Unscrew the screws from the removal plate/core and discard.

9.

Unscrew the rods to remove the gasket (discard).

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/2/2014

IK1201113 ­ 2010 MaxxForce 11 & 13 and 2013 N13 HT EGR Core Removal/Installation Page 8 of 14

Figure 5: HT Diffuser O-Rings
Item 1: HT Housing
Item 2: Manifold (joint) Plate
Item 3: O-Rings

10. Use a pick to remove the four o-rings in the center of the cooler and discard. The o­rings must be replaced
every time the core is replaced. Non-compliance will result in premature failure of the core.

INSTALLATION PROCEDURE:

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/2/2014

IK1201113 ­ 2010 MaxxForce 11 & 13 and 2013 N13 HT EGR Core Removal/Installation Page 9 of 14

Figure 6: HT Diffuser O-Rings
Item 1: HT Housing
Item 2: Manifold (joint) Plate
Item 3: O-Rings

1.

Install the four o-rings from the HT kit (Figure 6, Item 3).

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/2/2014

IK1201113 ­ 2010 MaxxForce 11 & 13 and 2013 N13 HT EGR Core Removal/Installat... Page 10 of 14

Figure 7: Cooler Core Kit O-Rings

WARNING
There are two o-ring designs and both are the same size with different durometers. Make sure to use only the black o-rings on the HT
core and pink o­rings on the LT core.

2.

Apply generous amounts of P-80 to the four o-rings.

3.

Install the two dowel pins into the housing. Use a hammer to tap them in, if necessary.

4.

Install the core to housing gasket.

5.

Screw in the four rods from the tool kit (tighten using a 9mm open-end wrench).

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/2/2014

IK1201113 ­ 2010 MaxxForce 11 & 13 and 2013 N13 HT EGR Core Removal/Installat... Page 11 of 14

Figure 8: HT Core Installation
Item 1: Core to Housing Gasket
Item 2: Installation Plate
Item 3: Removal Plate
Item 4: Dowel Pin

6.

Apply liberal amounts of P-80 to the outlet manifold and spring clips of the HT core.

7.

Slide the HT Core into the housing.

8.

Attach the insertion plate to the tool and slide it over the rods.

9.

Screw the thumbscrews onto the rods.

10. Use a torque wrench to tighten the bolt, which will drive the core into the housing. Stop when the core header
touches the gasket.
NOTE

DO NOT OVER TIGHTEN. Stop when the plate merely touches the gasket/housing.
The core should take up to 10 lb-ft of bolt torque to slide in. Damage to the tubes will occur if the torque
exceeds 15 lb-ft (equates to 1000 lb force).
11.

Remove the knobs, tool and rods.

12.

Install the EGR Valve gasket.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/2/2014

IK1201113 ­ 2010 MaxxForce 11 & 13 and 2013 N13 HT EGR Core Removal/Installat... Page 12 of 14

Figure 9: EGR Valve Bolt Notation

13.

Install the EGR valve and torque as follows, referencing Figure X for bolt position notation.

a.

Hand tighten all

b.

Torque "1-5-7-4" to 5 N-m (4 lb-ft)

c.

Torque "5-1-6-2-7-3-4-8-9" to 24 N-m (18 lb-ft)

14.

Attach all coolant lines for cooling system refill. Do not begin truck reassembly yet.

15.

Perform vacuum fill of the cooling system while watching for an inability to maintain vacuum.

NOTE
If the system is unable to maintain vacuum, perform a cooling system pressure decay test. If no external leaks can
be found, pressure test the EGR Cooler using the leak detection tool.
The vacuum fill is a critical aspect of the repair. Any issues (cut/damaged/missing o-rings) will be caught here, as
well as ensuring no air pockets are left in the system (which can reduce the life of the cooler or make the system
appear leaking as the pockets are burped).
If there is no choice but to use the bucket fill method, it will be CRITICAL to pressure test the cooling system after
the repair.
16.

Assemble the remaining components removed for pressure testing

17.

Per best practice, verify repair.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/2/2014

IK1201113 ­ 2010 MaxxForce 11 & 13 and 2013 N13 HT EGR Core Removal/Installat... Page 13 of 14

For an internal leaking cooler
Replace the engine oil and filter for coolant contamination and follow iKNow IK1201065 for
Lambda Sensor Relearn.
Provide the customer with oil change information.

WARRANTY INFORMATION
Warranty Claim Coding:
Group: 12000 - Engine
Noun: 892 - Cooler, EGR

Standard Repair Times: WILL BE UPDATED WHEN THEY ARE PUBLISHED
Step Description

SRT

Hours

HT CORE REPLACEMENT IN CHASSIS
HT core replacement (including pressure test) - ProStar

R12­6892U­

4.4

HT core replacement (including pressure test) - TranStar

Q12­6892U­

4.1

HT core replacement (including pressure test) - WorkStar

N12­6892U­

4.4

HT core replacement (including pressure test) ­ CAT CT660

TC12-6892U-

4.4

MODULE ASSEMBLY REPLACEMENT (unable to replace core only)
ProStar+ HT and/or LT Replacement

R12-3892U-34

7.6

TranStar HT and/or LT Replacement

Q12-3892U-34

7.4

WorkStar HT and/or LT Replacement

N12-3892U-34

7.9

CAT CT660 HT and/or LT Replacement

TC12­3892U­34

LT CORE R&R IN CHASSIS WITH HT (see LT iKNow when LT ONLY rep'd)
ProStar+122 LT Core Replacement in Chassis

R12­6892U­

1.4

ProStar+113 LT Core Replacement in Chassis

R12-6892U-

1.5

TranStar LT Core Replacement in Chassis

Q12­6892U­

1.8

WorkStar LT Core Replacement in Chassis

N12­6892U­

1.8

CAT CT660 LT Core Replacement in Chassis

TC12-6892U-

1.8

LT CORE R&R OFF CHASSIS (add-on when HT MODULE replaced)
ProStar+122 LT Core Replacement off Chassis

R12­6892U­6

0.3

ProStar+113 LT Core Replacement off Chassis

R12­6892U­6

0.3

TranStar LT Core Replacement off Chassis

Q12­6892U­6

0.3

WorkStar LT Core Replacement off Chassis

N12­6892U­6

0.3

CAT CT660 LT Core Replacement off Chassis

TC12-6892U-6

0.3

HT CORE R&R ADD-ON

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/2/2014

IK1201113 ­ 2010 MaxxForce 11 & 13 and 2013 N13 HT EGR Core Removal/Installat... Page 14 of 14

All Models--for situations where a tech already has parts down
to the cooler removed. Examples: EGR Valve repair, EGR Tubes,
Exhaust Manifold, etc.

0.5

MISCELLANEOUS RELEVANT SRTs
Cooling System Leak Test

A09-9022A

0.3

Engine Oil Replacement
*Already in HT and/or LT Module Assembly Replacement SRT
*Use when core is leaking and the only part replaced

A12­1889U

0.6

Lambda Relearn or Replacement (see SRT section of iKNow)

IK1201065

EXAMPLE: A ProStar+113 has the HT replaced for leaking and the LT replaced for 2659-21. The warranty claim
should be HT Core R&R (R12­6892U­X, 4.4 hrs), LT Core R&R (R12­6892U­X, 1.5 hrs), Oil Change (A12­1889U, 0.6
hrs), and lastly, Lambda relearn/replacement, which depends on the condition of the Lambda.
With the warranty claim comments, we need only the basics--"Truck came in with leaking HT and plugged LT. Replaced both cores, oil,
and performed lambda relearn/replacement."

SRT Manual

OTHER RESOURCES
2010 MaxxForce 11/13 Resource Center (IK1200548)
2010 MaxxForce 11/13 Diagnostic Manual
2010 MaxxForce 11/13 Service Manual
HT Tool Instructions (TL2900093)
EGR Low Flow - 2659-21 (IK1201100)

LT Core Removal/Install Tool Instructions (TL2900085)
ProStar LT Instructions (iKNow 1201096)

TranStar LT Instructions (iKNow 1201097)
WorkStar/CAT LT Instructions (iKNow 1201098)

Hide Details

Feedback Information
Viewed:

642

Helpful:

4

Not Helpful: 0
No Feedback Found

Copyright © 2014 Navistar, Inc.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/2/2014