property damage, personal injury, and / or death.
20. Ensure that the shut-off valve (Figure 10, Item 4) is closed and the regulator (Figure 10, Item 1) is backed off
completely.

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Figure #11: Connecting Shop Air
Item 1: Shop Air
Item 2: Regulator Assembly
Item 3: Shut­Off Valve

21. Connect shop air (Figure 11, Item 1) to the regulator assembly (Figure 11, Item 2).
22. Regulate air pressure to 60 PSI (Figure 11, Item 2).
23. Point the injector into a bucket, open the shut-off valve (Figure 11, Item 3) and watch the injector spray pattern. If
the injector is not misting the cleaning solution, clean the injector using a blow gun. Point the blow gun at the tip of the
injector and apply air pressure to clear any debris. Once complete insert the blow gun into the inlet of the injector, point
the injector into a bucket or towards the drain and apply air pressure for 30 seconds to 1 minute. If that doesn't fix the
issue, replace the injector and re-test.
24. Close the shut-off valve on the tank.
25. Ensure the shut-off valve (Figure 11, Item 3) is in the closed position, disconnect shop air (Figure 11, Item 1) from
the regulator assembly (Figure 11, Item 2) and allow the compressed air to completely discharge from the tank.
26. Remove hose assembly from injector.

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Figure #12: Inlet Elbow Removal
Item 1: Bolt (2)
Item 2: Engine Layover Harness

27. If needed, to aid in injector installation remove the two bolts (Figure 12, Item 1) securing the engine layover
harness (Figure 12, Item 2) to the engine harness support bracket.

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Figure #13: Injector Installation
Item 1: Injector Assembly
Item 2: Grommet

28. Install injector (Figure 13, Item 1) into the brass fitting (Figure 13, Item 2) on the inlet elbow, torque to 10 in-lb.

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Figure #14: Hose Assembly Fitting Installation
Item 1: Hose Assembly Fitting
Item 2: Injector
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.
CAUTION

Secure the Induction Cleaning Tool hoses away from hot and moving engine parts with cable ties while
performing cleaning.
29. Connect and secure hose assembly fitting (Figure 14, Item 1 ) onto injector (Figure 14, Item 2).
30. Connect to the 9 pin connector with an Electronic Service Tool (EST).
31. Open ServiceMaxx and connect to vehicle and start the engine.
32. If the engine is not already at operating temperature, warm up to 170 F (77 C).
33. Set cruise control to 1,500 RPM.
34. Once the engine is at operating temperature, record the Intake Manifold Temperature via ServiceMaxx.
CAUTION
In the event of engine shutdown, immediately shut off induction cleaning system tank valve to prevent intake
flooding. Failure to comply may result in property damage.

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35. Open the tank shut­off valve.

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NOTE
If a substantial amount of fluid is remaining in the tank after the test procedure is performed and IMT has
increased near previously recorded temperature, injector may be in need of service (12­544­01).
36. During injection of the cleaning solution monitor the Intake Manifold Temperature, the IMT will drop while the
cleaning solution is being injected. The cleaning typically lasts between 40 and 60 minutes.
37. A rise in Intake Manifold Temperature signals the end of the procedure. Allow the engine to run for an additional 5
minutes at 1,500 RPM before shutting down.
38. Close the Shut-Off valve on the tank.
39. Shut down the engine.

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INSTALLATION PROCEDURE
1. Disconnect the Electronic Service Tool (EST) from the 9 pin connector.

Figure #15: Hose Assembly Fitting Removal
Item 1: Injector
Item 2: Hose Assembly Fitting
2. Remove the hose fitting assembly (Figure 15, Item 2) from the injector (Figure 15, Item 1).

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Figure #16: Injector Removal
Item 1: Injector
Item 2: Brass Fitting
3. Remove the injector (Figure 16, Item 1) from the brass fitting (Figure 16, Item 2) on the inlet elbow.

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Figure #17: Discharging Compressed Air
Item 1: Shop Air
Item 2: Regulator Assembly
Item 3: Shut­Off Valve
WARNING
Before performing Step 3, make sure pressure regulator is set to 0 psi. Failure to comply may result in
property damage, personal injury, and / or death.
4. Ensure the shut-off valve (Figure 17, Item 3) is in the closed position, disconnect shop air (Figure 17, Item 1) from
the regulator assembly (Figure 17, Figure 2) and allow the compressed air to completely discharge from the tank.

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Figure #18: Verify Cleaning Solution Level
Item 1: Lid
Item 2: Tank
5. Once the compressed air has been exhausted, remove the lid (Figure 18, Item 2) from the tank (Figure 18, Item 1)
and verify level of fluid remaining is minimal.

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Figure #19: Removing Vent Hoses
Item 1: Vent Hose
Item 2: Breather Redirect Tube
Item 3: Turbocharger Down Pipe Vent Hose
6. Remove breather redirect tube (Figure 19, Item 2) and turbocharger down pipe vent hose (Figure 19, Item 3) from
vent hose (Figure 19, Item 1).

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Figure #20: Removing Road Draft Tube Vent
Item 1: Road Draft Tube
Item 2: Breather Redirect Tube
7. Remove the breather redirect tube (Figure 20, Item 2) from the road draft tube (Figure 20, Item 1).

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Figure #21: Turbocharger Down Pipe
Item 1: Turbocharger Down Pipe Clamp
Item 2: Turbocharger Down Pipe
8. Loosen the turbocharger down pipe clamp (Figure 21, Item 1).

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Figure #22: Repositioning Turbocharger Down Pipe
Item 1: Turbocharger Down Pipe
Item 2: Jack Stand
Item 3: Turbocharger Down Pipe Vent Hose
Item 4: DOC Inlet
9. Remove turbocharger down pipe vent hose (Figure 22, Item 3) and reposition turbocharger down pipe (Figure 22,
Item 1) onto the DOC inlet (Figure 22, Item 4) for installation.

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Figure #23: Re-connecting DOC
Item 1: Nut (2)
Item 2: Bolts (2)
Item 3: Nuts (2)
Item 4: Turbocharger Down Pipe
Item 5: DOC Inlet
10. Install two bolts (Figure 23, Item 2) and two nuts (Figure 23, Item 1) securing the DOC to the DOC hanger
Bracket.
11. Torque the two bolts (Figure 23, Item 2) and two nuts (Figure 23, Item 1) to 35 to 46 lbf-ft.
12. Install two nuts (Figure 23, Item 3) to secure the turbocharger down pipe (Figure 23, Item 4)to the DOC inlet
(Figure 23, Item 5).
13. Torque the two nuts (Figure 23, Item 3) to 35 to 37 lbf-ft.
14. Torque the turbocharger down pipe clamp (Figure 21, Item 1) to 124 to 168 inch lbs.

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Figure #24: Re-connecting EGR Valve
Item 1: EGR Valve Electrical Connector
Item 2: EGR Valve
15. Reconnect the EGR Valve Electrical connector (Figure 24, Item 1) onto the EGR Valve (Figure 24, Item 2).

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Figure #25: 12-544-01-19 Removal
Item 1: 12-544-01-19
Item 2: Inlet Duct
Item 3: Clamp (2)
Item 4: Boost Line
16. Remove the boost line (Figure 25, Item 2) from 12-544-01-19 (Figure 25, Item 1).
17. Loosen the two hose clamps (Figure 25, Item 3) and remove the inlet duct from 12-544-01-19(Figure 25, Item
3) then remove 12-544-01-19.

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Figure #26: Inlet Elbow Re-installation
Item 1: Boost Line
Item 2: Inlet Elbow
Item 3: Inlet Duct
Item 4: Clamp (2)
18. Re-install the original inlet elbow (Figure 26, Item 2) and inlet duct (Figure 26, Item 3) with two clamps (Figure 26,
Item 4).
19. Torque the clamps (Figure 26, Item 4) to 48 in lbs.
20. Re-install the boost line (Figure 26, Item 1) onto the inlet elbow (Figure 26, Item 4) .

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Figure #27: Engine Layover Harness Installation
Item 1: Bolt (2)
Item 2: Engine Layover Harness

21. If removed, re-align the engine layover harness (Figure 27, Item 2) with the engine harness support bracket and
install the two previously removed bolts (Figure 27, Item 1).
22. Torque bolts (Figure 27, Item 1) to 100 in lbs.
23. Replace engine oil, and oil filter. Refer to EPA 10 MaxxForce 7 Engine Service Manual.
24. Close and latch hood.
25. Remove wheel chocks.
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WARRANTY INFORMATION
Claim Requirements/Approvals:
None
Warranty Claim Coding:
Group: 12000 - Description
Noun: 135 - Description
Warranty Coding Manual

Step

Description

Chassis

Engine

SRT

Hours

All

Turbocharger Cleaning

TerraStar

MaxxForce 7 EPA 10

TS12­6135X­21

2.8

All

Turbocharger Cleaning

A / E Bus

MaxxForce 7 EPA 10

TG12­6135X­21

2.8

All

Turbocharger Cleaning

DuraStar

MaxxForce 7 EPA 10

KL12­6135X­21

2.8

All

Turbocharger Cleaning

CE / BE

MaxxForce 7 EPA 10

GY12-6135X-21

2.8

OTHER RESOURCES
Master Service Information Site
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