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IK1200938 ­ Replacement Procedure for High­Pressure Turbocharger Center Section o... Page 14 of 23

Figure 13. Oil Supply Tube.
1. M6 x 16 bolt
2. Oil supply tube assembly

9. Connect oil supply tube (Figure 13, Item 2) to HP turbocharger.
10. Install oil supply tube (Figure 13, Item 2) with M6 X 16 bolt (Figure 13, Item 1).

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IK1200938 ­ Replacement Procedure for High­Pressure Turbocharger Center Section o... Page 15 of 23

Figure 14. Oil Drain Tube.
1. Bolt
2. Oil drain tube
3. P­clamp
11. Install bolt (Figure 14, Item 1) in P­clamp (Figure 14, Item 3) on oil drain tube (Figure 14, Item 2).

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IK1200938 ­ Replacement Procedure for High­Pressure Turbocharger Center Section o... Page 16 of 23

Figure 15. HP Turbocharger O-Ring.
1. 2.62 X 61.6 ID o-ring
2. HP turbocharger
12. Install new O-ring (Figure 15, Item 1) into groove on HP turbocharger (Figure 15, Item 2).

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IK1200938 ­ Replacement Procedure for High­Pressure Turbocharger Center Section o... Page 17 of 23

Figure 16. Crossover Tube.
1. V­band clamp
2. Crossover tube
NOTE: Perform Steps 12 through 15 of installation procedure if not equipped with ISC.
13. Inspect crossover tube (Figure 16, Item 2) seal for damage. If damaged, discard seal.
14. Apply P-80 or equivalent to outside of crossover tube seal and inside of interstage inlet duct.
Push crossover tube onto crossover tube seal until it pops into place.
15. Install crossover tube (Figure 16, Item 2) on to HP turbocharger with V-band clamp (Figure 16, Item
1).

Figure 17. Turbocharger 2 Wastegate Control (TC2WC) Valve.
1. Bolt (2)
2. TC2WC valve
3. Insulator (2)
16. Install TC2WC valve (Figure 17, Item 2) onto crossover tube with two insulators (Figure 17, Item 3)
and bolts (Figure 17, Item 1).

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IK1200938 ­ Replacement Procedure for High­Pressure Turbocharger Center Section o... Page 18 of 23

Figure 18. Turbocharger Inlet Elbow.
1. Turbocharger inlet elbow
2. V-band clamp
NOTE: Perform Steps 16 through 20 of installation procedure if the engine is equipped with an ISC.
17. Position turbocharger inlet elbow (Figure 18, Item 1) onto HP turbocharger with V-band clamp
(Figure 18, Item 2) hand tight.

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IK1200938 ­ Replacement Procedure for High­Pressure Turbocharger Center Section o... Page 19 of 23

Figure 19. Interstage Cooler (ISC).
1. M8 x 110 bolt (2)
2. M8 x 110 stud bolt (2)
3. Interstage cooler (ISC)

18. Install new ISC outlet lip seal.
19. Install ISC (Figure 19, Item 3) onto turbocharger inlet elbow and valve cover with two bolts (Figure
19, Item 1) and two stud bolts (Figure 19, Item 2).
20. Using torque wrench, torque bolts and stud bolts to 23 lb-ft (31 N•m).
21. Using torque wrench, torque V-band clamp to 13 lb-ft (17 N•m).

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IK1200938 ­ Replacement Procedure for High­Pressure Turbocharger Center Section o... Page 20 of 23

Figure 20. HPCAC Duct.
1. Clamp (2)
2. HPCAC duct
3. Bolt
4. P-clamp

22. Install HPCAC duct (Figure 20, Item 2) with two clamps (Figure 20, Item 1) .
23. Install bolt (Figure 20, Item 3) in P-clamp (Figure 20, Item 4) on HPCAC duct (Figure 20, Item 2).
24. Install air box and bracket with nut and two bolts.

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IK1200938 ­ Replacement Procedure for High­Pressure Turbocharger Center Section o... Page 21 of 23

Figure 21. MAF Sensor and Air Compressor Inlet Hose.
1. Air box
2. Air compressor inlet hose
3. LP turbocharger inlet elbow duct
4. LP turbocharger inlet elbow duct clamp
5. MAF sensor connector
6. MAF sensor
25. Install air box outlet into LP turbocharger inlet elbow duct (Figure 21 Item 3) and torque clamp
(Figure 21 Item 4).
26. Connect air compressor inlet hose (Figure 21, Item 2) to air box (Figure 21, Item 1).
27. Connect MAF sensor connector (Figure 21, Item 5) to MAF sensor (Figure 21, Item 6).
28. Install right side inner fender with four washers and bolts.
29. Connect negative battery cable and close battery box.
30. Run engine to verify proper operation, no leaks, and no fault codes.
31. Close and latch hood.
32. Remove wheel chocks.
33. Connect to truck with EZ-Tech and using ServiceMaxx recalibrate the Mass Air Flow (MAF) Sensor.

SRT Information:
12 - TURBOCHARGER H.P CENTER SECTION, REPLACE
Hours

Code

Model Engine

Brakes Transmission

Chassis

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IK1200938 ­ Replacement Procedure for High­Pressure Turbocharger Center Section o... Page 22 of 23

Qualifier Qualifier Qualifier
1
2
3

1.0 GY12-6135T-23

1.1 GY12-6135T-24

1.0 KL12-6135T-23

CE / BE

With
|MAXXFORCE
Engines
2010
DT/9/10|
below
Emission
245 HP
Engines

CE / BE

With
With
|MAXXFORCE
245 HP
2010
DT/9/10|
and
Emission
Above
Engines
Engines

Body
Style

With
|MAXXFORCE
Engines
2010
4300,4400 DT/9/10|
below
Emission
245 HP
Engines

With
With
|MAXXFORCE
245 HP
1.1 KL12-6135T-24
2010
4300,4400 DT/9/10|
and
Emission
Above
Engines
Engines

7300,
1.1 M12-6135T-24
7400,
7500

With
With
|MAXXFORCE
245 HP
2010
DT/9/10|
and
Emission
Above
Engines
Engines

7300,
7400,
7500

With
|MAXXFORCE
Engines
2010
DT/9/10|
below
Emission
245 HP
Engines

1.0 M12-6135T-25

Hours

1.1

Hours

Code

Model Engine

A09-3925A

Code

3.5 KL09-3925T

Qualifier Qualifier Qualifier
Body
Brakes Transmission
Chassis
1
2
3
Style

All Models

Model

Engine

|All Engines|

With Cleaning
CAC R&R Not
Management
Included
Tool

Qualifier Qualifier Qualifier
Body
Brakes Transmission
Chassis
1
2
3
Style

With
|MAXXFORCE
2010
4300,4400 DT/9/10|
Emission
Engines

Group: 12000
Noun:

135

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IK1200938 ­ Replacement Procedure for High­Pressure Turbocharger Center Section o... Page 23 of 23

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