Using a clean emery cloth, clean turbine housing and mating surfaces.

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IK1200938 ­ Medium Duty (I6) High Pressure Turbo Center Section Replacement Proc... Page 13 of 30

Figure 11: Turbo Oil Drain Tube O-ring
Item 1: O­ring
Item 2: HP Turbocharger Oil drain tube
28.

Remove HP turbocharger oil drain O-ring (Figure 11, Item 1). Discard O­ring.

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IK1200938 ­ Medium Duty (I6) High Pressure Turbo Center Section Replacement Proc... Page 14 of 30

Figure 12: Oil Supply Tube to Low Pressure Turbocharger
Item 1: M6 X 16 Bolt
Item 2: Oil supply tube to Low Pressure Turbocharger
29.

Remove bolt (Figure 12, Item 1) from oil supply tube (Figure 12, Item 2), and discard bolt.

30.

Disconnect oil supply tube from LP turbocharger.

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IK1200938 ­ Medium Duty (I6) High Pressure Turbo Center Section Replacement Proc... Page 15 of 30

Figure 13: Oil Supply Tube at Oil Cooler Housing
Item 1: M6 X 12 Bolt
Item 2: Oil Supply Tube Assembly
Item 3: Turbocharger Oil Supply Tube Nut
Item 4: Fitting and O-ring (with screen)
31.

Remove M6 X 12 bolt (Figure 13, Item 1) securing turbocharger oil supply tube retainer from EGR cooler.

32.

Remove turbocharger oil supply tube nut (Figure 13, Item 3) from fitting and o-ring (Figure 13, Item 4) on the oil cooler housing and discard oil supply tube.

33.

Remove o-ring from fitting (Figure 13, Item 4) and discard.

34.

Refer to Service Manual for inspection and cleaning of oil supply tube fitting screen.

If center section is not available, remove center section from complete
turbocharger, and proceed to installation section.

If replacing LP Center Section proceed to IK1201238 Removal Section, Step 1.
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IK1200938 ­ Medium Duty (I6) High Pressure Turbo Center Section Replacement Proc... Page 16 of 30

REPAIR-INSTALLATION PROCEDURE
If replacing LP Center Section perform the installation steps in IK1201238 before
continuing.
1.

If HPCAC is internally contaminated with oil, refer to IK1201175 for the cleaning procedure.

2.

Install new O-ring (Figure 11, Item 1) onto the oil drain tube (Figure 11, Item 2) and lubricate with P­80.

Figure 14: HP Turbocharger Center Section Priming
Item 1: HP turbocharger center section
Item 2: Oil supply port
Item 3: Turbine wheel nut
Item 4: Oil drain port
3. Using 15W­40 engine oil, prime the new HP turbo center section oil supply port (Figure 14, Item 2) while spinning the turbine wheel nut (Figure 14, Item 3) until
oil begins exiting the oil drain port (Figure 14, Item 4).
WARNING
Make sure the oil drain tube is fully seated in the HP turbo when installing the turbo into the turbine housing. Failure to comply will result in personal
injury or damage to equipment.
4.

Install new HP turbo center section onto the HP oil drain tube while installing into the turbine housing.

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IK1200938 ­ Medium Duty (I6) High Pressure Turbo Center Section Replacement Proc... Page 17 of 30

Figure 15: Turbo Wastegate Actuator
Item 1: Turbine v-band clamp
Item 2: Wastegate actuator
Item 3: M8 x 16 bolt (2)
5.

Install turbine V-band clamp (Figure 15, Item 1) on HP turbocharger.

6. Using torque wrench, torque turbine V-band clamp (Figure 15, Item 1) to 13 lb-ft (17 N•m).

CAUTION
Be sure not to bend or damage the wastegate actuator rod and ensure it is positioned such that adjustment is not compromised.
Failure to do so may result in damage to equipment.
7.

Install wastegate actuator (Figure 15, Item 2) with two bolts (Figure 15, Item 3).

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IK1200938 ­ Medium Duty (I6) High Pressure Turbo Center Section Replacement Proc... Page 18 of 30

Figure 16: Turbo Oil Supply Tube
Item 1: M6 x 16 bolt
Item 2: Oil supply tube assembly
8.

Connect oil supply tube (Figure 16, Item 2) to HP turbocharger.

9.

Install oil supply tube (Figure 16, Item 2) and secure with new M6 X 16 bolt (Figure 16, Item 1).

10.

Torque M6 X 16 bolt to 110 in-lbs.

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IK1200938 ­ Medium Duty (I6) High Pressure Turbo Center Section Replacement Proc... Page 19 of 30

Figure 17: Oil Supply Tube to Low Pressure Turbocharger
Item 1: M6 X 16 Bolt
Item 2: Oil supply tube to Low Pressure Turbocharger
11.

Connect oil supply tube (Figure 17, Item 2) to LP turbocharger, secure with new M6 X 16 bolt (Figure 17, Item 1).

12.

Torque M6 X 16 bolt to 110 in-lbs.

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IK1200938 ­ Medium Duty (I6) High Pressure Turbo Center Section Replacement Proc... Page 20 of 30

Figure 18: Oil Supply Tube at Oil Cooler Housing
Item 1: M6 X 12 Bolt
Item 2: Oil Supply Tube Assembly
Item 3: Turbocharger Oil Supply Tube Nut
Item 4: Fitting and O-ring (with screen)
13.

Install new o-ring onto fitting (Figure 18, Item 4).

14.

Connect turbocharger oil supply tube nut (Figure 18, Item 3) to fitting and o-ring (Figure 18, Item 4) (with screen) on the oil cooler housing.

15.

Torque turbocharger oil supply tube nut (Figure 18, Item 3) to 18 lb­ft.

16.

Install M6 X 12 bolt securing turbocharger oil supply tube assembly retainer to EGR cooler. Torque M6 X 12 bolt (Figure 18, Item 1) to 110 in-lbs.

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IK1200938 ­ Medium Duty (I6) High Pressure Turbo Center Section Replacement Proc... Page 21 of 30

Figure 19: Turbo Oil Drain Tube
Item 1: Bolt
Item 2: Oil drain tube
Item 3: P-clamp
17.

Install bolt (Figure 19, Item 1) in P­clamp (Figure 19, Item 3) on oil drain tube (Figure 19, Item 2).

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IK1200938 ­ Medium Duty (I6) High Pressure Turbo Center Section Replacement Proc... Page 22 of 30

Figure 20: HP Turbocharger O-Ring
Item 1: 2.62 X 61.6 ID o­ring
Item 2: HP turbocharger
18.

Install new O-ring (Figure 20, Item 1) into groove on HP turbocharger (Figure 20, Item 2).

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IK1200938 ­ Medium Duty (I6) High Pressure Turbo Center Section Replacement Proc... Page 23 of 30

Figure 21: Turbo Crossover Tube
Item 1: V-band clamp
Item 2: Crossover tube

Follow steps 19 through 21 for non-ISC engines only.
19.

Inspect crossover tube (Figure 21, Item 2) seal for damage. If damaged, discard seal.

20. Apply P-80 or equivalent to outside of crossover tube seal and inside of interstage inlet duct. Push crossover tube onto crossover tube seal until it pops into
place.
21.

Install crossover tube (Figure 21, Item 2) on to HP turbocharger with V­band clamp (Figure 21, Item 1).

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IK1200938 ­ Medium Duty (I6) High Pressure Turbo Center Section Replacement Proc... Page 24 of 30

Figure 22: Turbocharger 2 Wastegate Control (TC2WC) Valve
Item 1: Bolt (2)
Item 2: TC2WC valve
Item 3: Insulator (2)
22.

Install TC2WC valve (Figure 22, Item 2) onto crossover tube with two insulators (Figure 22, Item 3) and bolts (Figure 22, Item 1).

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IK1200938 ­ Medium Duty (I6) High Pressure Turbo Center Section Replacement Proc... Page 25 of 30

Figure 23: ISC Outlet Seal Installation
Item 1: ZTSE4937-4 Press (3/4 inch Wrench is required to operate press)
Item 2: ISC Outlet
Item 3: ISC Outlet Lip Seal
23.

Apply P­80 to new ISC outlet lip seal.

24.

Position ZTSE4937­1A seal installer into ZTSE4937­4 (Figure 23, Item 1) press with new outlet lip seal (Figure 23, Item 3).

NOTE
Make sure the seal is properly aligned with the ISC outlet.
25.

Tighten forcing screw until seal installer is flush with the bottom of the outlet (Figure 23, Item 2).

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IK1200938 ­ Medium Duty (I6) High Pressure Turbo Center Section Replacement Proc... Page 26 of 30

Figure 24: Turbocharger Inlet Elbow
Item 1: Turbocharger inlet elbow
Item 2: V-band clamp

Follow steps 26 through 29 for only ISC equipped engines.
26.

Position turbocharger inlet elbow (Figure 24, Item 1) onto HP turbocharger with V­band clamp (Figure 24, Item 2) hand tight.

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IK1200938 ­ Medium Duty (I6) High Pressure Turbo Center Section Replacement Proc... Page 27 of 30

Figure 25: Interstage Cooler (ISC)
Item 1: M8 x 110 bolt (2)
Item 2: M8 x 110 stud bolt (2)
Item 3: Interstage cooler (ISC)
27.

Install ISC (Figure 25, Item 3) onto turbocharger inlet elbow and valve cover with two bolts (Figure 25, Item 1) and two stud bolts (Figure 25, Item 2).

28.

Using torque wrench, torque bolts and stud bolts to 23 lb-ft (31 N•m).

29.

Using torque wrench, torque V­band clamp to 13 lb­ft (17 N•m).

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IK1200938 ­ Medium Duty (I6) High Pressure Turbo Center Section Replacement Proc... Page 28 of 30

Figure 26: HPCAC Duct
Item 1: Clamp (2)
Item 2: HPCAC duct
Item 3: Bolt
Item 4: P-clamp
30.

Install HPCAC duct (Figure 26, Item 2) with two clamps (Figure 26, Item 1) .

31.

Install bolt (Figure 26, Item 3) in P­clamp (Figure 26, Item 4) on HPCAC duct (Figure 26, Item 2).

32.

Install air box and bracket with nut and two bolts.

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IK1200938 ­ Medium Duty (I6) High Pressure Turbo Center Section Replacement Proc... Page 29 of 30

Figure 27: MAF Sensor and Air Compressor Inlet Hose
Item 1: Air box
Item 2: Air compressor inlet hose
Item 3: LP turbocharger inlet elbow duct
Item 4: LP turbocharger inlet elbow duct clamp
Item 5: MAF sensor connector
Item 6: MAF sensor
33.

Install air box outlet into LP turbocharger inlet elbow duct (Figure 27, Item 3) and torque clamp (Figure 27, Item 4).

34.

Connect air compressor inlet hose (Figure 27, Item 2) to air box (Figure 27, Item 1).

35.

Connect MAF sensor connector (Figure 27, Item 5) to MAF sensor (Figure 27, Item 6).

36.

Install right side inner fender with four washers and bolts.

37.

Connect negative battery cable and close battery box.

38.

Run engine to verify proper operation, no leaks, and no fault codes.

39.

Close and latch hood.

40.

Remove wheel chocks.

41.

Connect to truck with EZ­Tech and using ServiceMaxx recalibrate the Mass Air Flow (MAF) Sensor
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IK1200938 ­ Medium Duty (I6) High Pressure Turbo Center Section Replacement Proc... Page 30 of 30

WARRANTY INFORMATION
Warranty Claim Coding:
Group: 12000 - Engine
Noun: 135 - Turbo, High Pressure or Single
Standard Repair Times:
SRTs are subject to change without notice, the time posted on the SRT homepage are correct and should be used.
High­PressureTurbo Center Section Replacement
Step Repair

Model

Engine

All H.P. Turbo Center Section Replacement

CE / BE

Engines below 245hp

All H.P. Turbo Center Section Replacement

CE / BE

Engines with 245hp and up

All H.P. Turbo Center Section Replacement

4300 / 4400

Engines below 245hp

SRT

High-Pressure Turbocharger Center
Section (SRTs)
All H.P. Turbo Center Section Replacement

4300 / 4400

Engines with 245hp and up

All H.P. Turbo Center Section Replacement

7300 / 7400 / 7500

Engines below 245hp

All H.P. Turbo Center Section Replacement

7300 / 7400 / 7500

Engines with 245hp and up

All

All

CAC Cleaning

High-Pressure CAC Cleaning (SRT)

Alternatively, the SRT code can be searched for, here.

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OTHER RESOURCES
2010 MaxxForce DT/9/10 Resource Center (IK1200549)
2010 MaxxForce DT/9/10 Diagnostic Manual
2010 MaxxForce DT/9/10 Service Manual
Master Service Information Site
Tools Resource Center (TL2900008)
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