IK1201105 ­ I­6 Engine Hydro­locked

Page 1 of 4

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IK1201105
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3/24/2014

Greg
Tomaszkiewicz

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47

5

Title : I-6 Engine Hydro-locked
Applies To : MaxxForce DT, 9, 10, N9 & N10

CHANGE LOG
Please refer to the change log text box below for recent changes to this article:
12/2/15 - Removed link to IK1201086 in step 4 (matured document).
6/5/15 - Added change log, updated SRT codes to correct coding and clarified what parts need to be changed for a hydrolocked cylinder
3/24/14 - Published




DESCRIPTION
Standard repair procedure for a hydrolocked engine.
SYMPTOM(s)
1.
2.
3.
4.
5.

Engine will not crank
Engine will not start
Engine overheat
Coolant loss
Slow cranking speed

DIAGNOSTICS

1. Verify the complaint by attempting to bar the engine over by the dampener bolts. If the engine will turn over with minimal
effort proceed to step 2 if difficult or unable to turn over proceed to step 3.
2. Pressure test the cooling system per the applicable engine service manual.
3. If applicable remove the inter­stage cooler and check for the presence of coolant at the inlet port. If no coolant is present or
unit is not equipped with inter-stage cooler proceed to step 4, if coolant is present see the engine service manual
0000001624 Engine Symptom Diagnostics for inter-stage testing, then proceed to step 5.
4. Pressure test the EGR cooler following the diagnostic manual. If a leak is found proceed to step 5, if no leak is present
reassemble and retest for complaint.
5. Remove all 6 fuel injectors, bar each cylinder to TDC (top dead center) and remove coolant from the cylinder using a hand
operated vacuum tool. Once completed, check for a bent connecting rod using the following procedure.

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IK1201105 ­ I­6 Engine Hydro­locked

Page 2 of 4

Piston Height Measurement (Shown in figure 1 below)

Use a Vernier Caliper depth probe to measure distance between the bottom of each injector cup to the top of the piston crown
when the piston is at TDC.
1. Extend the depth probe and place it inside the injector cup so that the main scale rests against the bottom of the
injector cup and the probe extends into the cylinder.
2. Hold caliper in place while someone else bars over the engine slowly by hand towards TDC.
3. Continue barring the engine slowly by hand until the piston moves past TDC; the piston will push the depth probe to
the shortest possible measurement.
4. Record the value in the table below.
5. Repeat 3 times for each cylinder.
6. Use the 3 readings to determine the average measurement of the cylinder.
7. Compare the readings to the other cylinders. A difference of .007” in (0.1778 mm) or more indicates a possible bent
connecting rod.
If a bent connecting rod is found remove the cylinder head & replace the connecting rod & cylinder kit (piston, rings, liner,
bearings) then road test to verify repair.

Note: A hydro-locked cylinder only causes damage to components in that cylinder. Components in all other cylinders can still be
used. i.e. if there is a bent rod in cylinder 1 and 2, do not replace rods or cylinder kits in any of the remaining cylinders.
(Cylinder head, Turbochargers, Injectors etc. should not need to be replaced, if further guidance is needed please contact tech services)
Cylinder #

1

2

3

4

5

6

Measurement 1
Measurement 2
Measurement 3
Total
Total ÷ 3 =
Average

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IK1201105 ­ I­6 Engine Hydro­locked

Page 3 of 4

Related SRT’s:
12 - EGR Cooler Pressure Test, In Vehicle
Hours

Code

1.4

Model

Engine

Models, ALL

MAXXFORCE DT/9/10

Qualifier 1
With 2010 Emission
Engines

A12-6892T-20
Models, ALL

MAXXFORCE DT/9/10

Qualifier 2
Use only when EGR
Cooler is not replaced
With Centrifugal Oil
Filter
(Frame
Mounted)

With 2010 Emission
Engines
12 – Only EGR Cooler, Replace (If cylinder head is removed EGR cooler R&R is included)

1.5

A12-6892T-21

Group 1200 Noun 892
Hours

Code

Model

Engine

Qualifier 1

Qualifier 2

4.9

E12-6892T

HC Bus

MAXXFORCE DT/9/10

With 2010 Emission
Engines

Engines with 245 HP
and Up

4.6

E12-6892T-20

HC Bus

MAXXFORCE DT/9/10

With 2010 Emission
Engines

Engines below 245 HP

4.6

G12-6892T

CE

MAXXFORCE DT/9/10

With 2010 Emission
Engines

Engines below
245 HP

4.9

GY12-6892T

CE / BE

MAXXFORCE DT/9/10

With 2010 Emission
Engines

Engines with 245 HP
and Up

5.6

I12-6892T-20

RE

MAXXFORCE DT/9/10

With 2010 Emission
Engines

2010 Emissions Level

6.7

K12-6892T

4300

MAXXFORCE DT/9/10

With 2010 Emission
Engines

Engines below 245 HP

7.2

KL12-6892T

4300, 4400

MAXXFORCE DT/9/10

With 2010 Emission
Engines