Figure 2A

Figure 3A
27/57

NTB16-097

Compressor housing and wheel inspection (continued)

No
contact
marks

Compressor
wheel
Compressor
housing
Passes
inspection:
Passes
Replace
HP
inspection
turbocharger
(go to page 29)

Figure 4A

Compressor
wheel

Minor
contact
marks

Compressor
housing
Figure 5A

Compressor
housing
Compressor
wheel
Excessive
contact marks Fails Inspection
(go to page 56)

Figure 6A

Figure 7A

28/57

NTB16-097

Install High Pressure Turbocharger Assembly

1. Remove the high pressure turbocharger
from its packaging, and then install tape
where shown in Figure 57.

Tape
Figure 57
2. Install the oil drain line (see Figure 58).


Use a new gasket and O-ring.



Cummins O-ring P/N: 3029820.
NOTE: All parts in the parts kit are
labeled with Cummins part numbers.
See Parts Cross Reference List.



Bolts torque: 9.8 N•m (1.00 kg-m,
87 in-lbs)



Coat the O-ring with clean engine oil.

New O-ring
and gasket

Oil drain line
Bolts
Bolt

NOTE: The turbocharger compressor
outlet connection assembly will be
installed later on.

Figure 58

3. Remove the cap, tape, and plug shown
in Figure 59.

Tape
O-ring
under cap

4. Replace the low pressure turbocharger’s
O-ring with a new one (see Figure 59).


Cummins P/N: 2835314.

Plug

 See Parts Cross Reference
List.


Coat the O-ring with P80® Emulsion
(see PARTS INFORMATION and
the CAUTION below it).

29/57

Figure 59

NTB16-097

5. Position the new high pressure
turbocharger on the low pressure
turbocharger (see Figure 60).
a. Install a new gasket.

Banjo bolts



A gasket fits between the two
turbochargers.
b. Apply suitable anti-seize to the bolt’s
threads.
c. Loosely install the three (3) bolts
(see Figure 61).
NOTE: There are extra bolts in the
parts kit. Replace as needed.
CAUTION: Do not lean on the stage 2
fuel filter assembly at any time while it is
unbolted (see Figure 60).

6. Remove the tape, and then install both
banjo bolts finger tight with new copper
gaskets (see Figure 61).


Do not use the old copper gaskets.



The “low pressure” banjo bolt cannot
be seen in Figure 60 or 61.



Do not torque the banjo bolts at this
time.

NEVER lean on this part

Figure 60

Banjo
bolts

Figure 61

7. Fully insert the oil drain line with new
O-ring into the engine block, and then
install the bolt (see Figure 62).


Make sure the O-ring is coated with
engine oil.



Bolt torque: 9.8 N•m (1.00 kg-m,
87 in-lbs)

Bolt

Oil drain line
Figure 62

30/57

NTB16-097

8. Install the turbocharger compressor
outlet connection assembly.
a. Remove the cap and plug from the
high pressure turbocharger.
b. Coat the O-rings with P80® Emulsion
(see CAUTION under PARTS
INFORMATION).
c. Put the turbocharger compressor
outlet connection assembly in place.
d. Install two new bolts (see Figure 63).


Bolts

Step 8e

Do not reuse the old bolts. The
new bolts come with a thread
lock coating.

Figure 63

e. Install the T45 TORX® bolt finger
tight (see Figure 63).
 There are extra TORX® bolts in
the parts kit. Replace this bolt
as needed.

“High
pressure”
banjo bolt

9. Torque the three (3) bolts shown in
Figure 64.


Bolts torque: 32 N•m (3.3 kg-m,
24 ft-lbs)

Figure 64
10. Torque the banjo bolts (see Figure 64
and 65).


“High Pressure” banjo bolt torque:
22 N•m (2.2 kg-m, 16 ft-lbs)



“Low Pressure” banjo bolt torque:
34 N•m (3.5 kg-m, 25 ft-lbs)

“Low pressure”
banjo bolt

Figure 65

31/57

NTB16-097

11. Torque the T45 TORX® bolt, and two (2)
new bolts shown in Figure 66.



T45 TORX® torque: 18 N•m
(1.8 kg-m, 13 ft-lbs)

Step 13:
tape

Bolts

Step 12:
tape

Bolts torque: 10 N•m (1.0 kg-m,
84 in-lbs)

Step 11
Figure 66

12. Install the low pressure turbocharger
boost pressure sensor tube (see
Figure 67).


Remove the tape (see Figure 66).



Replace the O-ring with a new one
and coat it with P80® Emulsion.

Step 13

Clamp

 See PARTS INFORMATION and
the CAUTION below it.


Bolt C

Bolt B

Bolt A

Cummins P/N: 3779750
 See Parts Cross Reference
List.



Bolt A

Bolt A torque: 10.2 N•m (1.0 kg-m,
96 in-lbs)

Step 12: Tube

13. Install the high pressure turbocharger
speed sensor (see Figure 67).

Figure 67



Remove the tape (see Figure 66).



Replace the O-ring with a new one and coat it with P80® Emulsion.
 Cummins P/N: #3787623
 See PARTS INFORMATION and the CAUTION below it.



Bolt B torque: 10.2 N•m (1.0 kg-m, 96 in-lbs)



Bolt C torque: 5.5 N•m (0.56 kg-m, 49 in-lbs)

32/57

NTB16-097

“Air inlet”
assembly

14. Remove the cap from the low pressure
turbocharger, and then install the air
inlet connection assembly (see
Figure 68).
Screw


Clamp screw torque: 4.5 N•m
(0.46 kg-m, 40 in-lbs)

Figure 68



The air inlet connection assembly is
properly mated to the low pressure
turbocharger when the notch is
seated in the cut-out (see Figure 69
and 70).

Notch

Figure 69

Cap
removed

Cut-out

Figure 70

33/57

NTB16-097

15. Connect the two (2) connectors (see
Figure 71).

Connectors
Figure 71

16. Connect the vacuum hose (see
Figure 72).

Vacuum hose
Figure 72

17. Remove the tape, and then connect the
charge-air cooler tube to the charge-air
cooler outlet hose (see Figure 73).


Clamp nuts torque: 10 N•m
(1.0 kg-m, 84 in-lbs)

Nut

“Outlet” hose

“Cooler” tube
Figure 73

34/57

NTB16-097

18. Remove the plug, and then remove the
EGR bypass valve coolant tube (see
Figure 74).


Plug

Replace both O-rings with new ones
(# 4977258), and then coat them
with P80® Emulsion.

Step 18:
Coolant tube

 See the Parts Cross Reference
List, PARTS INFORMATION,
and the CAUTION below it.

Paint
mark

19. Fully insert the EGR bypass valve
coolant tube to the intake manifold
(see Figure 75).


Figure 74

The upper O-ring will hold the EGR
bypass valve coolant tube in place.

Step 19:
Tube

NOTE: The EGR bypass valve coolant
tube only needs to be in the generally
correct position at this time.

O-rings

NOTE: Make sure the paint mark(s) are
facing upward as shown in Figure 74
once the intake manifold is installed.


For additional reference, also see
page 38, Figure 84.

Step 20:
19:
O-rings

20. Replace the two water transfer
connection tube O-rings with new ones
(see Figure 75).


Coat the O-rings (# 5266152) with
P80 Emulsion.
 See the Parts Cross Reference
List, PARTS INFORMATION
and the CAUTION below it.

Figure 75

Press
in firmly

21. Install all O-ring gaskets in the intake
manifold (see Figure 75).


Make sure the surfaces the O-ring
gaskets come in contact with are
clean.



Make sure all O-rings are in place
and properly seated (see Figure 76).

35/57

Figure 76

NTB16-097

22. Replace the EGR bypass tube gasket
with a new one (see Figure 77).

Gasket

Figure 77

23. Install all eight (8) intake manifold bolts
in place (see Figure 78).


Use new bolts from the parts kit.
These bolts come with O-rings. They
are to hold the bolts in place.

