Centinel System – Repair Manual – 010-033   Turbocharger

Automotive with CM870 or CM871

• Add one unit of fluorescent tracer, Part Number 3376891, to each 38 liters [10 gal] of engine lubricating oil.
• If a bearing housing coolant leak is suspected, use the turbocharger coolant leak test kit, Part Number 3164682.
• Operate the engine at low idle for 10 minutes.

NOTE: Brush away any loose dirt from around the area of air handling connections to avoid contamination of the interior of the engine.

Shut off the engine.

Allow the turbocharger to cool.

Remove the intake piping and compressor discharge piping. Cover the openings in the pipes with caps from the Air Handling and Vehicle Air Plumbing Clean Care Kits, Part Numbers 4919403, and 4919425 respectively.

Inspect the turbocharger compressor impeller blades for damage.

Replace the turbocharger if damage is found.

Use a high-intensity black light, Part Number 3163337 (100 watt), or equivalent, or Part Number 3163338 (50 watt), or equivalent, to inspect the compressor intake and discharge for signs of oil.

If oil is present in the compressor intake, as well as the discharge, check upstream of the turbocharger for the source of the oil.

If oil is present only in the discharge side, check for intake restriction.

If no intake restriction is found, replace the turbocharger.

If the compressor impeller is damaged, inspect the intake air piping and the filter element for damage.

Repair any damage before operating the engine further.

Inspect the turbine wheel for damage.

Replace the turbocharger if damage is found.

Install the intake piping and compressor discharge piping.

Disconnect the exhaust pipe from the turbocharger.

Use a high-intensity black light, Part Number 3163337 (100 watt), or 3163338 (50 watt), to inspect the turbine outlet for leaks.

A dark blue glow indicates a fuel leak. A yellow glow indicates an oil leak.

If oil is found in the exhaust outlet of the turbine housing, remove the oil drain line and check for restrictions.

Clear any restrictions found and/or replace damaged components as required.

Check the engine breather or the crankcase vent tube for restrictions.

Clear any restrictions and/or replace damaged components. Refer to Procedure 003-001 in Section 3.

If equipped, check the engine crankcase ventilation filter assembly for excessive restriction or blockage. Refer to Procedure 003-001 in Section 3.

Inspect the bearing housing for external oil or coolant leaks.

Remove the oil supply and oil drain tubes from the turbocharger.

Discard the oil drain tube gasket.

Check for evidence of coolant in the oil supply and oil drain fittings.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

Variable Geometry

• Drain the cooling system. Refer to Procedure 008-018 in Section 8.
• Inspect the bearing housing for external oil or coolant leaks.
• Remove the oil supply, oil drain, coolant inlet, and coolant outlet tubes from the turbocharger.
• Disconnect the variable geometry turbocharger actuator air supply line (CM870 engines).
• Discard the oil drain tube gasket.
• Check for evidence of coolant in the oil supply and oil drain fittings.

Remove the air intake and charge-air cooler piping from the turbocharger.

Examine the compressor intake and discharge for oil.

If oil is present in the compressor intake, as well as the discharge, check upstream of the turbocharger for the source of the oil.

If oil is present only in the discharge side, check for intake restriction. Refer to Procedure 010-031 in Section 10.

If no intake restriction is found, replace the turbocharger.

Install the air intake and charge-air cooler piping to the turbocharger and tighten the clamp.

Operate the engine at full throttle and maximum load, and check for air leaks.

Connect a turbocharger coolant leak test kit, Part Number 3164682, to the coolant inlet and outlet.

Use shop air supply to pressurize the turbocharger to 276 kPa [40 psi].

Close the air pressure regulator.

Watch for the pressure to decrease. Pressure must not decrease more than 34 kPa [5 psi] in 1 minute.

If the pressure decreases greater than 34 kPa [5 psi] in 1 minute, use a spray bottle of soapy water to wet all hose connections. Bubbles will appear if the connections are leaking.

If the pressure does decrease excessively, and the hose connections are not leaking, replace the turbocharger.

ISX Automotive with CM570, QSX15 with CM570, and Power Generation with CM570

• Remove the wastegate actuator hose. Refer to Procedure 010-050 in Section 10.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

• Drain the coolant. Refer to Procedure 008-018 in Section 8.
• Disconnect the turbocharger speed sensor. For Signature™ and ISX engines, see the following procedure in the Troubleshooting and Repair Manual, CM870 Electronic Control System Signature™ and ISX Engines, Bulletin 4021334. Refer to Procedure 019-390 in Section 19.
• Disconnect the turbocharger compressor air inlet temperature sensor. For ISX engines, see the following procedure in the Troubleshooting and Repair Manual, CM870 Electronic Control System Signature™ and ISX Engines, Bulletin 4021334.Refer to Procedure 019-395 in Section 19.
• Disconnect the variable geometry actuator air supply line. Refer to Procedure 010-113 in Section 10.
• Remove the turbocharger coolant hoses. Refer to Procedure 010-041 in Section 10.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

NOTE: Brush away any loose dirt from around the area of the air handling connections to avoid contamination of the interior of the engine.

• Drain the coolant. Refer to Procedure 008-018 in Section 8.
• Disconnect the turbocharger speed sensor. For ISX and ISM engines, see the following procedure in the ISX CM871 and ISM CM876 Electronic Control System, Troubleshooting and Repair Manual, Bulletin 4021560. Refer to Procedure 019-390 in Section 19.
• Disconnect the turbocharger compressor air inlet temperature sensor. For ISX and ISM engines, see the following procedure in the ISX CM871 and ISM CM876 Electronic Control System, Troubleshooting and Repair Manual, Bulletin 4021560. Refer to Procedure 019-395 in Section 19.
• Remove the turbocharger coolant hoses. Refer to Procedure 010-041 in Section 10.
• Remove the charge-air piping. Use protective caps from the Air Handling Clean Care Kit, Paart Number 4919403. to cover open points.
• Remove the turbocharger air inlet piping. Use protective caps from the Air Handling and Vehicle Air Plumbing Clean Care Kits, Part Numbers 4919403, and 4919425 respectively to cover open points.
• Disconnect the aftertreatment adapter pipe. Use protective cap from the Air Handling Clean Care Kit, Part Numbers 4919403 and 4919425 respectively, to cover the turbocharger exhaust outlet.Refer to Procedure 011-043 in Section 11.

WARNING  This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component.

Automotive, Industrial, and Power Generation with CM570

• Remove the oil supply, oil drain tube, and brace (if equipped) from the turbocharger.

Remove the intake and exhaust pipes from the turbocharger.

Remove the charge-air cooler piping from the discharge elbow.

Remove the clamp, o-ring, and discharge elbow from the turbocharger.

Discard the o-ring.

NOTE: In some applications, the turbocharger will not clear the lubricating oil cooler assembly during removal and installation. It will, perhaps, be necessary to remove the exhaust manifold and turbocharger together, and then separate the two components. If the two components must be removed together for the removal and installation of the exhaust manifold. Refer to Procedure 011-007 in Section 11.

If the turbocharger mounting nuts do not loosen freely, split the nuts to avoid breaking a mounting stud.

Remove the four turbocharger mounting nuts.

Remove the turbocharger and discard the gasket.

WARNING  This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component.

CAUTION  When installing a lifting eye, be sure the shoulder of the lifting eye is bottomed against bearing housing. Failure to do so can result in failure of the lifting eye and personal injury.

CAUTION  If the lifting eye is installed in the turbocharger bearing housing, it is to be used exclusively for turbocharger removal and installation. It is not to be used in removal of the exhaust manifold, or engine. Doing so will cause damage to the turbocharger.

Remove the oil supply and the oil drain tube from the turbocharger.

Remove the intake and the exhaust pipes from the turbocharger.

Remove the charge-air cooler piping from the discharge elbow.

Remove the clamp, o-ring, and discharge elbow from the turbocharger.

Discard the o-ring.

The capscrew in the top of the turbocharger bearing housing can be removed and replaced with a lifting eye to aid in removal of the turbocharger.

If the turbocharger mounting nuts do not loosen freely, split the nuts to avoid breaking a mounting stud.

Remove the four turbocharger mounting nuts.

Remove the turbocharger and discard the gasket.

WARNING  This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component.

Thread a lifting strap around the turbocharger bearing housing. Take care not to bend the coolant lines when lifting the turbocharger.

Care must be taken not to damage the turbocharger compressor inlet air temperature sensor, the turbocharger speed sensor, and the turbocharger actuator coolant lines when removing the turbocharger.

Remove the four turbocharger mounting nuts.

NOTE: If the turbocharger mounting nuts do not loosen freely, split the nuts to avoid breaking a mounting stud.

Remove the turbocharger and discard the gaskets.

Cover the turbocharger exhaust inlet port with heavy tape or a protective cap from the Air Handling and the Vehicle Air Plumbing Clean Care Kit, Part Numbers 4919403 and 4919425 respectively. Cover the opening on the exhaust manifold with heavy tape.

If the turbocharger is being replaced with a new turbocharger, remove the variable geometry turbocharger actuator.

Refer to Procedure 010-134 in Section 10.

Turbine Housing Replacement for ISX Automotive with CM570, QSX15 with CM570, and Power Generation with CM570

• Place the turbocharger outlet on a clean flat surface. Create an alignment mark on the turbine housing, bearing housing and the V-band clamp. This mark will make certain the components are oriented correctly during the assembly process.

NOTE: This procedure applies ONLY to Automotive with CM570, QSX15 with CM570, and Power Generation with CM570. Do NOT disassemble variable geometry turbochargers (VGT).

Loosen the turbine side V-band locknut. Remove and discard the V-band clamp.

CAUTION  Turbine blades can be easily damaged and care is required for the turbine housing removal process.

Use a soft hammer to tap the turbine housing down against a soft bench surface.

As the bearing housing and compressor housing assembly loosen, gently lift the assembly out of the turbine housing.

Wastegate mounting is not affected by this disassembly process.

Always clean the turbine housing before assembly, paying particular attention to the surface close to the turbine housing and the bearing housing location.

Turbine Housing Cleaning for ISX Automotive with CM570, QSX15 with CM570, and Power Generation with CM570

• The turbocharger turbine housing surface adjacent to the turbine compressor wheels must be clean, smooth, and free from deposits.
• Inspect the components to detect signs of burning and other conditions, in order to obtain as much information as possible before washing.

NOTE: This procedure applies ONLY to Automotive with CM570, QSX15 with CM570, and Power Generation with CM570. Do NOT disassemble variable geometry turbochargers (VGT).

CAUTION  Wear appropriate eye and face protection when using non-corrosive metal cleaner.

Soak the turbocharger turbine housing in a non-corrosive, low flash point metal cleaner to loosen deposits.

CAUTION  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Scale-like deposits, if any, must be removed by using a non-metallic bristle brush. After removing the deposits, wash and dry the components.

Dry the components with compressed air.

CAUTION  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

NOTE: Do not bead blast aluminum and cast iron components together.

NOTE: To prevent bead spray impinging directly on the clamp plate and turbine flange threads, mask and plug off all items.

NOTE: Prevent the bead spray impinging directly on the wastegate valve spindle, as beads can penetrate the spindle bore, and lead to spindle seizure.

It is permissible to bead blast the turbocharger turbine housing if chemical and brush cleaning is not effective.

After removing the deposits, wash and dry the components.

ISX Automotive with CM570, QSX15 with CM570 and Power Generation with CM570

• Clean the retaining nut mating surfaces of the turbocharger and the exhaust manifold.
• Clean the mating surfaces with Scotch-Brite™ 7448 abrasive pad.
• The surface under the mounting nuts must be free of dirt, rust, or any other debris, before applying anti-seize compound, Part Number 3823097.

Inspect the wastegate actuator. Refer to Procedure 010-050 in Section 10.

Inspect the turbocharger casings.

Replace the housing if through cracks are found in the outer walls.

Cracking in the turbine housing inlet flange and the inlet duct generally requires replacement of the turbine housing. Acceptance and rejection guidelines are shown in these illustrations. If an exhaust gasket is available, always make certain that cracks do not exist within the sealing area.

Check the turbine housing inlet flange flatness. It must be within 0.1 mm [0.004 in] to be acceptable for reuse.

Flange Fasteners – Clearance Holes

Check the fastener hole diameter. It must not be more than 1.5 mm [0.006 in] larger than the maximum thread diameter of the fastener.

CAUTION  If external cracks are found on the turbine housing, the turbine housing must be replaced.

CAUTION  Turbine blades can be easily damaged and care is required for the turbine housing installation process.

Cracking of the internal wall at the entry to the turbine wheel (tongue) is acceptable as a service condition, and the turbine housing can be re-used.

Inspect the turbocharger compressor v-band outlet and the discharge elbow v-band connection for dents or fretting.

Replace the turbocharger or discharge elbow, if damaged, to prevent compressed air leaks.

Use dial depth gauge, Part Number ST-537.

Push the rotor assembly away from the gauge.

Set the gauge to zero (0).

Push the rotor assembly toward the gauge and record the reading.

Turbocharger Axial Clearance

If the turbocharger axial clearance is not within specifications, the turbocharger must be replaced.

Use a dial indicator to check radial movement at the compressor impeller nose.

Push the impeller away from the gauge and set the indicator to zero. Push the impeller toward the gauge and record the reading.

Turbocharger Radial Bearing Clearance

If the turbocharger radial clearance is not within specifications, the turbocharger must be replaced.

If the engine experiences a turbocharger malfunction or any other occasion where oil or debris is put into the charge-air system, the charge-air system must be inspected and cleaned. Refer to Procedure 010-027 in Section 10.

Inspect for cracks in the turbocharger and compressor casings.

Replace the turbocharger if through cracks in the outer walls are found.

Inspect for cracks on the turbine inlet and exhaust mounting flanges. Replace the turbocharger if any cracks are found.

Clean the retaining nut mating surfaces of the turbocharger and the exhaust manifold.

Clean the mating surfaces with Scotch-Brite™ 7448 abrasive pad.

The surface under the mounting nuts must be free of dirt, rust, or any other debris before applying anti-seize compound, Part Number 3823097.

Inspect the turbocharger compressor v-band outlet and the discharge elbow v-band connection for dents or fretting.

Replace the turbocharger or discharge elbow, if damaged, to prevent compressed air leaks.

Inspect the compressor wheel for signs of rubbing against the compressor cover. Replace the turbocharger if rubbing evidence is seen.

Use light finger pressure to push the compressor wheel. If the compressor wheel contacts the cover, replace the turbocharger.

If the engine experiences a turbocharger malfunction or any other occasion where oil or debris is put into the charge-air system, the charge-air system must be inspected and cleaned. Refer to Procedure 010-027 in Section 10.

Check the axial movement of the turbocharger wheels and shaft.

Turbocharger Axial Clearance

If the turbocharger axial clearance is not within specifications, the turbocharger must be replaced.

Check the radial movement of the turbocharger wheels and shaft.

Use light finger pressure to push the compressor wheel toward the side of the compressor housing.

Repeat the procedure for the turbine wheel and housing.

Replace the turbocharger if either wheel contacts the housing.

Inspect the variable geometry actuator and mechanism for proper operation. Refer to Procedure 010-134 in Section 10.

Inspect for cracks in the turbocharger and compressor casings.

Replace the turbocharger if through cracks in the outer walls are found.

Inspect for cracks on the turbine inlet and exhaust mounting flanges. Replace the turbocharger if any cracks are found.

NOTE: All openings on the turbocharger, including the turbine inlet connection, must be plugged with caps from the Air Handling and Vehicle Air Plumbing Clean Care Kits, Part Numbers 4919403, and 4919425 respectively, during flange cleaning.

Clean the turbocharger and exhaust manifold where the retaining nut contacts the turbocharger and exhaust manifold.

Clean the mating surfaces with Scotch-Brite™ 7448 abrasive pad.

After abrasive cleaning, wipe debris from both surfaces with a clean shop towel.

The surface under the mounting nuts must be free of dirt, rust, or any other debris, before applying anti-seize compound, Part Number 3823097.

Replace turbocharger if any leaks are found.

Check for evidence of coolant in the oil supply and oil drain fittings.

Inspect the turbocharger compressor v-band outlet and the discharge elbow v-band connection for dents or fretting.

Replace the turbocharger or discharge elbow, if damaged, to prevent compressed air leaks.

Inspect the compressor wheel for signs of rubbing against the compressor cover. Replace the turbocharger if rubbing evidence is seen.

Use light finger pressure to push the compressor wheel. If the compressor wheel contacts the cover, replace the turbocharger.

If the engine experiences a turbocharger malfunction or any other occasion where oil or debris is put into the charge-air system, the charge-air system must be inspected and cleaned. Refer to Procedure 010-027 in Section 10.

Check the axial movement of the turbocharger wheels and shaft.

Turbocharger Axial Clearance

If the turbocharger axial clearance is not within specifications, the turbocharger must be replaced.

Check the radial movement of the turbocharger wheels and shaft.

Use light finger pressure to push the compressor wheel toward the side of the compressor housing.

Repeat the procedure for the turbine wheel and housing.

Replace the turbocharger if either wheel contacts the housing.

ISX Automotive with CM570, QSX15 with CM570 and Power Generation with CM570

• To install the turbine housing, position the V-band clamp over the bearing housing and align the ink marks applied during the disassembly process.
• Apply anti-seize compound to the bearing housing locating bore of the turbine housing.
• Carefully slide the bearing and compressor housing assembly into the turbine housing. Use the ink alignment mark to locate the turbine housing assembly in the correct orientation with the turbine housing.

Place the new V-band clamp in the correct orientation and torque the locknut.

Torque value for Cummins®-branded turbochargers.

Torque value for Holset®-branded turbochargers.

Loosen the locknut 180 degrees, and torque the locknut.

Torque value for Cummins®-branded turbochargers.

Torque value for Holset®-branded turbochargers.

Make certain the rotor assembly rotates freely and neither compressor wheel or turbine wheel is rubbing against the housing.

ISX Automotive with CM570, QSX15 with CM570, and Power Generation with CM570

• Apply a film of high-temperature anti-seize compound, Part Number 3823097, or equivalent, to the turbocharger mounting studs.

WARNING  This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component.

NOTE: If the exhaust manifold and turbocharger were removed together in order for the turbocharger to clear the lubricating oil cooler assembly, see the following procedure for installation of the exhaust manifold. Refer to Procedure 011-007 in Section 11.

Install a new mounting gasket, the turbocharger, and the four mounting nuts.

Tighten the mounting nuts.

Torque value for the standard nut:

Torque value for the Spiralock™ nut (identified by “SPL” on the nut flange):

Install the discharge elbow and clamp onto the charge-air cooler pipe connection.

Do not tighten the clamp until the elbow is installed on the turbocharger.

If a new turbocharger is being installed, the variable geometry turbocharger actuator from the original turbocharger must be reused.

Refer to Procedure 010-134 in Section 10.

Install a new o-ring, the clamp, and the discharge elbow to the turbocharger.

Tighten the clamp.

Install a new gasket, oil drain tube, and capscrews.

Tighten the capscrews.

Install the turbocharger anti-rotation brace (if equipped) . The end rests on the oil cooler housing.

This brace requires longer, 1.25 mm [0.049 in], capscrews.

Tighten the capscrews.

Pour approximately 50 to 60 cc [1.7 to 2 oz] of clean engine oil into the turbocharger oil supply opening.

CAUTION  Proper routing of the turbocharger oil supply tube is critical to prevent failure. Avoid any tube-to-metal contact. (The inlet supply fitting must be oriented slightly off vertical to allow proper alignment.)

If installing a new turbocharger, make sure the turbocharger is aligned, loosen the compressor and turbine v-bands, and adjust as needed. Tighten the v-bands.

If installing a new turbocharger, install the male union elbow.

Install the turbocharger oil supply tube on the elbow.

Install the intake and exhaust pipes to the turbocharger. Tighten the clamp.

Variable Geometry

• Apply a film of high-temperature anti-seize compound, Part Number 3823097, to the turbocharger mounting studs.

WARNING  This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component.

CAUTION  When installing lifting eye, be sure the shoulder of the lifting eye is bottomed against bearing housing. Failure to do so can result in failure of lifting eye and personal injury.

CAUTION  If a lifting eye is installed in turbocharger bearing housing, it is to be used exclusively for turbocharger removal and installation. It is not to be used in removal of the exhaust manifold, or engine. Doing so will cause damage to the turbocharger.

CAUTION  Do not rotate the turbocharger turbine housing. Loosening turbine v-band and rotating the turbine housing can cause damage to internal variable geometry mechanism.

The capscrew in the top of the turbocharger bearing housing can be removed and replaced with a lifting eye to aid in the installation of the turbocharger.

Install a new gasket, the turbocharger, and the four mounting nuts. Tighten the mounting nuts.

Install the discharge elbow and clamp onto the charge-air cooler pipe connection.

Do not tighten the clamp until the elbow is installed on the turbocharger.

Install a new o-ring, the clamp, and the discharge elbow to the turbocharger.

Tighten the clamp.

Install a new gasket, oil drain tube, and capscrews.

Tighten the capscrews.

Install the intake and exhaust pipes to the turbocharger, and tighten the clamps.

Apply a film of high-temperature anti-seize compound, Part Number 3823097, or equivalent, to the turbocharger mounting studs and to the flange area on the retaining nuts. Properly applying anti-seize compound will reduce the possibility of the nuts loosening over time.

If installing a new turbocharger, install the coolant and oil fittings into the bearing housing.

NOTE: Use a ratchet and deepwell socket to install these fittings.

CAUTION  Proper routing of the turbocharger oil supply tube is critical to prevent failure. Avoid any tube-to-metal contact.

Install the turbocharger oil supply hose onto the oil supply fitting. The oil supply hose must point directly downward in order for it to properly connect to the oil supply fitting on the lubricating oil filter head.

Install the turbocharger actuator coolant supply and return fittings into the electronic actuator. Refer to Procedure 010-041 in Section 10.

WARNING  This component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift this component.

CAUTION  Do not rotate the turbocharger turbine housing. Loosening turbine v-band and rotating the turbine housing can cause damage to internal variable geometry mechanism.

NOTE: Thread a lifting strap around the turbocharger bearing housing. Take care not to bend the coolant lines when lifting the turbocharger.

Care must be taken not to damage the turbocharger compressor inlet air temperature sensor, the turbocharger speed sensor, and the turbocharger actuator coolant lines when installing the turbocharger.

Install a new gasket, the turbocharger, and the four mounting nuts. Tighten the mounting nuts.

Install a new o-ring seal, the clamp, and the discharge elbow to the turbocharger.

Tighten the clamps.

Install a new gasket, oil drain tube, and capscrews.

Tighten the capscrews.

Connect the oil supply hose to the oil supply fitting located on the lubricating oil filter head.

Tighten the oil supply hose.

ISX Automotive with CM570, QSX15 with CM570, and Power Generation with CM570

• Install the wastegate actuator hose. Refer to Procedure 010-050 in Section 10.
• Start and operate the engine until the coolant temperature reaches 82°C [180°F] and check for air, coolant, and oil leaks.

CAUTION  Turbocharger speed sensor harness and turbocharger compressor inlet air temperature sensor harnesses must be tied securely and away from heat sources, such as the exhaust manifold and exhaust pressure sensor tube. Failure to do so can cause damage to the sensor harness.

CAUTION  The turbocharger compressor inlet air temperature sensor must be positioned so the sensor body is pointing up and away from the exhaust manifold. Failure to do so can cause sensor damage.

CAUTION  Do not twist coolant lines while tightening. Failure to do so will damage coolant lines.

• Install the turbocharger coolant hoses. Refer to Procedure 010-041 in Section 10.
• Connect the variable geometry actuator air supply line. Refer to Procedure 010-113 in Section 10.
• Connect the electrical connectors on the turbocharger speed sensor and the turbocharger compressor air inlet temperature sensor. For ISX engines, see the following procedure in the Troubleshooting and Repair Manual, CM870 Electronic Control System Signature™ and ISX Engines, Bulletin 4021334.Refer to Procedure 019-395 in Section 19. Also, see the following procedure in the Troubleshooting and Repair Manual, CM870 Electronic Control System Signature™ and ISX Engines, Bulletin 4021334.Refer to Procedure 019-390 in Section 19.
• Fill the cooling system with coolant. Refer to Procedure 008-018 in Section 8.
• Start and operate the engine until the coolant temperature reaches 82°C [180°F] and check for air, coolant, and oil leaks.

• Install the charge-air piping. Refer to Procedure 010-027 in Section 10.
• Install the aftertreatment adapter pipe. Refer to Procedure 011-043 in Section 11.
• Install the turbocharger coolant hoses. Refer to Procedure 010-041 in Section 10.
• Connect the turbocharger compressor air inlet temperature sensor. For the ISX and ISM engines, see the following procedure in the ISX CM871 and ISM CM876 Electronic Control System, Troubleshooting and Repair Manual, Bulletin 4021560.Refer to Procedure 019-395 in Section 19.
• Connect the electrical connector on the turbocharger speed sensor, turbocharger electric actuator and the turbocharger compressor air inlet temperature sensor. For the ISX and ISM engines, see the following procedure in Section 19 in the ISX CM871 and ISM CM876 Electronic Control System, Troubleshooting and Repair Manual, Bulletin 4021560.Refer to Procedure 019-390 in Section 19.
• Connect the aftertreatment adapter pipe. Refer to Procedure 011-043 in Section 11.
• Fill the cooling system. Refer to Procedure 008-018 in Section 8.
• Operate the engine and check for leaks.

If a malfunction resulted in coolant, oil, excessive fuel, or excessive black smoke entering the exhaust system, the aftertreatment system must be inspected. Refer to Procedure 014-013 in Section 14.