IK1201105 ­ EPA 2010 and Later I­6 Engine Hydro­locked

Page 1 of 5

CANADA,
COLOMBIA,
UNITED STATES

Document
IK1201105
ID:

Availability:
Major
System:
Current
Language:
Other
Languages:

ISIS

Revision:

0

ENGINES

Created:

3/24/2014

English

Last
Modified:

4/3/2014

NONE

Author:

Matthew
Lazarz

Viewed:

366

Countries:

Less Info
Coding Information

Hide Details

Copy Link

Copy Relative
Link

Bookmark

Add to
Favorites

Print

Provide
Feedback

View My
Bookmarks

Helpful

Not Helpful

6

1

Title : EPA 2010 and Later I-6 Engine Hydro-locked
Applies To : EPA 2010 and Later I-6 Engine ESN 3,300,000 and up

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 inter-stage 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 IK1201086. If a leak is found proceed to step 5, if
no leak is present reassemble and retest for complaint.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 5/5/2014

IK1201105 ­ EPA 2010 and Later I­6 Engine Hydro­locked

Page 2 of 5

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.
Piston Height Mearsurement

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” 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 then road test to verify repair.
Note: A hydro-locked cylinder only bends the connecting rod, all other components are
reusable.
(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

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

Code

Model

Engine

Qualifier 1

Qualifier 2

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 5/5/2014

IK1201105 ­ EPA 2010 and Later I­6 Engine Hydro­locked

1.4

A12-6892T
-20

Models, ALL

MAXXFORCE
DT/9/10

Models, ALL

MAXXFORCE
DT/9/10

Page 3 of 5

With 2010
Emission
Engines

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

With 2010
Emission
1.5
Engines
12 – Only EGR Cooler, Replace (If cylinder head is removed EGR cooler R&R is included)
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

Engines with 245
HP and Up

4.6

E12-6892T
-20

HC Bus

MAXXFORCE
DT/9/10

With 2010
Emission
Engines
With 2010
Emission
Engines

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

I12­6892T­
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

Engines with 245
HP and Up

4.9

M12-6892T

7300

MAXXFORCE
DT/9/10

With 2010