on the new
exhaust brake assembly housing and these will line
up with notches on the low-pressure turbocharger and 20. Apply Loctite® 262™Threadlocker or equivalent
turbo exhaust pipe. to new DMR 119 profile clamp threads.
16. Apply Loctite® 262™Threadlocker or equivalent 21. Reinstall turbo exhaust pipe and DMR 119 profile
to new DMR 114 profile clamp threads. clamp.
17. Position DMR 114 profile clamp and install new 22. Reinstall M10 x 20 hex bolt into turbo exhaust
exhaust brake assembly to correct location as pipe. Tighten bolt to 31 N·m (23 lbf·ft).
marked. Tighten profile clamp to 6 N·m (44 lbf·in).
23. Tighten profile clamp to 6 N·m (44 lbf·in).
18. Loosely connect new exhaust brake pressure
sensor tube assembly to exhaust brake assembly.
Do not tighten at this time.

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Installation (cont.)
NOTE: Make sure air supply hose assembly and
exhaust brake valve tube assembly are installed as
shown.

Figure 33 Retarder control

1. M8 x 55 bolt (2)
2. Retarder control
3. Retaining clip Figure 35 Exhaust brake valve tube assembly
connections

NOTE: The retarder is now installed upside down 1. Clip

relative to its original position. 2. Threaded fitting (with O-ring)
3. Male end (part of exhaust brake valve tube assembly)
24. Reinstall retarder control using two new M8 x 55 4. Exhaust brake valve tube assembly
hex bolts. Tighten hex bolts to 31 N·m (23 lbf·ft).
25. Secure retarder control wiring harness into
retaining clip on exhaust brake valve support 26. Lubricate new exhaust brake valve tube assembly
assembly. threaded fitting O-ring with P-80® Rubber
Lubricant or equivalent. Install clip and threaded
fitting into retarder control. Tighten threaded
fitting to 12 N·m (106 lbf·in).
27. Install and push new exhaust brake valve tube
assembly into threaded fitting until a click is heard.

Figure 34 Exhaust brake valve tube assembly

and air supply hose assembly
1. Air supply hose assembly
2. Exhaust brake valve tube assembly

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Installation (cont.)
30. Install new M10 x 1.0 37 deg flare fitting to retarder
control and tighten to 15 N·m (11 lbf·ft).

Figure 36 Air supply hose assembly

connections
1. Clip
Figure 38 Retarder control components
2. Threaded fitting (with O-ring)
3. Male end (part of air supply hose assembly) 1. Exhaust brake valve tube assembly
4. Air supply hose assembly 2. Air supply hose assembly
3. Exhaust brake pressure sensor tube assembly
4. M6 x 12 bolt
28. Lubricate new air supply hose assembly threaded 5. Tie strap
fitting O-ring with P-80® Rubber Lubricant or
equivalent. Install clip and threaded fitting into
retarder control. Tighten threaded fitting to 12 31. Loosely connect exhaust brake pressure sensor
N·m (106 lbf·in). tube assembly to M10 x 1.0 37 deg flare fitting.
Do not tighten at this time.
29. Install and push new air supply hose assembly
into threaded fitting until a click is heard. 32. Attach exhaust brake pressure sensor tube
assembly to exhaust brake assembly actuator
plate using new M6 x 12 bolt (3, Figure 31).
Tighten bolt to 13 N·m (115 lbf·in).
33. Install and position new tube clamp on exhaust
brake pressure sensor tube assembly. Attach
tube clamp to exhaust brake valve support
assembly using new M6 x 12 bolt (4, Figure 38)
and tighten to 13 N·m (115 lbf·in).
34. Tighten exhaust brake pressure sensor tube fitting
nut at retarder control to 16 N·m (12 lbf-ft).
35. Tighten exhaust brake pressure sensor tube
fitting nut at exhaust brake assembly to 20 N·m
(15 lbf-ft).
36. Using a locally obtained tie strap, secure exhaust
Figure 37 M10 x 1.0 37 deg flare fitting brake valve tube assembly to the exhaust brake
pressure sensor tube assembly.

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Installation (cont.)
39. Push air supply hose assembly into 90 degree
quick disconnect.

Figure 39 Air supply hose assembly

1. EGR control valve
2. Air supply hose assembly
Figure 41 Wastegate hose (BCS supply) routing

37. Lubricate new air supply hose assembly threaded 40. Clip wastegate hose (BCS supply) into new
fitting O-ring with P-80® Rubber Lubricant or support bracket assembly, and route hose forward
equivalent. Install new threaded fitting and new on engine adjacent to EGR/retarder air supply
clip into EGR control valve. Tighten threaded hose assembly.
fitting to 12 N·m (106 lbf·in).
38. Install and push new air supply hose assembly
into threaded fitting until a click is heard.

Figure 42 Wastegate hose (BCS output)

1. Wastegate hose (BCS output)
2. Strap lock clip
Figure 40 Wastegate hose (BCS supply) and air 3. Wastegate actuator
supply hose assembly
1. Wastegate hose (BCS supply) 41. Position new crimp clamp on wastegate hose
2. Banjo bolt (BCS output) and connect line to wastegate
3. 90 degree quick disconnect; air supply hose actuator. Push the wastegate hose (BCS output)
assembly all the way down to the base of the wastegate

15 1171963R1
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Installation (cont.)
actuator and position the crimp clamp 2 mm 46. Connect wastegate hose (BCS supply) and install
(0.078 in) from base of fitting. banjo bolt with two new Parker 853009-10 copper
washers. Tighten banjo bolt to 10 N·m (89 lbf·in).
42. Using correct crimping tool, crimp wastegate hose
(BCS output) crimp clamp.

Figure 44 Wastegate hose (BCS supply) tie

straps
Figure 43 Strap lock clip

47. Secure wastegate hose (BCS supply) to air line

43. Secure wastegate hose (BCS output) to Charge
mounting bracket using tie straps obtained locally.
Air Cooler (CAC) return coolant pipe using new
strap lock clip. 48. Install new sensor harness assembly. See
“Engine Electrical” section of EGES 415-1 Engine
44. Position crimp clamp and install wastegate hose
Service Manual.
(BCS supply) onto new wastegate valve air supply
(banjo) fitting. Push the wastegate hose (BCS 49. Connect yellow wire harness jumper for retarder
supply) all the way down to the base of the banjo control and black wire harness jumper for EGR
fitting and position the crimp clamp 2 mm (0.078 actuator to new sensor harness assembly.
in) from base of fitting.
50. Install P-clamps to driver’s side of new sensor
45. Using correct crimping tool, crimp banjo fitting harness assembly.
crimp clamp.

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Installation (cont.)
NOTE: Install any missing tie straps to the chassis 56. Contact Tech Central and inform them that
harness. AFC09902 has been completed before
performing recalibration using NETS.
51. Install ECM and electronic control unit bracket.
See “Engine Electrical” section of EGES 415-1 NOTE: The BCS constantly purges air when the
Engine Service Manual. engine is running. This is normal operation.
52. Install air cleaner and inlet pipe. 57. Start engine and build air pressure to normal
operating levels.
53. Install engine cover.
58. Perform an Actuator Test to verify repairs.
54. Install both inner fenders to vehicle.
55. Connect ground cable to negative terminal of
batteries.

17 1171963R1
© 2008 Navistar, Inc.