IK1201100 ­ MaxxForce 11/13L ­ SPN 2659 FMI 21 ­ EGR Low Flow

Page 1 of 17

Countries:

AUSTRALIA, CANADA, UNITED
STATES, MEXICO, PUERTO RICO,
NEW ZEALAND

Document
ID:

IK1201100

Availability:

ISIS, FleetISIS

Revision:

5

Major System: ENGINES

Created:

3/13/2014

Current
Language:
Other
Languages:

English

Last
Modified:

10/14/2014

NONE

Author:

Aaron
Wenthold

Viewed:

20543
Less Info

Coding Information

Hide Details

Copy Link

Copy Relative Link

Bookmark

Add to Favorites

Print

Provide Feedback

Helpful

Not Helpful

40

2

View My Bookmarks

Title : MaxxForce 11/13L ­ SPN 2659 FMI 21 ­ EGR Low Flow
Applies To : 2010 Emissions MaxxForce 11/13 All truck models

CHANGE LOG
2014/10/14 ­ Added comment about no code, put "diagnostics" into step based
2014/10/09 - Fixed Service Action Repair Plan Links (Symptoms)
2014/09/12 - Revised vacuum fill information and included in the procedure. Revised wording for o­rings.
2014/08/12 ­ Removed AFC information, fixed SRTs for PayStar and LoneStar, Added HT Core P/N
2014/06/18 - Aligned Pressure Testing SRT with SRT Manual
2014/06/12 Added link to Video Instructions on LMS, in the repair procedure. Fixed SRT for in chassis pressure testing.




DESCRIPTION
This document will guide the user through the diagnostics and repair procedure for Diagnostic Trouble Code 2659-21 (EGR
Cooler Low Flow). Listed below are the symptoms, common tools and parts necessary for repair, repair procedures and
warranty information. The document will guide the user through the new Low Temp (LT) core removal and installation
procedure, which is faster and more effective than prior repair methods--we are no longer cleaning EGR Coolers.
This document replaces/retires:
• 2010 MaxxForce 11 & 13L EGR Cooler Resource Center
• EGR Cooler Low Flow Triage (Flow Chart)
• EGR Cooler iApproval (no longer necessary)

REPAIR VIDEO
The entire repair procedure for a ProStar (basic 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.

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

Description

SPN 111 FMI 1

Low Coolant

SPN 2659 FMI 21

EGR Low Flow

Customer Observations or Concerns:
- Malfunction Indicator Light (MIL)

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1201100 ­ MaxxForce 11/13L ­ SPN 2659 FMI 21 ­ EGR Low Flow

Page 2 of 17

- Red Stop Lamp (RSL)
- Coolant consumption
­ Low coolant
- Coolant puddling under engine
­ White smoke from the exhaust
- Coolant in the oil or oil analysis

SPECIAL TOOLS
Tool Description

Tool Number

Comments

Instructions

LT Core Removal/Install Tool

12­892­04

Link

Coolant Management Tool

KL5007NAV

Link

EGR Leak Detection Kit

12­892­02

Only if necessary

Link

EGR Cooler Alignment Tool

12­892­01

Only if necessary

Link

EGR Cooler Lifting Bracket

12­892­03

Only if necessary

DIAGNOSTIC STEPS
NOTE
Visual inspection is not an approved method for diagnosing a low temp cooler. There are many parameters considered by
the ECM when determining EGR flow, and it is not simply a restriction across the cooler. Navistar has always had (and will
continue to have) the stance that "no code means no replacement." Warranty will not be honored if there is no code in the
health report.
Cleaning or replacement of the high temp cooler for fouling (plugging) is never necessary, as it can only plug if the core is
leaking (failed).

Step Action
DIAGNOSTIC:

Decision
MaxxForce 11/13. Proceed to
Step 2

Is the engine a MaxxForce 11/13 or a 2013 N13?

1

N13. Ensure calibration is upto-date and open a tech
services case file. Measures
have been taken to reduce
effects of plugging, so the
code is likely being tripped
falsely.

Step Action
DIAGNOSTIC:

Decision
Yes. Proceed to Step 5

Is SPN 111-1 or coolant consumption present along with SPN 2659-21?

2

No. Proceed to Step 3

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1201100 ­ MaxxForce 11/13L ­ SPN 2659 FMI 21 ­ EGR Low Flow

Step Action
DIAGNOSTIC:

Page 3 of 17

Decision
ProStar+ 113 or 122.
Proceed to IK1201096

No diagnostics are necessary--simply replace the cooler per chassis
instructions.
Which model of truck is being worked on?
TranStar. Proceed to
IK1201097

3

WorkStar or Cat. Proceed
to IK1201098
PayStar or LoneStar.
Proceed to Step 4

Step Action
A procedure for in­chassis core replacement has not been developed. This
is not to say it's not possible. At this time, we are recommending offchassis replacement of the core.

4

Step Action
DIAGNOSTIC:

Decision
Follow the Engine Service
Manual for EGR Cooler
removal and proceed to the
off­chassis core R&R
instructions in the REPAIR
PROCEDURE.

Decision
Yes. Review concern and
return to Step 3

Are any of the following a possibility for a coolant loss false possitive?

5

-Vehicle recently had a cooling system repair and improperly
refilled
-Vehicle recently repaired and the fault code not successfully
cleared
-Operator unaware of the proper filling procedure (over-filling)

Step Action

No. Proceed to Step 6

Decision
Proceed to Step 7

Use the coolant management tool to drain the cooling system. Reference chassis specific
service manuals to disassemble truck for EGR Cooler pressure testing.

6

Step Action
DIAGNOSTIC:
7
Use KL20060NAV (EGR cooler pressure tester) to test the EGR Cooler--Low
Temp section first.

Decision
HT. Proceed to IK1201113.
After replacing the HT core
(and coolant still drained),
return to Step 3.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1201100 ­ MaxxForce 11/13L ­ SPN 2659 FMI 21 ­ EGR Low Flow

Page 4 of 17

Which section is leaking?

HT and LT. Proceed to Step 8.
Reference Figure 1 for a cooler configuration visual aid (dearation fittings).

LT Internally. Return to Step 3
and follow core replacement
instructions

LT Externally. Proceed to
Step 4
Neither. Proceed
to IK1201066 for coolant loss
diagnostics. When repair is
complete, return to Step 3.

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)

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1201100 ­ MaxxForce 11/13L ­ SPN 2659 FMI 21 ­ EGR Low Flow

Step Action

Decision

DIAGNOSTIC:

8

Page 5 of 17

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. Always
pressure test the LT section THEN the HT section.

Yes. Proceed to IK1201113.
After replacing the HT core
(and coolant still drained),
return to Step 3.

No. Return to Step 7

Are both halves still leaking?

SERVICE PARTS INFORMATION
Kit Description

Part
Number

Quantity
Required

Kit, Low Temp Core

2513209C91

1

MF 11/13 and N13

Kit, High Temp Core

2513445C91

1

MF 11/13 and N13

Kit, Low Temp Seal

2512193C91

1

If Leaking from LT Joint Seal

Module, HT

3014254C95

1

For HT Failure Only

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

P­80 Assembly Lube

2511097C1

Case of 6 Pints

REPAIR STEPS
The following repair steps are for the LT core removal and installation off chassis. There is no limitation to the
number of times this procedure can be used for a Low Temp housing, as long as there are no physical concerns with the
housing itself (cracks, damage, broken fittings, etc) and ALL o­rings are replaced during every repair.

REPAIR VIDEO
The entire repair procedure for a ProStar (basic 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
At this point, the cooler should still be off the truck. This procedure can be performed at any point during the HT repair. If done
when the two coolers are separated, it will be much easier to replace the o­rings.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1201100 ­ MaxxForce 11/13L ­ SPN 2659 FMI 21 ­ EGR Low Flow

Page 6 of 17

Figure 2: EGR Outlet Cover, Bolts and Tubes
Item 1: EGR Outlet Tube Bolts
Item 2: Engine Harness Bracket Bolts
Item 3: EGR Outlet Cover Bolts
1. Remove the eight bolts and one stud bolt from the front cover, and remove (Figure 2, Item 3).

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1201100 ­ MaxxForce 11/13L ­ SPN 2659 FMI 21 ­ EGR Low Flow

Page 7 of 17

Figure 3: Soot Build-Up on the Core Face
Significant build-up will not allow the tool to sit against the core.
2.

If necessary, scrape off soot build-up on the outlet of the core. The plate must sit flat against the face.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1201100 ­ MaxxForce 11/13L ­ SPN 2659 FMI 21 ­ EGR Low Flow

Page 8 of 17

Figure 4: Low Temp EGR Core Extractor
Item 1: Removal Bolt
Item 2: Thumb Screws
Item 3: Removal Plate
Item 4: LT Core
Item 5: LT Housing
Item 6: Self Tapping Screws
3.

Install the LT EGR Core Puller Tool (12­892­04), per the tool instructions.

4.

Back out the bolt (Figure 4, Item 1) until the core pulls loose (typically 3/4" from the housing).

5.