Instruction Sheet

Air and Exhaust Gas Recirculation (EGR) Mixer Duct Assembly

Heater Element Replacement

4328220R3

Application WARNING: To prevent personal injury and /

or death, read all safety instructions in the “Safety
MaxxForce® DT, 9, & 10 (EPA 10) with HD-OBD
Information” section of the Engine Service Manual
MaxxForce® DT, 9, & 10 (EPA 10) or Engine Diagnostic Manual.
N9 and N10 (EPA 10) with SCR
WARNING: To prevent property damage,
personal injury, and / or death, park vehicle on
Kit Contents
a hard, flat surface, turn engine off, set parking
brake, and install wheel chocks to prevent vehicle
Description Quantity
from moving in both directions.
Element, Intake Heater 1
Gasket, Inlet Duct to Intake Manifold 1 WARNING: To prevent personal injury and /
or death, make sure the engine has cooled before
Instruction Sheet 1
removing components.

WARNING: To prevent property damage,

personal injury, and / or death, remove ground
cable from negative terminal of main battery
before disconnecting or connecting electrical
components. Always connect ground cable last.

WARNING: To prevent personal injury and /

or death, always wear safe eye protection when
performing vehicle maintenance.

1
Read all safety instructions in the "Safety Information" section of the appropriate Engine Service or Diagnostic Manual.
Follow all warnings, cautions, and notes.
© 2017 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
Procedure
Removal
CAUTION: To prevent property damage, do
not remove Exhaust Gas Recirculation (EGR)
valve for intake heater replacement. Damaged
EGR valves resulting from this procedure will not
be warrantable.
1. Bring truck into shop and park on flat surface.
2. Shift transmission to Park or Neutral, set parking
brake, and install wheel chocks.
3. Unlatch and open hood.
4. Open battery box and disconnect negative battery
cable.
5. Remove air and EGR mixer duct assembly. Refer
to Engine Service Manual, MaxxForce® DT, 9, and
10, 0000001835 or Engine Service Manual, N9
and N10, 0000004021.
NOTE: Note orientation of mounting hardware
prior to removal of intake heater element for ease
during installation.
6. Loosen two nuts and bolt assemblies
(Figure 1, Items 1 and 5) and remove intake
heater element (Figure 1, Item 2) and two ceramic
assemblies (Figure 1, Item 3) and discard.
7. Remove ground side nut, two washers, and bolt
(Figure 1, Item 1) from vehicle. Save nut, bolt,
and two washers for reuse.
8. Remove nut, two steel washers, two mica
washers, and bolt (Figure 1, Item 5) from vehicle.
Save nut, steel washers, mica washers, and bolt
for reuse.

Figure 2. Silicone Insulators

1. Silicone insulator (2) (one not shown)

Figure 1. Intake Heater Element

9. Remove two silicone insulators (Figure 2, Item 1)
1. Bolt, washer (2), and nut from air and EGR mixer duct assembly. Save
2. Intake heater element silicone insulators for reuse.
3. Ceramic assembly (2)
4. Air and EGR mixer duct assembly
5. Bolt, steel washer (2), mica washer (2), and nut

4328220R3 2
© 2017 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
Removal (cont.)
Installation

Figure 4. Exploded View of Components

1. M6 nut (2)
2. Steel washer (4)
3. M6 x 20 mm bolt
4. Ceramic holder assembly (2)
5. Heating element
Figure 3. Soot Buildup Areas 6. M6 x 30 mm bolt
7. Mica washer (2)
8. 7.1 mm seal
10. Clean housing hardware contact points 9. 10 mm seal
(Figure 3) and intake heater element seat area 10. 4.3 mm seal
with soft brush or steel wool.

3 4328220R3
© 2017 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
Installation (cont.)

2
1

3
4

5 Figure 7. Long (POS) Bolt Assembly

6

7
8 0000413842

Figure 5. Long (POS) Bolt Assembly, Installation

1. Casting
2. Heating element
3. Mica washer (outer)
4. Bolt
5. Nut
6. Steel washer (outer)
7. Mica washer (inner)
8. Steel washer (inner)

Figure 6. Short (GND) Bolt Assembly

Figure 8. Components and Assembly

Orientation
1. Short (GND) bolt assembly
2. Long (POS) bolt assembly

4328220R3 4
© 2017 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
Installation (cont.)

CAUTION: To prevent property damage,

loss, or misassembling of components, DO
NOT disassemble component assemblies until
instructed (Figure 5).
NOTE: The Long (POS) bolt assembly can be
identified by its M6 x 30 mm bolt, single 10 mm
silicon seal, and two mica washers (Figure 7).
1. Remove M6 nut (Figure 5, Item 5), one steel
washer (Figure 5, Item 6), and one mica washer
(Figure 5, Item 3) from M6 x 30 mm bolt (Figure 5,
Item 4). This will leave the silicone seal (Figure 4,
Item 8), one mica washer, and one steel washer
on the bolt.
2. Install M6 x 30 mm bolt (Figure 5, Item 4) from
inside of mixer duct assembly on positive (right)
side as shown in Figure 8.
3. Install removed mica washer (Figure 5, Item 3)
onto M6 x 30 mm bolt (Figure 5, Item 4).
4. Install removed steel washer (Figure 5, Item 6)
onto M6 x 30 mm bolt (Figure 5, Item 4).
Figure 9. Heating Element and Ceramic Holder
5. Install M6 nut (Figure 5, Item 5) onto M6 x 30 mm Assemblies
bolt (Figure 5, Item 4) hand tight.
1. Ceramic holder assembly (2)
NOTE: The Short (GND) bolt assembly can be 2. Heating element
identified by its M6 x 20 mm bolt and paired 7.1
mm and 4.3 mm silicone seals (Figure 6).
9. Assemble heating element (Figure 9, Item 2) and
6. Remove M6 nut (Figure 4, Item 1) and one steel two ceramic holder assemblies (Figure 9, Item 1)
washer (Figure 4, Item 2) from M6 x 20 mm bolt as shown.
(Figure 4, Item 3). This will leave the silicone seals
(Figure 4, Items 9 and 10) and one steel washer 10. Partially insert heating element assembly (Figure
on the M6 x 20 mm bolt. 9, Item 1) into mixer duct assembly with looped
end on ground (left) side.
7. Install M6 x 20 mm bolt (Figure 4, Item 3) from
inside of mixer duct assembly on ground (left) side 11. Carefully position looped (left) end of heating
as shown in Figure 8. element (Figure 9, Item 2) between steel washer
(Figure 4, Item 2) and M6 x 20 mm bolt head
8. Install removed steel washer (Figure 4, Item 2) (Figure 4, Item 3).
and M6 nut (Figure 4, Item 1) onto M6 x 20 mm
bolt (Figure 4, Item 3) hand tight. 12. Fully insert heating element assembly and
ceramic holder assemblies into mixer duct
assembly, while guiding the heating element ends
into their bolt assemblies.
13. Inspect final positioning of heating element ends
and verify ends are placed between their bolt
heads and steel washers as shown in Figure 8.
14. Verify that positive (right) side has a mica washer
against each side of casting. The heating
element ends must be fully seated into their bolt

5 4328220R3
© 2017 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
Installation (cont.)
assemblies, and ceramic holder assemblies must
be flush or below gasket surface.
CAUTION: To prevent property damage,
ensure that bolt head and heating element
remain stationary and tighten without twisting or
distortion.
15. Using torque wrench, tighten two nuts
(Figure 4, Item 1) to 125 lb-in (14.1 N•m).
16. Install air and EGR mixer duct assembly. Refer to
Engine Service Manual, MaxxForce® DT, 9, and
4328220R3 6
© 2017 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
10, 0000001835 or Engine Service Manual, N9
and N10, 0000004021.
17. Connect negative battery cable and close battery
box.
18. Perform Intake Air Heater (IAH) functionality test.
Refer to Engine Diagnostic Manual, MaxxForce®
DT, 9, and 10, 0000001624 or Engine Diagnostic
Manual, N9 and N10, 0000003721.
19. Close and latch hood.
20. Remove wheel chocks.