IK1200656 ­ Turbocharger Coking: How to Clean

Page 1 of 3

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AUSTRALIA, BAHAMAS, BOLIVIA, BELIZE, CANADA, CHILE,
TAIWAN, COLOMBIA, COSTA RICA, DOMINICAN REPUBLIC,
ECUADOR, EL SALVADOR, TRINIDAD AND TOBAGO, UNITED
Document
STATES, URUGUAY, VENEZUELA, ARUBA, NICARAGUA, PERU,
IK1200656
ID:
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HONDURAS, JAMAICA, KOREA, SOUTH KOREA, NEW
ZEALAND, PANAMA

Availability: ISIS, Bus ISIS, FleetISIS
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Revision: 12
Created:

10/7/2011

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Last
Modified:

12/18/2015

Author:

Alex
Buzgau

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Title : Turbocharger Coking: How to Clean
Applies To : 2010 I6 MaxxForce Engines DT, 9, and 10 - ESN 3300000 through 3999999

CHANGE LOG
Please refer to the change log text box below for recent changes to this article:
12/18/2015 - Added warranty information section.
06/19/2015 - Author updated for feedback purposes.
04/06/2015 - Author updated for feedback purposes.
02/17/2015 - Added Australia and New Zealand to country coding.




DESCRIPTION
Turbocharger has soot built up on the impeller. The main cause of this condition is oil carry over in the intake system. Medium to light coking does NOT affect
engine performance.

SYMPTOMS
Low power due to low boost pressure

TROUBLESHOOTING
1. Remove intake piping attached to turbos.
2. Inspect for coking (Figure 1).

Figure 1:
Two examples of turbo coking. Both cases caused low boost pressure and resulted in
frequent regens.
RESOLUTION
If coking is found:
1. Use the
NEW I334 turbo cleaning kit P/N 7091592C91 to clean turbocharger.
- DO NOT remove Turbochargers
­F
ollow procedure included in the: turbo cleaning kit instructions
2. Diagnose root cause of coking. Inspect for the following conditions:

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IK1200656 ­ Turbocharger Coking: How to Clean

Page 2 of 3

• Oil breather for proper operation See IK1200914
• Excessive Crankcase pressure
• Excessive idling operation
• Engine running poorly
• Air Cleaner restriction
• Use test equipment ZTSE­4341 to perform the air leak test
4. Diagnosing Turbocharger Oil Discharge:
• iKNow articles: IK1200535
• Check ITV for proper operation: iKNow article: IK1200466
5. Boost leaks:
• Include CAC pressure test per s12006
• Reference Low Power due to low boost: iKNow article IK1200648

Turbo replacement is only required with the following conditions:
1. Turbo does not spin freely (some contributing conditions):
• Excessive coking behind compressor wheel
• Excessive axial play causing contact with the housing
• Fin / housing interference (metal to metal)
• Any foreign object damage to the compressor wheel
- During cleaning, interference is identified during housing inspection
2. Turbo Oil discharge:
- Turbocharger Oil Discharge Diagnostic Tree (click on links below):
• Diagnosing Turbocharger Oil Discharge From the Compressor Outlet
• Diagnosing Turbocharger Oil Discharge From the Turbine Outlet

FINAL STEPS
After any exhaust or intake system repair, the following steps must be completed:
1. Mass Air Flow (MAF) calibration.
2. On Board Filter Cleanliness Test (OBFCT).
3. 0-60 mph Performance test and snapshot to confirm EBP and Boost meet specifications per EGES 455.
NOTE:
It is best to record OBFCT and 0-60 mph with snapshots in case it becomes necessary to review with I6 Tech Service.

This new cleaning process will, in most cases, eliminate the need for complete turbocharger replacement related to low power complaints.
Turbochargers that DO NOT meet the above replacement criteria, and have been replaced under warranty, will no longer be supported.

WARRANTY INFORMATION
Warranty Claim Coding:
Group: 12000 - Engines
135 - Twin Turbocharger Assembly, High Pressure Turbo
Noun:
505 - Twin Turbocharger Assembly, Low Pressure Turbo

Standard Repair Time(s):
Description

Chassis

Engine

TURBOCHARGER,
CLEANING

Models, ALL

MAXXFORCE
DT/9/10

Qualifier 1

Qualifier 2

SRT

Hours

A12-6135K-20

Link
to

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IK1200656 ­ Turbocharger Coking: How to Clean

Models, ALL

Page 3 of 3

MAXXFORCE 11/13
MAXXFORCE
DT/9/10

Pre 2010 EPA
With 2010 Emission
Engines

HC Bus

MAXXFORCE 7

2010 Emissions

CE

MAXXFORCE 7

HC Bus

CE / BE

E12-6135T-20
E12-6135X-21
G12-6135J-20

MAXXFORCE
DT/9/10
MAXXFORCE
DT/9/10

CE / BE

A12-6135L-20
W/245 H.P. and Above
Engines

With 2010 Emission
Engines
With 2010 Emission
Engines

Engines below 245 HP

GY12­6135T­21

W/245 H.P. and Above
Engines

GY12-6135T-22

Updated SRT

GY12-6135TS21

CE / BE

N 9/10

CE / BE

MAXXFORCE 7

4100

MAXXFORCE 7

J12-6135J-20

4300 M7

MAXXFORCE 7

K12-6135J-20

4300,4400
4300,4400

2010 Emissions

MAXXFORCE
DT/9/10
MAXXFORCE
DT/9/10

With 2010 Emission
Engines
With 2010 Emission
Engines

4300,4400

N 9/10

4300,4400

MAXXFORCE 7

2010 Emissions

MAXXFORCE
DT/9/10
MAXXFORCE
DT/9/10

With 2010 Emission
Engines
With 2010 Emission
Engines

7300, 7400, 7500
7300, 7400, 7500

GY12­6135X­21

Engines below 245 HP

KL12­6135T­21

W/245 H.P. and Above
Engines

KL12-6135T-22

Updated SRT

KL12-6135TS21

Hours

KL12­6135X­21
Engines below 245 HP

M12-6135T-22

W/245 H.P. and Above
Engines

M12-6135T-23

Updated SRT

M12-6135TS-21

7300, 7400, 7500

N 9/10

A/E Bus

MAXXFORCE 7

2010 Emissions

TG12­6135X­21

TerraStar

MAXXFORCE 7

2010 Emissions

TS12­6135X­21

AC Bus

MAXXFORCE 7

2010 Emissions

V12-6135X-21

BE

MAXXFORCE 7

Y12-6135J-20

3200

MAXXFORCE 7

Z12-6135J-20

Add-on If Required:
Description

Chassis

Qualifier 1

Qualifier 2

MAXXFORCE
DT/9/10

Turbocharger H.P. Center Section,
Replace Add-On

ENGINES
2010 Emissions BELOW 245
H.P.

CE / BE

MAXXFORCE
DT/9/10

Turbocharger H.P. Center Section,
Replace Add-On

2010
Emissions

Turbocharger L.P.
Center Section,
Replace

4300,4400

MAXXFORCE
DT/9/10

Turbocharger H.P. Center Section,
Replace Add-On

ENGINES
2010 Emissions BELOW 245
H.P.

KL12-6135T
­1

Turbocharger L.P.
Center Section,
Replace

4300,4400

MAXXFORCE
DT/9/10

Turbocharger H.P. Center Section,
Replace Add-On

Turbocharger L.P.
Center Section,
Replace

7300, 7400,
7500

MAXXFORCE
DT/9/10

Turbocharger H.P. Center Section,
Replace Add-On

ENGINES
2010 Emissions BELOW 245
H.P.

M12-6135T1

Turbocharger L.P.
Center Section,
Replace

7300, 7400,
7500

MAXXFORCE
DT/9/10

Turbocharger H.P. Center Section,
Replace Add-On

ENGINES 245
M12-6135T2010 Emissions H.P. AND
2
ABOVE

Turbocharger L.P.
Center Section,
Replace

CE / BE

Turbocharger L.P.
Center Section,
Replace

Hide Details

Engine

Qualifier 3

SRT

Hours

GY12­
6135T-1

ENGINES 245
GY12­
H.P. AND
6135T-2
ABOVE

Link to
Hours
ENGINES 245
KL12-6135T
2010 Emissions H.P. AND
­2
ABOVE

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