New Turbocharger Turbine Housing Repair Kit

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Technical Service Bulletin Number
TSB150095

Technical Service Bulletin

Subject
New Turbocharger Turbine Housing Repair Kit

Warranty Statement
The information in this document has no effect on present warranty coverage or repair
practices, nor does it authorize TRP or Campaign actions.

Contents
Product Affected

ISX12 G CM2180 EJ

Description of Change
This document announces the release of new HE300WG turbocharger turbine housing repair
kits, Part Numbers 4034271 and 4034272.
Service Instructions
The new turbocharger turbine housing repair kits, Part Number 4034271 or 4034272, are to be
used to replace the existing turbocharger turbine housing if the turbocharger housing does not
pass the inspection criteria or for the following conditions:

Turbocharger turbine intake temperature sensor seized
Turbocharger wastegate seized
Damaged turbocharger wastegate actuator
Broken capscrews

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New Turbocharger Turbine Housing Repair Kit

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Inlet flange does not meet reuse guidelines

NOTE: The turbine housing kit is not to be used for Grade 1 or 2 cracked turbine
housings. A cracked turbine housing with no signs of turbine wheel rubbing is not a
malfunctioning turbocharger and does not require replacement.
See the HE300WG Turbocharger Turbine Housing Reuse Guidelines, Bulletin 4367442.
See the ISX12 G CM2180 EJ Service Manual, Bulletin 4310682, for inspection criteria and
turbine housing removal and installation procedures. Refer to Procedure 010-033 in section
10.
Part Identification

Figure 1, Turbocharger Data Plate
1. Turbocharger Assembly Number - This is used on QuickServe® Online to determine
turbocharger kit number.
2. Turbocharger Serial Number
3. Turbocharger Part Number - This will be the kit number on a replacement turbocharger
4. Model Number
Service Parts Availability
See Figure 1 above for associated number locations in Table 1 below.

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Table 1, Service Parts
Assembly
Number
Option
(Figure 1, Item Number
1)

Original
Turbocharger Part
Number (Figure 1,
Item 3)

Replacement
Turbocharger Kit Part
Number (Figure 1,
Item 3)

New Turbine
Housing
Repair Kit Part
Number

3788265

PP20166
(Mid
Mount)

3788266

4352254*

4034271

3787965

PP20167
(Low
Mount)

3787966

4352139*

4034272

*NX Recon Equivalent Available
Table 2, Turbocharger Turbine Housing Repair Kit, Part Number 4034271
Part Number

Description

Quantity

2840781

Screw, hexagon head set

6

2839879

Plate, clamping

2

3786294

Kit, turbocharger gasket

1

5324845

Housing, turbine (with preset wastegate)

1

Table 3, Turbocharger Turbine Housing Repair Kit, Part Number 4034272
Part Number

Description

Quantity

2840781

Screw, hexagon head set

6

2839879

Plate, clamping

2

3786294

Kit, turbocharger gasket

1

5324846

Housing, turbine (with preset wastegate)

1

Publications Affected
See the ISX12 G CM2180 EJ Service Manual, Bulletin 4310682. Refer to Procedure 010-033
in section 10.
See the ISX12 G CM2180 EJ Service Manual, Bulletin 4310682. Refer to Procedure 010-050
in Section 10.
See the HE300WG Turbocharger Turbine Housing Reuse Guidelines, Bulletin 4367442

Document History

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7/6/2015

New Turbocharger Turbine Housing Repair Kit

Date
2015-6-12

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Details
Module Created

Last Modified: 23-Jun-2015
Copyright © 2000-2010 Cummins Inc. All rights reserved.

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010-033 Turbocharger

General Information
NOTE: Only those steps required for the
specific repair need to be completed.
Cleaning and compressor section removal
is not required for replacement of the
turbine housing.
NOTE: Before disassembly, check for
turbine and compressor blade damage.
Measure the bearing radial movement and
axial clearance to be sure that the bearing
housing is within the MIN/MAX limits.
Turbine Housing Kit
The Turbocharger Turbine Housing Repair Kit
should be used to replace the existing turbine
housing if the housing does not pass the
inpsection criteria or for the following
conditions:

Turbine intake temperature sensor
seized
Wastegate siezed
Damaged wastegate actuator
Broken capscrews
Inlet flange damage.

Initial Check

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Remove the intake pipe from the
turbocharger. See the Remove section in
this procedure.
Inspect the turbocharger compressor
impeller blades for damage.
Replace the turbocharger if damage is
found. See the Remove and Install
sections in this procedure.
If the compressor impeller is damaged,
inspect the intake piping and filter element
for damage.
Repair any damage before operating the
engine.

Remove the exhaust pipe from the
turbocharger. See the Remove section in
this procedure.
Inspect the turbine wheel for damage.
Replace the turbocharger if damage to the
turbine wheel is found. See the Remove
and Install sections in this procedure.

Inspect the turbine housing and wastegate
valve seat for white deposits. White
deposits in the turbine housing and
wastegate valve seat may indicate an
exhaust gas recirculation (EGR) cooler
leak. An EGR cooler leak that occurs for a
prolonged period of time may cause the
turbocharger wastegate valve to bind or
seize.
If white deposits are found, pressure test
the EGR cooler. Refer to Procedure 011019 in Section 11.
If the EGR cooler passes the pressure

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test, perform a cooling system Leak Test.
Refer to Procedure 008-020 in Section 8.
NOTE: Red or pink deposits are normal
and do not indicate that the EGR cooler
needs to be tested.

Axial Clearance Check

NOTE: The axial clearance check
can be performed with the
turbocharger mounted on the
engine.
Secure the turbine housing and
check the axial clearance using dial
depth gauge, Part Number ST537.
Push the rotor assembly away from
the gauge.
Set the gauge to zero.
Push the rotor assembly toward the
gauge and record the reading.

Rotor Assembly Axial Clearance
mm
0.127
0.025

in
MAX
MIN

0.005
0.001

If the axial clearance does not meet the
specification, the turbocharger must be
replaced. Go to the Remove and Install
sections in this procedure.

Radial Clearance Check

NOTE: The radial clearance check
can be performed with the
turbocharger mounted on the
engine.
Secure the turbine housing and
check the radial clearance using dial
depth gauge, Part Number ST537,

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configured to measure radial
distance.
Push the rotor assembly away from
the gauge.
Set the gauge to zero.
Push the rotor assembly toward the
gauge and record the reading.

Rotor Assembly Radial Clearance
mm
0.508
0.330

in
MAX
MIN

0.020
0.013

If the radial clearance does not meet the
specification, the turbocharger must be
replaced. Go to the Remove and Install
sections in this procedure.

Lubricating Oil Leak Check

Inspect the turbocharger compressor
intake and discharge for oil.
If oil is present in the compressor
intake as well as in the discharge,
check upstream in the turbocharger
for the source of the oil.

If oil is present only in the discharge side,
install the air intake and charge-air cooler
piping. See equipment manufacturer
service information.
Check for intake restriction. Refer to
Procedure 010-031 in Section 10.
NOTE: If the engine experiences a
turbocharger malfunction or any other
occasion where oil is put into the
charge-air system, the charge-air
system must be inspected and cleaned.

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Refer to Procedure 010-027 in Section
10.
NOTE: If the engine experiences a
turbocharger malfunction that results
in coolant or oil entering the intake, the
charge-air cooler system as well as the
fuel control housing must be inspected
and cleaned. Use the following
procedure for the charge-air cooler.
Refer to Procedure 010-027 in Section
10. Use the following procedure for the
fuel control housing. Refer to
Procedure 005-009 in Section 5.
NOTE: If the engine experiences a
turbocharger malfunction or any other
occasion where oil is put into the
exhaust, the aftertreatment
components must be inspected.
Inspect the exhaust catalyst. Refer to
Procedure 011-078 in Section 11.

Fluorescent Dye Tracer
Add one unit of fluorescent tracer, Part
Number 3376891, to each 38 liters [10 gal]
of engine lubricating oil.
Operate the engine at low idle for 10
minutes.

Shut the engine OFF.

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Allow the turbocharger to cool.
Remove the exhaust pipe from the turbine
housing. See the Remove Section in this
procedure.

Use a high-intensity black light, Part
Number 2892320, to inspect the turbine
outlet for leaks.
A yellow glow indicates an oil leak.

If oil is found in the turbine housing,
remove the oil drain line and check for
restrictions. Refer to Procedure 010-045 in
Section 10.
Clear any restrictions found.

If these checks do not reveal the problem,
remove the turbocharger. See the Remove
and Install sections in this procedure.

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Use a high-intensity black light, Part
Number 2892320, to inspect the turbine
inlet for leaks.
A yellow glow indicates an oil leak from
the engine.
If a yellow glow is not seen in the turbine
inlet, replace the turbocharger. See the
Remove and Install sections in this
procedure.

Install the exhaust pipe onto the
turbocharger turbine outlet and tighten the
clamp. See the Install section in this
procedure.
Install the intake pipe onto the
turbocharger compressor inlet and tighten
the clamp. See the Install section in this
procedure.

Leak Test
WARNING
Do not remove the pressure cap from a
hot engine. Wait until the coolant
temperature is below 50°C [120°F]
before removing the pressure cap.
Heated coolant spray or steam can

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