IK : High-Pressure Turbocharger Replacement. Study Guide. Course Code: 8472

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1 IK : High-Pressure Turbocharger Replacement Study Guide Course Code: 8472

2 1 IK : High-Pressure Turbocharger Replacement Study Guide 2013 Navistar, Inc Navistar Drive, Lisle, IL All rights reserved. No part of this publication may be duplicated or stored in an information retrieval system without the express written permission of Navistar, Inc. IK200938: High-Pressure Turbocharger Replacement 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective

3 IK : High-Pressure Turbocharger Replacement Study Guide 2 Table of Contents Introduction... 3 Required Tools... 3 Before you Begin... 4 Removal... 4 Step 1: Remove the Inner Fender... 4 Step 2: Remove Air Intake System... 4 Step 3: Remove HPCAC Inlet Duct... 5 Step 4: Remove Crossover Tube... 5 Step 5: Remove High-Pressure Inlet Elbow... 6 Step 6: Disconnect Oil Supply Line... 7 Step 7: Remove Wastegate Actuator... 7 Step 8: Remove Turbocharger... 8 Step 9: Remove ISC Lip Seal... 9 Installation Step 10: Prime Turbocharger Step 11: Install Drain Tube O-ring Step 12: Install ISC Lip Seal Step 13: Install High-Pressure Turbocharger Step 14: Install Wastegate Actuator Step 15: Secure Oil Lines Step 16: Install Crossover Tube Step 17: Install High-Pressure Inlet Elbow Step 18: Install HPCAC Inlet Duct Step 19: Install Air Intake System Step 20: Install Inner Fender Step 21: Calibrate Mass Air Flow Sensor Before Returning the Vehicle to Service Conclusion NOTES IK : High-Pressure Turbocharger Replacement 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective

4 3 IK : High-Pressure Turbocharger Replacement Study Guide Introduction Welcome to the Navistar training course for IK This course is intended to provide you with the approved repair procedure for replacing the high-pressure Turbocharger Center Section on MaxxForce DT, 9 and 10 engines meeting EPA 2010 certifications both with and without HD-OBD. If you have questions or concerns regarding the playback of this program, please contact Navistar Service Education by submitting a case file (Dealer Personnel); or by calling THE INFORMATION PROVIDED WITHIN THIS COURSE IS FOR TRAINING PURPOSES ONLY. ALWAYS CONSULT THE LATEST SERVICE, DIAGNOSTIC, AND TOOL INFORMATION, LOCATED ON NAVISTAR S SERVICE PORTAL, PRIOR TO PERFORMING SERVICE ON NAVISTAR ENGINES, VEHICLES, AND EQUIPMENT. Required Tools This is a list of the tools required to complete this procedure. 3/8 in. drive 8mm deep socket Tongue and groove Pliers 3/8 in. drive 10mm deep socket 6 in. flat blade screwdriver 3/8 in. drive 13mm deep socket 90 pick tool 3/8 in. drive 4mm Allen socket Flashlight 3/8 in. drive 3 in. extension Soft blow mallet 3/8 in. drive 10 in. extension Navistar cap kit (ZTSE4296) 3/8 in. drive air ratchet or electric impact P80 lubricant or equivalent 3/8 in. drive ratchet Rust penetrant 3/8 in. drive torque wrench Clean emery cloth IK200938: High-Pressure Turbocharger Replacement 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective

5 IK : High-Pressure Turbocharger Replacement Study Guide 4 Before you Begin Park the vehicle on a level surface, shift the transmission into park or neutral, turn the wheels to the full right position, and set the parking brake. You will also need to install a set of wheel chocks, then unlatch and open the hood. Step 1: Remove the Inner Fender Removal DRAINING OF THE COOLING SYSTEM AND REMOVAL OF THE OIL CENTRIFUGE FILTER IS NOT REQUIRED TO PERFORM THIS PROCEDURE. To begin this procedure, you will need to remove the bolts from the right-side inner fender, and then remove the fender from the vehicle. Step 2: Remove Air Intake System Next, disconnect the Mass Air Flow sensor. Now remove the air compressor inlet hose from the air box. Then, install a cap into the inlet hose and a cap onto the fitting the hose connects to. Loosen the clamp securing the low-pressure turbocharger inlet duct to the air box outlet. Next, remove the bolt and two nuts securing the air box bracket to the bulkhead, and then remove the air box from the vehicle. Now install a cap into the low-pressure turbocharger inlet duct to prevent contamination. IK : High-Pressure Turbocharger Replacement 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective

6 5 IK : High-Pressure Turbocharger Replacement Study Guide Step 3: Remove HPCAC Inlet Duct Next, remove the bolt securing the P-clamp to the High-Pressure Charge-Air-Cooler inlet duct (HPCAC inlet duct). Then loosen the clamp at the high-pressure charge-air-cooler inlet port, and position the clamp out of the way. Also loosen the clamp at the high-pressure turbocharger outlet port, and position the clamp out of the way. Next, remove the high-pressure charge-air-cooler inlet duct from the vehicle. To avoid contamination, install a cap onto the high-pressure turbocharger outlet and into the highpressure charge-air-cooler inlet. Step 4: Remove Crossover Tube PERFORM STEP 4 IF THE ENGINE IS NOT EQUIPPED WITH AN INTERSTAGE COOLER (ISC). Before removing the crossover tube, loosen the lower bolt securing the Turbocharger 2 Wastegate Control Valve to the crossover tube, and then completely remove the upper bolt and isolator. Slide the valve from under the lower bolt and position it out of the way. Next, loosen the V-band clamp securing the crossover tube outlet to the high-pressure turbocharger inlet. Spread the clamp enough to remove it from the high-pressure turbocharger and then remove the crossover tube and clamp from the engine. Remove and discard the clamp from the crossover tube. Using a small pick tool, remove and discard the O-ring from the high-pressure turbocharger inlet, and then install a cap onto the high-pressure turbocharger inlet. Remove the crossover tube seal at this time if it was not removed with the crossover tube. Install a cap onto the low-pressure turbocharger outlet to prevent contamination. IK200938: High-Pressure Turbocharger Replacement 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective

7 IK : High-Pressure Turbocharger Replacement Study Guide 6 Step 5: Remove High-Pressure Inlet Elbow PERFORM STEP 5 IF THE ENGINE IS EQUIPPED WITH AN INTERSTAGE COOLER (ISC). Loosen the Interstage Cooler (ISC) by removing the four fasteners securing the ISC to the top of the engine. Next, remove and discard the nut from the V-band clamp around the High-Pressure turbocharger inlet elbow. Now remove the clamp from the turbocharger inlet flange, and then remove the high-pressure turbocharger inlet elbow from the vehicle and discard the clamp. Using a small pick tool, remove and discard the O-ring from the high-pressure turbocharger inlet, then install a cap onto the high-pressure turbocharger inlet, and onto the ISC outlet to prevent contamination. IK : High-Pressure Turbocharger Replacement 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective

8 7 IK : High-Pressure Turbocharger Replacement Study Guide Step 6: Disconnect Oil Supply Line Next, loosen and remove the bolt for the oil supply line retaining plate. Now rotate the retaining plate 180 degrees, and spray penetrating oil where the oil supply line meets the turbocharger. Position a flat blade screwdriver between the retaining plate and the high-pressure turbocharger. Gently pry upwards on the retaining plate and lift the oil supply line out of the turbocharger. Once the oil supply line is free, use a small pick tool to remove and discard the O-ring from the line. Now, install a cap into the oil supply port of the high-pressure turbocharger, and onto the oil supply line to prevent contamination. Step 7: Remove Wastegate Actuator WHEN POSITIONING THE WASTEGATE ACTUATOR FOR ACCESS TO THE HIGH-PRESSURE TURBOCHARGER, MAKE SURE NOT TO BEND OR DAMAGE THE WASTEGATE ACTUATOR ROD, AND MAKE SURE NOT TO POSITION IT IN A WAY THAT THE ADJUSTMENT WOULD BE COMPROMISED. FAILURE TO DO SO MAY RESULT IN DAMAGE TO EQUIPMENT. Continue the procedure by removing the bottom mounting bolt for the wastegate actuator, then removing the upper bolt as well. It is normal for the wastegate actuator to contract slightly after the mounting bolts have been removed. IK200938: High-Pressure Turbocharger Replacement 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective

9 IK : High-Pressure Turbocharger Replacement Study Guide 8 Step 8: Remove Turbocharger Now remove the bolt securing the oil drain tubes to the engine. Then loosen the V-band clamp securing the high-pressure turbocharger center section to the turbine housing. Now remove the V-band clamp from the turbine housing, and use a soft-blow mallet to tap the high-pressure turbocharger until it is loose from the housing. Once the turbocharger center section is loose, remove it from the turbine housing and the oil drain tube. The turbine housing and mating surfaces must be cleaned with a piece of emery cloth. After cleaning the turbine housing, install a cap over the opening to prevent contamination. Using a small pick tool, remove and discard the O-ring from the high-pressure turbocharger oil drain tube. Then install a cap into the oil drain tube. IK : High-Pressure Turbocharger Replacement 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective

10 9 IK : High-Pressure Turbocharger Replacement Study Guide Step 9: Remove ISC Lip Seal THE THREADS OF THE SEAL REMOVER HAVE SHARP EDGES, HANDLE TOOLS PROPERLY. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY AND/OR DEATH PERFORM STEP 9 IF THE ENGINE IS EQUIPPED WITH AN INTERSTAGE COOLER (ISC). Loosely install the previously removed Interstage Cooler mounting hardware. Remove the cap from the Interstage Cooler, and install ZTSE Seal Remover into the Interstage Cooler outlet. Using a 1 1/4 in combination wrench, thread the Interstage Cooler Seal Remover into the outlet until it tightly grips the crossover tube seal. Secure the box end of a 1 1/4-in combination wrench to the Interstage Cooler Seal Remover with the proper equipment. Using an up-and-down prying motion, rock the seal out of the Interstage Cooler outlet. IK200938: High-Pressure Turbocharger Replacement 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective

11 IK : High-Pressure Turbocharger Replacement Study Guide 10 Installation Step 10: Prime Turbocharger Before priming the new turbocharger, remove the installed caps. Then add 15W40 engine oil to the new center section oil supply port and spin the turbine wheel. Continue this procedure until oil starts to seep from the oil drain port. Step 11: Install Drain Tube O-ring LUBRICATE ALL O-RINGS WITH P-80 OR EQUIVALENT LUBRICANT. Remove the cap from the oil drain tube, and install a new O-ring. Now remove the cap from the oil supply line, and install a new O-ring onto the line. IK : High-Pressure Turbocharger Replacement 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective

12 11 IK : High-Pressure Turbocharger Replacement Study Guide Step 12: Install ISC Lip Seal MAKE SURE LIP SEAL IS PROPERLY ALIGNED WITH THE INTERSTAGE COOLER OUTLET OPENING. APPLY P-80 OR EQUIVALENT LUBRICANT TO THE NEW INTERSTAGE COOLER LIP SEAL. PERFORM STEP 12 IF THE ENGINE IS EQUIPPED WITH AN INTERSTAGE COOLER (ISC). Remove the mounting hardware from the ISC. Then, position ZTSE4937-1A, Interstage Cooler Seal Installer, and ZTSE4937-4, Interstage Cooler Press, onto the Interstage Cooler with the new seal, then thread the forcing screw into the press until the seal comes into contact with the Interstage Cooler outlet port. Tighten the forcing screw to press the new seal into the Interstage Cooler until the seal installer is flush with the bottom of the Interstage Cooler outlet. When the seal is fully installed, remove the installer and the press. IK200938: High-Pressure Turbocharger Replacement 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective

13 IK : High-Pressure Turbocharger Replacement Study Guide 12 Step 13: Install High-Pressure Turbocharger MAKE SURE THE OIL DRAIN TUBE IS FULLY SEATED IN THE HIGH-PRESSURE TURBOCHARGER CENTER SECTION WHILE INSTALLING IT INTO THE TURBINE HOUSING. FAILURE TO COMPLY MAY RESULT IN PROPERTY DAMAGE, PERSONAL INJURY AND/OR DEATH. Now remove the cap from the turbine housing. Then install the center section and a new clamp onto the oil drain tube while positioning the assembly into the turbine housing. Fully seat the center section into the turbine housing by lining up the locating pins and then pushing the new center section into place. Spread the new V-band clamp and place it around the mating flanges on the turbocharger center section and the turbine housing. Install a new nut onto the turbine housing V-band clamp. Then use a torque wrench to tighten the nut to the specified torque value. IK : High-Pressure Turbocharger Replacement 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective

14 13 IK : High-Pressure Turbocharger Replacement Study Guide Step 14: Install Wastegate Actuator WHEN INSTALLING THE WASTEGATE ACTUATOR, MAKE SURE NOT TO BEND OR DAMAGE THE WASTEGATE ACTUATOR ROD, AND MAKE SURE NOT TO POSITION IT IN A WAY THAT THE ADJUSTMENT WOULD BE COMPROMISED. FAILURE TO DO SO MAY RESULT IN DAMAGE TO EQUIPMENT. Next, pull the wastegate actuator to its original position and install the upper mounting bolt. Now, install the lower mounting bolt. Using a torque wrench, tighten both bolts to the specified torque value. Step 15: Secure Oil Lines Continue by inserting the oil supply line into the high-pressure turbocharger. Position the retaining plate into the proper location, and install a new retaining bolt. Using a torque wrench, tighten the new oil supply line retaining bolt to the specified torque value. Secure the oil drain tubes to the engine with the previously removed bolt. Then use a torque wrench to tighten the bolt to the specified torque value. IK200938: High-Pressure Turbocharger Replacement 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective

15 IK : High-Pressure Turbocharger Replacement Study Guide 14 Step 16: Install Crossover Tube PERFORM STEP 16 IF THE ENGINE IS NOT EQUIPPED WITH AN INTERSTAGE COOLER (ISC). Now remove the cap from the high-pressure turbocharger inlet and install a new O-ring into the groove on the front of the high-pressure turbocharger. Next remove the cap from the low-pressure turbocharger outlet. Inspect the crossover tube seal for damage. If the seal is damaged, it must be discarded and replaced. Apply -P-80 or an equivalent lubricant to the outside of the crossover tube seal, and ensure it is completely installed into the crossover tube. Now place a new V-band clamp onto the crossover tube, and install the tube into the low-pressure turbocharger outlet port. Next, install the clamp around the mating flanges of the crossover tube and the high-pressure turbocharger. Secure the clamp into place with a new nut. Then use a torque wrench to tighten the nut to the specified torque value. After the crossover tube is secured, install the turbocharger 2 wastegate control valve behind the lower mounting bolt, then install the upper mounting bolt and isolator. Using a torque wrench, tighten the two bolts to the specified torque value. IK : High-Pressure Turbocharger Replacement 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective

16 15 IK : High-Pressure Turbocharger Replacement Study Guide Step 17: Install High-Pressure Inlet Elbow PERFORM STEP 17 IF THE ENGINE IS EQUIPPED WITH AN INTERSTAGE COOLER (ISC). Now remove the cap from the Interstage cooler outlet, as well as the high-pressure turbocharger inlet. Install a new O-ring into the groove on the front of the high-pressure turbocharger. Next, install the high-pressure inlet elbow into the Interstage cooler outlet. Position the new V-band clamp around the mating flanges of the high-pressure turbocharger and the high-pressure inlet elbow. Then loosely install the new nut. Then fully seat the high-pressure inlet elbow into the Interstage cooler outlet, and install the mounting hardware. Using a torque wrench, tighten the Interstage cooler mounting hardware to the specified torque value. Then, tighten the nut on the V-band clamp for the high-pressure inlet elbow to the specified torque value. Step 18: Install HPCAC Inlet Duct Next, remove the protective caps from the high-pressure turbocharger outlet, as well as the highpressure charge-air-cooler inlet. With the caps removed, install the high-pressure charge-air-cooler inlet duct between the high-pressure turbocharger and the high-pressure charge-air-cooler. Install the clamp around the high-pressure charge-air-cooler inlet, and then tighten the clamp to the specified torque value. Next, install the clamp at the high-pressure turbocharger outlet, and then tighten the clamp to the specified torque value. Now secure the P-clamp to the high-pressure charge-air-cooler inlet duct with the previously removed bolt. Use a torque wrench to tighten the bolt to the proper torque value. Step 19: Install Air Intake System Next, remove the cap from low-pressure turbocharger inlet duct. Position the air box in the vehicle and attach the inlet duct. Now secure the low-pressure turbocharger inlet duct to the air box by tightening the clamp to the specified torque value. Next remove the caps from the air compressor inlet fitting, as well as the inlet hose. Reinstall the air compressor inlet hose onto the fitting, and then secure it into place with the clamp. Next reconnect the Mass Air Flow sensor. Now reinstall the bolt and two nuts that secure the air box bracket to the bulkhead. Then use a torque wrench to tighten each of the fasteners to the specified torque value. IK200938: High-Pressure Turbocharger Replacement 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective

17 IK : High-Pressure Turbocharger Replacement Study Guide 16 Step 20: Install Inner Fender Reinstall the right side inner fender and secure it into place with the previously removed bolts. Use a torque wrench to tighten each of the bolts to the specified torque value. Step 21: Calibrate Mass Air Flow Sensor THE MASS AIR FLOW SENSOR MUST BE CALIBRATED AFTER THE HIGH-PRESSURE TURBOCHARGER CENTER SECTION IS REPLACED. Connect to the vehicle using ServiceMaxx. Ensure there are no trouble codes and that the Engine Coolant Temperature and Engine Oil Temperature are both above the specified value. When both values are in the proper range, click on "TESTS". Then click "KEY ON ENGINE RUNNING (K-O-E-R) TESTS" and perform the "STANDARD TEST". After the "STANDARD TEST" is completed successfully, click the "PROCEDURES" button at the top of the screen. Select "KEY ON ENGINE RUNNING PROCEDURES", and then select "MASS AIR FLOW (MAF) SENSOR CALIBRATION". Once the calibration is completed, you can close the ServiceMaxx software, and disconnect the computer from the vehicle. Before Returning the Vehicle to Service... Before returning the vehicle to service, be sure to properly secure the hood and remove the wheel chocks. IK : High-Pressure Turbocharger Replacement 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective

18 17 IK : High-Pressure Turbocharger Replacement Study Guide Conclusion This concludes the Navistar training course for IK Thank you for your participation. NOTES IK200938: High-Pressure Turbocharger Replacement 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective