IK1201173 ­ EPA 10 MaxxForce 7 Turbocharger Cleaning

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IK1201173

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2

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ENGINES

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8/1/2014

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Author:

5/11/2015
Caleb
Iverson

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Title : EPA 10 MaxxForce 7 Turbocharger Cleaning
Applies To : Cleaning, Induction cleaning, Turbocharger cleaning, turbochargers,

CHANGE LOG
2015/05/07 - Added Injector cleaning procedure to step 23
2014/12/10 - Added replace/retire to description
2014/12/01 - Initial Article Release

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QUICK LINKS
Description

Symptoms

Tools

Parts

Diagnostics

Repair-Removal

Repair-Installation

Warranty

DESCRIPTION
The current repair for turbochargers calls for replacement, anytime the compressor housing is found fouled/coked. A
new procedure will allow cleaning of the turbo without removing it from the engine, and utilizes the induction cleaner tool
with adapters. This document will cover the repair procedure for cleaning turbochargers on EPA 10 MaxxForce 7
Engines.
This Document replaces / retires the following:
• TR3000011 - MaxxForce® 7 Turbocharger Compressor Cleaning
• IK1200965 - 2010 ­ 2013 MaxxForce 7 Turbo Cleaning

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SYMPTOMS
See symptoms leading to iKNows IK1201172.
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SPECIAL TOOLS
Tool Description

Tool Number

Comments

Instructions

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IK1201173 ­ EPA 10 MaxxForce 7 Turbocharger Cleaning

Medium Duty Induction Cleaner

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12­544­02
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IK1201173 ­ EPA 10 MaxxForce 7 Turbocharger Cleaning

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SERVICE PARTS INFORMATION

Kit Description

Part Number

Quantity
Required

Notes

Cleaning Solution

3015979C1

1

Parts Catalog

Oil Filter Kit

1899332C91

1

Parts Catalog

Engine Oil

Source Locally

As Needed Source Locally

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PROCEDURE OVERVIEW
WARNING
To prevent personal injury or death, read all safety instructions in the "Safety Information" section of the
diagnostic manual, linked here.
WARNING
To prevent personal injury or death, shift transmission to park or neutral, set parking brake, and block wheels
before doing diagnostic or service procedures.
WARNING
To prevent personal injury or death, make sure the engine has cooled before removing components.
WARNING
To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and nails using
hand cleaner and wash with soap and water. Wash or discard clothing and rags contaminated with engine
fluids.
WARNING
Install crankcase breather tube into shop exhaust vent. Failure to comply may result in personal injury / or
death.
WARNING
Always wear safe eye protection when performing vehicle maintenance. Failure to do so may result in
personal injury and / or death.
WARNING
Park vehicle on hard flat surface, turn the engine off, set the parking brake, and block the wheels to prevent
the vehicle from moving in either direction. Failure to do so may result in property damage, personal injury,
and / or death.
WARNING
When cleaning turbochargers on MaxxForce® 7 (EPA 10) with HD-OBD engine, connect the Induction
Cleaning Tool only if the vehicle is parked and the parking brake is set. Never drive the vehicle with the
Induction Cleaning Tool (or hoses) connected to the engine. Failure to comply may result in property
damage, personal injury, and / or death.

DIAGNOSTIC STEPS
All diagnostics should be completed through either of the following iKNows; IK1201172.
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IK1201173 ­ EPA 10 MaxxForce 7 Turbocharger Cleaning

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REPAIR STEPS
REMOVAL PROCEDURE
1. Bring truck into shop and park on flat surface.
2. Shift transmission to Park or Neutral, set parking brake, and install wheel chocks.
3. Unlatch and open hood.

Figure #1: Inlet Elbow Removal
Item 1: Boost Line
Item 2: Inlet Elbow
Item 3: Inlet Duct
Item 4: Clamp (2)

4. Remove boost line (Figure 1, Item 1) from turbo inlet elbow (Figure 1, Item 2).
5. Loosen the two hose clamps (Figure 1, Item 4) on the inlet elbow and remove inlet duct (Figure 1, Item 3) from inlet
elbow, then remove inlet elbow (Figure 1, Item 2).

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Figure #2: 12-544-01-19 Installation
Item 1: Turbocharger Inlet Adapter (12-544-01-19)
Item 2: Inlet Duct
Item 3: Clamp (2)
Item 4: Boost Line
6. Install Turbocharger Inlet Adapter (12-544-01-19) (Figure 2, Item 1), then re-install inlet duct (Figure 2, Item
2) and torque both clamps to 48 in lbs.
7. Re-install boost line (Figure 2, Item 4) onto Turbocharger Inlet Adapter (12­544­01­19) (Figure 2, Item 1).

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Figure #3: Disconnecting EGR Valve
Item 1: EGR Valve Electrical Connector
Item 2: EGR Valve

CAUTION
Position Exhaust Gas Recirculation (EGR) valve connector away from any moving/hot components and
surfaces, failure to comply may result in property damage.
8. Disconnect the EGR Valve electrical connector (Figure 3, Item 1) from EGR Valve (Figure 3, Item 2), and reposition
as necessary.

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IK1201173 ­ EPA 10 MaxxForce 7 Turbocharger Cleaning

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Figure #4: Loosening Turbocharger Down Pipe
Item 1: Turbocharger Down Pipe Clamp
Item 2: Turbocharger Down Pipe
9. Loosen turbocharger down pipe clamp (Figure 4, Item 1).

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Figure #5: Disconnecting DOC
Item 1: Bolt
Item 2: Nut (2)
Item 3: Nut (2)
Item 4: Turbocharger Down Pipe
Item 5: DOC Inlet

10. Remove two nuts (Figure 5, Item 3) securing the turbocharger down pipe (Figure 5, Item 4) to the DOC inlet
(Figure 5, Item 5).
11. Remove two nuts (Figure 5, Item 2) and two bolts (Figure 5, Item 1) from DOC hanger bracket.

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Figure #6: Repositioning Turbocharger Down Pipe
Item 1: Turbocharger Down Pipe
Item 2: Jack Stand
Item 3: Turbocharger Down Pipe Vent Tube
Item 4: DOC

CAUTION
Redirecting the exhaust flow is critical, failure to do so may result in damage to equipment.
12. Reposition the turbocharger down pipe (Figure 6, Item 1) so exhaust flow doesn't enter the DOC (Figure 6, Item
4), if needed use a jack stand (Figure 6, Item 2) to assist in repositioning.
13. Torque turbocharger down pipe clamp (Figure 4, Item 1) to 124 to 168 in lbs.
14. Install turbocharger down pipe vent hose (Figure 6, Item 3).

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Figure #7: Installing Road Draft Tube Vent
Item 1: Road Draft Tube
Item 2: Breather Redirect Tube

WARNING
Install crankcase breather tube into shop exhaust vent. Failure to comply may result in personal injury and /
or death.

15. Install breather redirect tube (Figure 7, Item 2) onto road draft tube (Figure 7, Item 1).

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Figure #8: Vent Hose
Item 1: Vent Hose
Item 2: Breather Redirect Tube
Item 3: Turbocharger Down Pipe Vent Hose

WARNING
Install crankcase breather tube and turbocharger down pipe vent tube into shop exhaust vent. Failure to
comply may result in personal injury and / or death.

16. Install vent hose (Figure 8, Item 1) to turbocharger down pipe vent hose (Figure 8, Item 3) and breather redirect
tube (Figure 8, Item 2).

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Figure #9: Filling Tank
Item 1: Tank
Item 2: SMT250
NOTE
In some instances, the EGR cleaning solution has been found to crystallize due to freezing temperatures. If
you find any crystallization in the fluid, drain the induction cleaning system tank assembly of any solution,
and start over with a fresh bottle of solution until no crystallization is found, Using a crystallized solution in
the induction cleaning system will cause blockage and will not perform as intended.
17. Remove lid from tank, install filter element (Figure 9, Item 2), then fill the tank with the 2.5 gallon container of
Cleaning Solution and 2.5 gallons of clean water.

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Figure #10: Tank Installation
Item 1: Regulator
Item 2: Lid
Item 3: Tank
Item 4: Shut-Off Valve

18. Re-install lid (Figure 10, Item 2) and secure to tank (Figure 10, Item 3).
19. Secure the hose assembly to the injector.
WARNING
Before performing Step 20, make sure pressure regulator is set to 0 psi. Failure to comply may result in