Remove the tool and pull the core from the housing.

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Figure 5: Low Temp Cooler Housing Face
Item 1: Housing
Item 2: Core O-Rings
Item 3: Housing Seal
6.

Remove the housing seal and discard (Figure 14, Item 3)

7.

Use a seal pick to remove the four o-rings at the housing inlet and discard (Figure 14, Item 2).

CAUTION
Use care not to damage the o-ring groove in the housing.

INSTALLATION PROCEDURE

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Figure 6: Low Temp Cooler Housing Face
Item 1: Housing
Item 2: Core O-Rings
Item 3: Housing Seal
1.

Install the new seal into the LT housing (Figure 6, Item 3).

2.

Clean the o-ring grooves of contaminates (soot). Coolant is not a concern, and will act as a lubricant.

3.

Install the new o-rings from the LT core kit (Figure 6, Item 2).

NOTE
Ensure no soot or other debris are left in the grooves. Debris can cause leaks from improper sealing and/or cause the o-ring
to be damaged by the core during installation.

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Figure 7: Low Temp Cooler Inlet Manifold
Item 1: Low Temp EGR Cooler Core
Item 2: Inlet Manifold Ports
3.

Use liberal amounts of P-80 to lubricate the LT core inlet manifold and the four o-rings in the LT housing.

4.

Insert the core into the housing and maneuver it into the o-rings.

CAUTION
The core header plate must be less than a 1/2" from the housing face (core resting in o-rings) before driving the core in.
Failure to comply will result in damage to the core, housing and tool.

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Figure 8: Low Temp Core Install Tool
Item 1: Insertion Bolt
Item 2: Thumb Screw
Item 3: Removal Plate
Item 4: LT Core
Item 5: LT Housing
Item 6: Installation Plate
5.

Install the LT Core installation tool, per the tool instructions.

6.

Press the EGR cooler core into the housing until the core header plate makes contact with the housing seal.

CAUTION
DO NOT over­torque the bolt, as damage to the core may result. Typical installation will take less than 5 lb­ft of torque to
drive the core in. It is normal for the core to sit a couple millimeters off the face of the housing, and will seat/seal when the
front cover is installed.

CAUTION
Never use the front cover to drive the core into the housing. Damage to the tube to header braze will result. Always use the
tool, as it also aids in alignment of the core.

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Figure 9: EGR Outlet Cover
Item 1: Front Cover
Item 2: Ring Seal
7. Inspect the front cover for reuse--Review IK1201087 - Front Cover Reuse Guidelines for direction.
8. Remove the seal from the groove and discard.
9. Insert the new seal from the LT Core kit.

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Figure 10: EGR Outlet Cover, Bolts and Tubes
Item 1: EGR Outlet Tube Bolts
Item 2: Engine Harness Bracket Bolts
Item 3: EGR Outlet Cover Bolts
10. Install the front cover, noting the location of the stud bolt in Figure 10.
11. Resume the cooler assembly installation instructions in the service manual.
12. Use the Coolant Management Tool to refill the cooling system.
13. If the system in unable to maintain vacuum, perform a cooling system pressure decay test . If no external leaks can be
found, pressure test the EGR Cooler.

NOTE
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.

14. Per best practice, verify repair.

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.

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15. If you have issues/concerns/comments/etc, PLEASE SUBMIT FEEDBACK. We can't fix something if we don't know it's
an issue...

WARRANTY INFORMATION
Warranty Claim Coding:
Group: 12000 - Engine
Noun:

892 - Cooler, EGR

Warranty Claim Comment Guidance:
"Vehicle came in with 2659-21 and [coolant consumption / 111-1]. Replaced HT section, replaced LT core, performed
Lambda [diagnostics / replacement / relearn]."
"Vehicle in with [coolant consumption / 111-1]. Both HT and LT failed. Replaced HT section, replaced LT core, performed
Lambda [diagnostics / replacement / relearn]."
Standard Repair Times:
Step Description

SRT

Hours

LT CORE REPLACEMENT OFF CHASSIS

All ProStar+ LT Core R&R during HT replacement (add­on)

R12-6892U-6

0.3

All TranStar LT Core R&R during HT replacement (add­on)

Q12-6892U-6

0.3

All WorkStar R&R during HT replacement (add­on)

N12-6892U-6

0.3

All CAT CT660 LT Core R&R during HT replacement (add-on)

TC12-6892U-6

0.3

All PayStar LT Core R&R during HT replacement (add­on)

T12-6892U-6

0.3

All LoneStar LT Core R&R during HT replacement (add­on)

S12-6892U-6

0.3

ProStar+ Full Cooler Removal and Install

R12-6892U-20

5.8

TranStar Full Cooler Removal and Install

Q12-6892U-20

5.6

WorkStar Full Cooler Removal and Install

N12-6892U-20

6.1

CAT CT660 Full Cooler Removal and Install

TC12­6892U

6.4

PayStar Full Cooler Removal and Install

T12-6892U-20

5.6

LoneStar Full Cooler Removal and Install

S12-6892U-20

5.8

ProStar+122 LT Core Replacement in Chassis

R12-7892U-20

1.7

ProStar+113 LT Core Replacement in Chassis

R12-7892U

1.8

TranStar LT Core Replacement in Chassis

Q12­7892U

2.1

WorkStar LT Core Replacement in Chassis

N12­7892U

2.1

MODULE ASSEMBLY REMOVAL

LT CORE R&R IN CHASSIS

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

CAT CT660 LT Core Replacement in Chassis

TC12­7892U

Page 16 of 17

2.1

EGR COOLER PRESSURE TESTING IN CHASSIS
ProStar+122 Cooler Pressure Test

R12­7892U­4

2.9

ProStar+113 Cooler Pressure Test

R12­7892U­4

2.9

TranStar Cooler Pressure Test

Q12­7892U­4

2.6

WorkStar Cooler Pressure Test

N12­7892U­4

2.6

CAT CT660 Cooler Pressure Test

TC12-7892U-4

3.9

PayStar Cooler Pressure Test

T12­7892U­4

2.7

LoneStar Cooler Pressure Test

S12­7892U­4

2.9

EGR COOLER PRESSURE TEST (add-on, w/cooler removal)
ProStar+ In-Chassis Pressure test add-on

R12­6892U­1

0.8

TranStar In-Chassis Pressure test add-on

Q12­6892U­1

0.8

ProStar In-Chassis Pressure test add-on

N12­6892U­1

0.8

CAT CT660 In-Chassis Pressure test add-on

TC12-6892U-1

0.8

PayStar In-Chassis Pressure test add-on

T12­6892U­1

0.8

LoneStar In-Chassis Pressure test add-on

S12­6892U­1

0.8

HT or LT MODULE SEPARATION AND ASSEMBLY (for half cooler replacement)
ProStar+ Cooler Half R&R

R12­6892U­3

0.5

TranStar Cooler Half R&R

Q12­6892U­3

0.5

WorkStar Cooler Half R&R

N12­6892U­3

0.5

CAT CT660 Cooler Half R&R

TC12-6892U-3

0.5

LoneStar Cooler Half R&R

T12­6892U­3

0.5

PayStar Cooler Half R&R

S12­6892U­3

0.5

Cooling System Leak Test

A09-9022A

0.3

EGR Cooler Pressure Test (add­on if LT core replaced for
leaking)

R12-6892U-1

0.8

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

A12­1889U

0.6

Lambda Relearn or Replacement (see SRT section of iKNow)

IK1201065

MISCELLANEOUS RELEVANT SRTs

SRT Manual
CLAIM SRT EXAMPLES:
For PayStar/LoneStar, the SRT will be the cooler removal (x12-6892U-20) and cooler core R&R (x12­6892U­6)
Example 1: ProStar+122 has low flow code ONLY
Core R&R in­chassis ­ R12-7892U-20, 1.7 hrs
Example 2: ProStar+122 has external coolant leak
Cooler Removal - R12-6892U-20, 5.8 hrs
Cooler Separation/assembly - R12­6892U­3, 0.5 hrs

OTHER RESOURCES
2010 MaxxForce 11/13 Resource Center (IK1200548)
2010 MaxxForce 11/13 Diagnostic Manual

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2010 MaxxForce 11/13 Service Manual
LT Core Removal/Install Tool Instructions (TL2900085)
Front Cover Reuse Guidelines (iKNow 1201087)
ProStar Instructions (iKNow 1201096)

TranStar Instructions (iKNow 1201097)
WorkStar/CAT Instructions (iKNow 1201098)
HT Core Removal/Installation (iKNow 1201113)
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