IK1201134 ­ 2010 EPA MaxxForce® 15L HP Turbo Center Cartridge Replacement

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CANADA, UNITED STATES, MEXICO Document ID: IK1201134

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ENGINES

Created:

6/3/2014

Current Language: English

Last Modified: 6/16/2014

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Dominic Venice

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Title : 2010 EPA MaxxForce® 15L HP Turbo Center Cartridge Replacement
Applies To : 2010 EPA MaxxForce® 15L

CHANGE LOG:
Dealers: Please refer to the change log text box below for recent changes to this article:
6/4/2014 - Launch to field.
6/11/2014- Added photos and corrected spelling error
6/16/14 - Modified format




DESCRIPTION:
This article provides the service procedure for replacing the High­Pressure (HP) turbocharger center section on 2010 EPA MaxxForce®15 engines.

SPECIAL TOOL(s) or SOFTWARE:
Tool Description

Tool Number

Navistar Coolant Managment Tool

KL5007NAV

Kit, CAC Cleaning

09­925­01

Comments

SERVICE PART(s) INFORMATION:
Kit Description

Part Number

Quantity Required

Ordering Instructions

KIT, TURBO HP

3014694C91

1

Order from Navistar

HOSE ASSY, HP TURBO OIL SUPPLY

3008174C92

1

Order from Navistar

NOTE: A center section kit is not offered for the 15L, use a COMPLETE turbocharger assembly and simply remove the center
section from the assembly. Return the old center section and the NEW turbine housing together in the box.

SERVICE PROCEDURE:

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
both directions. Failure to comply may result in property damage, personal injury, and / or death.

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IK1201134 ­ 2010 EPA MaxxForce® 15L HP Turbo Center Cartridge Replacement

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WARNING:
If the vehicle must be raised, do not work under the vehicle supported only by jacks. Jacks can slip or fall over, potentially resulting in
property damage, personal injury, and / or death.

WARNING:
Always wear safe eye protection when performing vehicle maintenance. Failure to comply may result in personal injury and / or death.

WARNING:
Keep flames or sparks away from vehicle and do not smoke while servicing the vehicle’s batteries. Batteries expel explosive gases.
Failure to comply may result in property damage, personal injury, and / or death.

WARNING:
Remove the ground cable from the negative terminal of the battery box before disconnecting any electrical components. Always connect
the ground cable last. Failure to comply may result in property damage, personal injury, and / or death.

Removal:
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.
4. Using Navistar Coolant Management Tool KL5007NAV, drain coolant from system. Place suitable drain pan under truck to collect any remaining coolant
throughout procedure.
5. Remove the components necessary to gain access to the High Pressure (HP) Turbocharger. See 15L Engine Service Manual.

CAUTION:
The oil supply tube must not be reused or damage to equipment will occur. If oil supply tube will not come out of the HP
turbocharger due to seizure, cut the oil supply tube into two pieces and leave the tube in the HP turbocharger for ease of
removal, then discard oil supply tube.

6. Remove HP turbocharger oil supply tube from engine and discard.
7. Disconnect oil return tube from HP turbocharger only and discard gasket.
8. Using a soft-blow mallet, gently tap HP turbocharger until loose from turbine housing.
9. Remove HP turbocharger Center Section from the turbine housing.
10. If HPCAC is internally contaminated with oil, clean using CAC cleaning tool 09-925-01.

Installation:

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IK1201134 ­ 2010 EPA MaxxForce® 15L HP Turbo Center Cartridge Replacement

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Figure 1. HP turbocharger Turbine Housing
Item 1: HP Turbocharger turbine housing
Item 2: HP Turbocharger turbine housing flange (exterior)

1. Using suitable solvent and clean emery cloth, clean inside HP turbocharger turbine housing (Figure 1, Item 1) and exterior flange (Figure 1, Item 2).

Figure 2.

NOTE:

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IK1201134 ­ 2010 EPA MaxxForce® 15L HP Turbo Center Cartridge Replacement

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Prime new HP turbocharger center cartridge with oil prior to installation.

2. While rotating turbocharger turbine wheel, add oil to turbocharger oil supply port until oil comes out drain port (Figure 2).
3. Install new HP turbocharger center cartridge into old turbine housing and let it rest freely. (A center section kit is not offered for the 15L, use a COMPETE
turbocharger assembly and simply remove the center section from the assembly.)
4. Align and fully seat HP turbocharger center section onto dowels.
5. Install and torque turbine housing V-band clamp to 110 lb-in (12.4 N·m).

Figure 3. HP turbocharger Center Section
Oil Supply Tube
Oil Drain Tube

CAUTION:
Make sure oil supply line does not bend. Failure to do so will result in damage to HP turbocharger. Damage or distortion will require replacement of oil supply line.

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IK1201134 ­ 2010 EPA MaxxForce® 15L HP Turbo Center Cartridge Replacement

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6. Install new gasket onto oil return tube and install into HP turbocharger. (Figure 3)
7. Install new HP turbocharger oil supply tube on engine. (Figure 3)
8. Install the components that were removed to gain access to the High Pressure (HP) Turbocharger. See 15L Engine Service Manual.
9. Fill cooing system using Navistar Coolant Management Tool KL5007NAV.
10. Start vehicle to verify proper operation, no leaks, and no fault codes are present.
11. Close and latch hood.
12. Remove wheel chocks.

WARRANTY INFORMATION:
Warranty Claim Coding:
Group: 12000 - Engine
Noun: 135 - Turbo, Hi Pressure or Single

Standard Repair Time(s):
Use the MaxxForce 11/13L Engine Turbocharger Center Section SRTs for the 15L center section replacement. Official SRTs for the 15L are under
development.
12 - TURBOCHARGER H.P CENTER SECTION, REPLACE

Hours

Code

2.3

N12-6135U-21

2.3

Q12-6135U-21

2.3

R12-6135U-21

2.3

S12-6135U-21

2.3

T12-6135U-21

2.3

TC12-6135U-21

Model

Engine

Qualifier 1

|MAXXFORCE 11/13|

7600

|MAXXFORCE 11/13|

8600

|MAXXFORCE 11/13|

ProStar

|MAXXFORCE 11/13|

LoneStar

|MAXXFORCE 11/13|

5000

|MAXXFORCE 11/13|

CAT CT660

12 - TURBOCHARGER OIL SUPPLY LINE, REPLACE

Hours

Code

0.8

R12-6869O-21

0.8

S12-6869O-21

0.8

T12-6869O-21

0.8

TC12-6869O-21

Hide Details

Model
ProStar
LoneStar
5000
CAT CT660

Engine

Qualifier 1

|MAXXFORCE 15|

Qualifier 2

Qualifier 3
HIGH PRESSURE TURBOCHARGER

|MAXXFORCE 15|

HIGH PRESSURE TURBOCHARGER

|MAXXFORCE 15|

HIGH PRESSURE TURBOCHARGER

|MAXXFORCE 15|

HIGH PRESSURE TURBOCHARGER

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