IK1200938 ­ High Pressure Turbo Center Section Replacement, DT/9/10

Page 1 of 30

Countries:

CANADA, UNITED STATES, MEXICO, Document
PUERTO RICO
ID:

Availability:

ISIS, Bus ISIS, FleetISIS

Revision:

7

Major System:

ENGINES

Created:

8/2/2013

Current
Language:

English

Last
Modified:

10/20/2014

Other
Languages:

NONE

Author:

Caleb
Iverson

Viewed:

11644

IK1200938

Less Info
Coding Information

Hide Details

Copy Link

Copy Relative Link

Bookmark

Add to Favorites

Print

Provide Feedback

View My Bookmarks

Helpful

Not Helpful

41

13

Title : High Pressure Turbo Center Section Replacement, DT/9/10
Applies To : 2010+ (EPA 10 Emissions) MaxxForce® DT, 9, 10 Engines

CHANGE LOG
2014/09/09 ­ Revised formatting, added steps for oil supply tube replacement, and new link to CAC cleaning.
2014/06/17 - Added training video inforamtion.
2014/04/28 ­ Added turbo center section part number. Removed steps for separating a new turbo.
2014/02/17 - Added step and SRTs for cleaning HPCAC if oil contaminated.
2013/08/03 Launch to Field




QUICK LINKS
Description

Symptoms

Tools

Parts

Procedure
Overview

Diagnostics

Repair-Removal

Repair-Installation

Warranty

Resources

DESCRIPTION
For most repairs it is unnecessary and time consuming to replace an entire turbocharger assembly. Therefore, a procedure—
outlined in this document—was developed to replace the center section of the High Pressure (HP) Turbocharger, in chassis. The
procedure applies to all 2010 and newer Medium Duty I6 engines (MaxxForce® DT, 9, 10) including the 2013 OBD and outlines
the tools, parts, and important notes, necessary for successful repair.
Return to top

SPECIAL TOOLS
Tool Description

Tool Number

Comments

Instructions

ISC Outlet Seal Removal Tool

ZTSE4937

Kit

In Procedure Below

CAC Cleaning Adapter Kit

09­925­01

ONLY if necessary

Link

Return to top

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1200938 ­ High Pressure Turbo Center Section Replacement, DT/9/10

Page 2 of 30

SERVICE PARTS INFORMATION
Kit Description

Part
Number

Quantity
Notes
Required

Kit, Turbo Cartridge

2512354C91

1

Required

Seal, LP Turbo

1881990C1

1

Only if necessary, High Torque

Seal, Lip Crossover Tube

1858048C2

1

Only if necessary, High Torque

Tube Assembly, Turbo Oil Supply

1885590C92

1

Required, Never reuse oil supply tubes

Oil Cooler to Oil Supply Tube Seal

7080336C1

1

Required

M6 X 1 MM X 16 MM Flanged Bolt

1817953C1

1

Required

Return to top

DIAGNOSTIC STEPS
All diagnostics should be completed through the diagnostics manual or performance diagnostic sheet.
Return to top

PROCEDURE OVERVIEW

GOVERNMENT REGULATION: Engine fluids (oil,
fuel, and coolant) may be a hazard to human health and the
environment. Handle all fluids and other contaminated
materials (e.g. filters, rags) in accordance with applicable
regulations. Recycle or dispose of engine fluids, filters,
and other contaminated materials according to applicable
regulations.

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.

To prevent personal injury or death, make sure the engine has cooled before removing
components.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1200938 ­ High Pressure Turbo Center Section Replacement, DT/9/10

Page 3 of 30

To prevent personal injury or death, shift transmission into park or neutral, set parking
brake, and block wheels before doing diagnostic or service procedures.
Return to top

REPAIR-REMOVAL PROCEDURE
1.

Bring truck into shop and park on flat surface with wheels turned fully to the right.

2.

Shift transmission to Park or Neutral, set parking brake, and install wheel chocks.

3.

Unlatch and open hood.

4.

Open battery box and disconnect negative battery cable.

Figure 1: MAF Sensor and Air Compressor Inlet Hose.
Item 1: Air box
Item 2: Air compressor inlet hose
Item 3: LP turbocharger inlet elbow duct
Item 4: LP turbocharger inlet elbow duct clamp
Item 5: MAF sensor connector
Item 6: MAF sensor
5.

Disconnect MAF sensor connector (Figure 1, Item 5) from MAF sensor (Figure 1, Item 6).

6.

Disconnect air compressor inlet hose (Figure 1, Item 2) from air box (Figure 1, Item 1).

7.

Loosen air box to LP turbocharger inlet elbow duct clamp (Figure 1, Item 4) and remove LP turbocharger inlet elbow duct (Figure 1, Item 3).

8.

Remove bolt, two nuts, and air box with bracket from vehicle.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1200938 ­ High Pressure Turbo Center Section Replacement, DT/9/10

Page 4 of 30

Figure 2: High Pressure Charge Air Cooler Duct
Item 1: Clamp
Item 2: HPCAC duct
Item 3. Bolt
Item 4. P-clamp
9.
10.

Remove bolt (Figure 2, Item 3) from P-clamp (Figure 2, Item 4) on HPCAC duct (Figure 2, Item 2).
Loosen two clamps (Figure 2, Item 1) and remove HPCAC duct (Figure 2, Item 2).

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1200938 ­ High Pressure Turbo Center Section Replacement, DT/9/10

Page 5 of 30

Figure 3: Turbocharger 2 Wastegate Control (TC2WC) Valve
Item 1: Bolt (2)
Item 2: TC2WC
Item 3: Insulator (2)

Perform Steps 11 and 12 only if the engine is NOT equipped with an Interstage Cooler (ISC).
11. Remove two bolts (Figure 3, Item 1) and insulators (Figure 3, Item 3) from TC2WC valve (Figure 3, Item 2) and position for access to High
Pressure (HP) turbocharger.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1200938 ­ High Pressure Turbo Center Section Replacement, DT/9/10

Page 6 of 30

Figure 4: Turbo Crossover Tube
Item 1: V-band clamp
Item 2: Crossover tube
12.

Remove V-band clamp (Figure 4, Item 1) and crossover tube (Figure 4, Item 2).

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1200938 ­ High Pressure Turbo Center Section Replacement, DT/9/10

Page 7 of 30

Figure 5: Interstage Cooler (ISC)
Item 1: M8 x 110 bolt
Item 2: M8 x 110 stud bolt
Item 3: Interstage cooler (ISC)

Perform Steps 13 through 19 of removal procedure only if equipped with an Interstage Cooler (ISC).
13.

Remove two bolts (Figure 5, Item 1) and stud bolts (Figure 5, Item 2) from Interstage Cooler (ISC) (Figure 5, Item 3).

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1200938 ­ High Pressure Turbo Center Section Replacement, DT/9/10

Page 8 of 30

Figure 6: Turbocharger Inlet Elbow
Item 1: Turbocharger inlet elbow
Item 2: V-band clamp
14.

Remove V-band clamp (Figure 6, Item 2) from turbocharger inlet elbow (Figure 6, Item 1).

15.

Raise ISC from valve cover and remove turbocharger inlet elbow.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1200938 ­ High Pressure Turbo Center Section Replacement, DT/9/10

Page 9 of 30

Figure 7: ISC Seal Removal
Item 1: ISC Outlet Seal
Item 2: ZTSE4937-2 Seal Remover
16.

Install ZTSE4937-2 seal remover (Figure 7, Item 2) into ISC Outlet Seal (Figure 7, Item 1).

17.

Using a 1-1/4 inch combination wrench, thread ISC seal remover into outlet until it tightly grips crossover tube lip seal.

18.

Using provided bolt and washer, secure box end of 1-1/4 inch box end wrench to seal remover.

19.

Using up-and-down prying motion, remove seal from ISC outlet.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1200938 ­ High Pressure Turbo Center Section Replacement, DT/9/10

Page 10 of 30

Figure 8: HP Turbocharger Oil Supply Tube
Item 1: M6 x 16 bolt
Item 2: Oil supply tube assembly
20.

Remove bolt (Figure 8, Item 1) from oil supply tube (Figure 8, Item 2). Discard bolt.

21.

Apply rust penetrating oil to oil supply tube (Figure 8, Item 2) and disconnect from HP turbocharger.

22.

Remove and discard oil supply tube O­ring.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1200938 ­ High Pressure Turbo Center Section Replacement, DT/9/10

Page 11 of 30

Figure 9: Turbo Wastegate Actuator
Item 1: Turbine v-band clamp
Item 2: Wastegate actuator
Item 3: M8 x 16 bolt

CAUTION
Be sure not to bend or damage the wastegate actuator rod and ensure it is positioned such that adjustment is not
compromised. Failure to do so may result in damage to equipment.
23.

Remove two bolts (Figure 9, Item 3) and position wastegate actuator (Figure 9, Item 2) for access to HP turbocharger.

24.

Remove turbine V-band clamp (Figure 9, Item 1) from HP turbocharger.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1200938 ­ High Pressure Turbo Center Section Replacement, DT/9/10

Page 12 of 30

Figure 10: Turbo Oil Drain Tube
Item 1: Bolt
Item 2: Oil drain tube
Item 3: P-clamp
25.

Remove bolt (Figure 10, Item 1) from P-clamp (Figure 10, Item 3) on oil drain tube (Figure 10, Item 2).

26.

Using a rubber mallet, tap HP turbocharger center section until loose and remove from turbine housing and oil drain tube.

27.

Using a clean emery cloth, clean turbine housing and mating surfaces.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1200938 ­ High Pressure Turbo Center Section Replacement, DT/9/10

Page 13 of 30

Figure 11: Turbo Oil Drain Tube O-ring
Item 1: O­ring
Item 2: HP Turbocharger Oil drain tube
28.

Remove HP turbocharger oil drain O-ring (Figure 11, Item 1). Discard O­ring.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1200938 ­ High Pressure Turbo Center Section Replacement, DT/9/10