IK1201096 ­ ProStar+ with MaxxForce 11/13L or N13 ­ LT EGR Core Removal and Inse... Page 1 of 32

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Title : ProStar+ with MaxxForce 11/13L or N13 - LT EGR Core Removal and Insertion
Applies To : 2010 MaxxForce 11/13, N13, ProStar+113, ProStar+122

CHANGE LOG
2015/10/12 - Removed outdated procedure links.
2015/09/16 - Updated O2 Sensor Relearn Procedure reference to manual.
2015/09/14 - Updated SRT to link to repair times.
2015/07/30 - Fixed hyperlinks, minor formatting revisions,
2014/06/12 Added link to Video Instructions on LMS, in the repair procedure.

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DESCRIPTION
A faster, more effective procedure for Low Temp (LT) Exhaust Gas Recirculation (EGR) Cooler repair has been
developed. This document will guide the user through the procedure of in chassis replacement of the cooler core on
a ProStar+113 or ProStar+122 with a 2010 Emissions MaxxForce 11 or 13 or the 2013 Emissions N13. The new
procedure will REPLACE LT cooler cleaning for fouling (plugging) and LT assembly replacement for internal leaks.

SYMPTOMS
Diagnostic Trouble Codes & Dashboard Indicator Lights:
DTC/Light

Description

SPN 111 FMI 1

Engine Coolant Level Below
Critical Warning

SPN 2659 FMI 21

EGR Low Flow Detected

Customer Observations or Concerns:
- Malfunction Indicator Light (MIL)
­ Red Stop Lamp (RSL)
­ Coolant consumption
- Low coolant
- Coolant puddling under engine

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- White smoke from the exhaust
- Coolant in the oil or oil analysis

SPECIAL TOOLS
Tool Description

Tool Number

LT EGR Core Puller Tool

12­892­04

Coolant Management Tool

KL5007NAV

EGR Leak Detection Kit

12­892­02

Comments

Instructions
Link
Link

Only if necessary

Link

SERVICE PARTS INFORMATION
Kit Description

Part
Number

Quantity
Required

Kit, Low Temp Core

2513209C91 1

Required

Module, HT

3014254C95

ONLY if necessary (HT failure)

Notes

Module, LT (MaxxForce) 3015862C92

For external leaks ONLY, in place of LT Kit

Module, LT (N13)

2511089C91

For external leaks ONLY, in place of LT Kit

Kit, LT Seal

2512193C91

Leak between LT housing and joint plate

P­80 Assembly Lube

2511097C1

Case of 6 Pints

DIAGNOSTIC STEPS
All diagnostic steps should be completed through the Service Action Repair Plans or Diagnostic Manual. At this point,
the truck should have been diagnosed with either;
• An internal coolant leak in the Low Temp EGR cooler (reference Figure 1 below for the cooler assembly
notation), or
• EGR Low Flow (2659­21)
The following procedure should NOT BE USED if the cooler is leaking externally for cracks, porosity, broken fittings,
etc. Instead, replace the entire LT cooler assembly.

NOTE: If BOTH cooler halves are found leaking, make sure the LT cooler did not appear failed due to residual air in
the core from the High Temp testing. Typically this happens when the leak detection hose is not vented to
atmosphere (left in water) between tests and/or when the HT is tested and the fittings are switched quickly--the air
pressure in the core passages is still enough to cause bubbles when putting pressure to the LT.

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Figure 1: 2010 MaxxForce 11/13 EGR Cooler Assembly
Item 1: High Temp (HT) Cooler
Item 2: Low Temp (LT) Cooler
Item 3: LT Cooler Pressure Test Port (dearation fitting)
Item 4: HT Cooler Pressure Test Port (dearation fitting)

REPAIR STEPS
The following repair steps are for the cooler removal and installation in chassis. There is no limitation to the number
of times this procedure can be used for a given housing, as long as there are no physical concerns with the housing
itself (cracks, damage, broken fittings, etc).

WARNING
To prevent personal injury or death, read all safety instructions in the "Safety Information" section of the diagnostic
manual, linked here.

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

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To prevent personal injury or death, do not let engine fluids 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 fluids.

REPAIR VIDEO
The entire repair procedure for a ProStar (core procedure is the same for all vehicles) has been put
into video and available in the Learning Management System. Go to the LMS via this link. Then
"Course Catalog," "Critical Repair Videos," "LT EGR Cooler Core Replacement Procedure," and
enroll. After enrolling, go back to "My Current Enrollments" to watch.

REMOVAL PROCEDURE
1.

Open the battery box and disconnect the negative battery cable.

2.

Use the Coolant Management Tool to drain the cooling system.

Figure 2: Top of Radiator
Item 1: Low Temp Radiator Hose
Item 2: Radiator Hose
3. Remove the Low Temp Radiator (LTR) hose (Figure 2, Item 1).
4.

Remove the Radiator hose (Figure 2, Item 2)

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Figure 3: Dearation Tank Assembly
Item 1: HP CAC Inlet
Item 2: Dearation Tank Side Bracket
Item 3: Radiator Dearation Hose
Item 4: Coolant Return Hose
Item 5: Coolant Level Sensor
Item 6: Engine Dearation Hoses
Item 7: Upper Tank Mount
Item 8: Dearation Tank

5.

Loosen the clamp and remove the driver side HP CAC inlet pipe (Figure 3, Item 1).

6.

Remove the 3 or 4 dearation lines from the tank (depending on configuration. Figure 3, Items 3 & 6).

For ProStar+113, continue with Steps 7 through 11.
For ProStar+122 skip to Step 12 (dearation tank does not need to be removed).
7.

Disconnect the engine harness from the Engine Coolant Level Sensor (Figure 3, Item 5).

8.

Remove the dearation tank return hose (Figure 3, Item 4).

9.

Cut any zip ties holding the LT radiator hose to the tank.

10. Remove the two nuts securing the mounting bracket to the radiator (Figure 3, Item 2).
11. Remove the four nuts securing the top of the tank to the radiator (Figure 3, Item 7), and remove the dearation
tank.

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Figure 4: A/C Line Bracket
Item 1: Recirculation Seal
Item 2: A/C Line Bracket
Item 3: Low Temp Radiator Hose
Item 4: A/C Bracket Nut
Item 5: A/C Lines
12. Remove the nut securing the A/C condenser line bracket to the radiator (Figure 4, Item 4).
13. Loosen the hose clamp and remove the Low Temp Radiator (LTR) return hose from the return tube (Figure 4,
Items 3).
14. Cut the recirculation seal to allow the condenser to swing around the engine (Figure 4, Item 1).
NOTE
It is common for this seal to have been cut in a prior repair. If this is the case, skip this step.

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Figure 5: A/C Condenser Mounting
Item 1: A/C Condenser
Item 2: Condenser Mounting Nuts/washers
Item 3: High Pressure Charge Air Cooler
15. Remove the four nuts and washers securing the A/C condenser to the HP CAC (Figure 5, Item 2).

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Figure 6: A/C Condenser Repositioning
Item 1: Passenger Front Tire
Item 2: A/C Condenser
Item 3: Air Intake Pipe
Item 4: A/C Lines
16. Carefully flip the A/C condenser over the cooling package and rest the driver side on the passenger front tire
(Figure 6). Secure the A/C lines to the intake pipe using a bungee cord or zip tie.

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Figure 7: Driver Side HPCAC
Item 1: Power Steering Reservoir Bolts
Item 2: HPCAC Clamp/hose
17. Loosen the driver side HPCAC outlet clamp and disconnect the HPCAC pipe (Figure 7, Item 2).
18. Remove the two power steering reservoir bolts, and reposition away from the radiator (Figure 7, Item 1).

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Figure 8: Fan Shroud Ring
Item 1: Fan Ring
Item 2: Fan Ring Bolts
19. Remove the three bolts securing the fan shroud ring to their respective brackets (Figure 8, Item 2).

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Figure 9: Passenger Side Radiator Support
Item 1: Radiator Support Rod
Item 2: Support Rod Nut/Bolt
20. Remove the nut and bolt from the passenger side radiator support rod.

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Figure 10: Driver Side Radiator Support
Item 1: Support Rod Nut/Bolt
Item 2: Radiator Support Rod
21. Remove the nut and bolt form the driver side radiator support rod.
22. Tilt the cooling package forward, allowing room for LT Core removal.

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Figure 11: EGR Outlet Cover, Bolts and Tubes
Item 1: EGR Outlet Tube Bolts
Item 2: Engine Harness Bracket Bolts
Item 3: EGR Outlet Cover Bolts
23. Disconnect the engine harness from the EGR Temperature (EGRT) sensor.
24. Remove the four bolts holding the outlet tubes to the front cover--discard the gaskets (Figure 11, Item 1).
25. Remove the two bolts holding the engine harness, and reposition as necessary, for front cover
removal (Figure 11, Item 2).