ISM, ISMe, and QSM11 – 010-033   Turbocharger

If turbocharger blade damage is suspected:

Remove the air intake pipe from the turbocharger.

Inspect the turbocharger compressor impeller blades for damage.

Replace the turbocharger if damage is found.

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

Repair any damage before operating the engine.

Remove the exhaust pipe from the turbocharger.

Inspect the turbine wheel for damage.

Replace the turbocharger if damage is found.

If a turbocharger compressor seal leak is suspected:

Inspect the compressor intake and discharge for oil.

If oil is present in the compressor intake, as well as in the discharge, check upstream from 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.

If a turbocharger turbine seal leak is suspected:

Add one unit of fluorescent tracer, Part Number 3376891, to each 38 liters [10 gal] of engine lubricating oil.

Operate the engine at low idle for 10 minutes.

Shut off the engine.

Allow the turbocharger to cool.

Remove the intake and the exhaust pipes from the turbocharger.

Remove the intake piping and compressor discharge piping.

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 any damaged components, as required.

Check the engine breather and the breather tube for restriction. Clear any restrictions found and/or replace any damaged components. Refer to Procedure 003-002 in Section 3.

If equipped, check the engine crankcase ventilation filter assembly for excessive restriction or blockage. Refer to Procedure 003-002 in Section 3.

If the oil drain line is not restricted, remove the turbocharger.

Use a high-intensity black light, Part Number 3824524 or 3824754, or equivalent, to inspect the turbine inlet for leaks.

A yellow glow indicates an oil leak from the engine.

If a yellow glow is not seen in the turbine inlet, replace the turbocharger.

On the automotive engines with CM570, CM870, and CM875, if a bearing housing coolant leak is suspected, use the turbocharger coolant leak test kit, Part Number 3164682.

Drain the coolant. Refer to Procedure 008-018 in Section 8.

Connect a turbocharger coolant leak test kit to the coolant inlet and outlet.

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

Shut off the air regulator.

Watch for the pressure to decrease. Pressure must not decrease more 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 and the hose connections are not leaking, replace the turbocharger.

Compare the assembly number (1) on the turbocharger dataplate with the turbocharger specified in the engine control parts list (CPL) number (2) listed on the engine dataplate.

If the correct turbocharger was not installed, remove it and install the correct turbocharger.

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.

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

CAUTION  When the lifting eye is installed, it is to be used for lifting the turbocharger only. Lifting additional weight may cause damage to the turbocharger.

CAUTION  When using a lifting eye, make sure the lifting eye is fully engaged in the turbocharger bearing housing and the shoulder of the lifting eye is in contact with the bearing housing.

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 cooling system. Refer to Procedure 008-018 in Section 8.
• Remove the exhaust connection and inlet air pipe. Refer to Procedure 010-024 in Section 10. Cover open points with caps from the Cummins® Vehicle Air Plumbing Clean Care Kit, Part Number 4919425.
• Remove the discharge elbow on the charge-air cooler connection. Refer to Procedure 010-027 in Section 10. Cover open points with caps from the Cummins® Vehicle Air Plumbing Clean Care Kit, Part Number 4919425.
• Disconnect the turbocharger speed sensor and compressor air inlet temperature sensors. Use the following procedure in the Electronic Control System Troubleshooting and Repair Manual, Bulletin 4021560. Refer to Procedure 019-390 in Section 19.
• Disconnect the coolant supply and return lines. Refer to Procedure 010-041 in Section 10.
• Disconnect the aftertreatment injector adapter tube. Refer to Procedure 011-043 in Section 11.
• Remove the oil supply line from the turbocharger. Refer to Procedure 010-046 in Section 10.
• Remove the oil drain line from the turbocharger. Refer to Procedure 010-045 in Section 10.

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.

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

CAUTION  When the lifting eye is installed, it is to be used for lifting the turbocharger only. Lifting additional weight may cause damage to the turbocharger.

CAUTION  When using a lifting eye, make sure the lifting eye is fully engaged in the turbocharger bearing housing and the shoulder of the lifting eye is in contact with the bearing housing.

• Drain the cooling system. Refer to Procedure 008-018 in Section 8.
• Remove the exhaust connection and inlet air pipe. Refer to Procedure 010-024 in Section 10.
• Remove the discharge elbow on the charge-air cooler connection. Refer to Procedure 010-027 in Section 10.
• Disconnect the turbocharger speed sensor and compressor air inlet temperature sensors. Refer to Procedure 019-390 in Section 19 in the Electronic Control System Troubleshooting and Repair Manul, Bulletin Number 4021560.
• Disconnect the actuator air supply line. Refer to Procedure 010-118 in Section 10.
• Disconnect the coolant supply and return lines. Refer to Procedure 010-041 in Section 10.
• Remove the oil supply line from the turbocharger. Refer to Procedure 010-046 in Section 10.
• Remove the oil drain line from the turbocharger. Refer to Procedure 010-045 in Section 10.

WARNING  Do no 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.

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

If a wastegated turbocharger is used, remove the wastegate actuator signal line by cutting the crimped hose clamp.

• Remove the exhaust connection and the inlet air pipes. Refer to Procedure 010-024 in Section 10.
• Remove the oil supply line. Refer to Procedure 010-046 in Section 10.
• Remove the oil drain line. Refer to Procedure 010-045 in Section 10.

NOTE: Some applications use water-cooled turbochargers.

• If a water-cooled turbocharger is used, drain the cooling system. Refer to Procedure 008-018 in Section 8.
• Remove the turbocharger coolant hoses from the turbocharger. Refer to Procedure 010-041 in Section 10.
• Remove the discharge elbow from the turbocharger compressor discharge outlet. Refer to Procedure 010-027 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  When installing the lifting eye, make sure the shoulder of the lifting eye is bottomed against the 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 the turbocharger.

CAUTION  The turbocharger actuator must not be used as a lifting mechanism. Doing so will cause damage to the turbocharger actuator.

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 from the engine.

Remove the four turbocharger mounting nuts.

Remove the nuts from the turbocharger studs and remove the turbocharger.

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 a cap from the Air Handling and Vehicle Air Plumbing Clean Care Kits, Part Number 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.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

CAUTION  When installing the lifting eye, make sure the shoulder of the lifting eye is bottomed against the 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 the turbocharger.

CAUTION  The turbocharger actuator must not be used as a lifting mechanism. Doing so will cause damage to the turbocharger actuator.

NOTE: ISM CM870 and CM570 – 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.

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 from the engine.

Remove the four turbocharger mounting nuts from the turbocharger studs and remove the turbocharger.

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.

Remove the four turbocharger mounting nuts.

Remove the turbocharger and gasket.

Turbine Housing Replacement for ISM Automotive with CM570, QSM11 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 ISM Automotive with CM570, QSM11 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.

The 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.

NOTE: This procedure only applies to Automotive with CM570, QSM11 with CM570, and Power Generation with CM570. Do not use these cleaning procdures on variable geometry turbochargers (VGT).

NOTE: The turbocharger turbine housing surface adjacent to the turbine compressor wheels must be clean, smooth, and free from deposits.

Automotive with CM570, QSM11 with CM570, and Power Generation with CM570

• Turbocharger Turbine Housing Cleaning
• Inspect the components to detect signs of burning and other conditions in order to obtain as much information as possible before washing.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING  Some solvents are flammable and toxic. Read the manufacturer’s instructions before using.

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

WARNING  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.

WARNING  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 off and plug all items.

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

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

After removing the deposits, wash and dry the components.

Clean the mounting nut mating surfaces of the turbocharger and the exhaust manifold 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 3824379.

Use a clean cloth to wipe around the turbocharger sealing surfaces.

NOTE: Take care not to drop any dirt or debris into the turbocharger.

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

Inspect the turbocharger, exhaust manifold gasket surfaces, and mounting studs for cracks or other damage.

Inspect the turbine and compressor housings.

If cracks exist on the outer walls, the housing must be replaced.

A charge-air cooler failure can cause progressive damage to the turbine housing. If the turbine housing is damaged, check the charge-air cooler. Refer to Procedure 010-027 in Section 10.

Cracks in the mounting flange longer than 15 mm [0.6 in] are not acceptable.

Cracks of any length that reach mounting holes are not acceptable.

Two cracks must be separated by at least 6.4 mm [0.25 in].

Cracks of any length that extend through the divider are acceptable but, only if they are separated by at least 12.5 mm [0.50 in].

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. Refer to Procedure 010-023 in Section 10.

Push the rotor assembly away from the gauge.

Set a dial depth gauge, Part Number ST-537, or equivalent, on 0.

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

Wastegate Axial Clearance

Variable Geometry Axial Clearance

Replace the turbocharger if the clearance does not meet the specifications.

For wastegate turbochargers, use a wire-type feeler gauge to measure the radial clearance between the compressor wheel and housing.

Gently push the compressor wheel toward the compressor housing and gauge.

Record the clearance.

With the feeler gauge in the same location, gently push the compressor wheel away from the compressor housing and measure the clearance between the compressor wheel and the housing.

Subtract the smaller clearance from the larger clearance. This is the radial bearing clearance.

Wastegate Radial Bearing Clearance

For variable geometry turbochargers, check the radial clearance of the rotor system by pushing the compressor wheel toward the wall of the compressor cover with light finger pressure. The turbocharger passes inspection if the wheel does not contact the compressor cover wall.

Repeat the procedure on the turbine wheel.

Replace the turbocharger if the radial bearing clearance does not meet specifications.

On water cooled bearing housing turbochargers, inspect the bearing housing and actuator for external oil or coolant leaks.

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

If evidence of coolant is found, see the Initial Check section of this procedure for the turbocharger coolant leak test.

ISM Automotive with CM570, QSM11 with CM570 and Power Generation with CM570

• 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 tighten the locknut.

Torque value for Cummins®-branded turbochargers.

Torque value for Holset®-branded turbochargers.

Loosen the locknut 180 degrees, and tighten the locknut.

Torque value for Cummins®-branded turbochargers.

Torque value for Holset®-branded turbochargers.

Make certain the rotor assembly rotates freely and the compressor wheel and turbine wheel are not rubbing against the housing.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

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

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

CAUTION  The turbocharger actuator must not be used as a lifting mechanism. Doing so will cause damage to the turbocharger actuator.

Thread a lifting strap around the turbocharger bearing housing. Take care to not 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.

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.

If installing a new turbocharger, install the coolant inlet and outlet fittings. Refer to Procedure 010-041 in Section 10.

If installing a new turbocharger, install the oil supply fitting. Refer to Procedure 010-046 in Section 10.

NOTE: Use a ratchet and deepwell socket on these fittings.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

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

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

CAUTION  The turbocharger actuator must not be used as a lifting mechanism. Doing so will cause damage to the turbocharger actuator.

NOTE: ISM CM870 and CM570 – 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.

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.

If installing a new turbocharger, install the coolant inlet and outlet fittings. Refer to Procedure 010-041 in Section 10.

If installing a new turbocharger, install the oil supply fitting. Refer to Procedure 010-046 in Section 10.

NOTE: Use a ratchet and deepwell socket on these fittings.

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

Apply a film of anti-seize compound, Part Number 3824879 or equivalent, to the turbocharger mounting studs.

Use a new gasket when installing the turbocharger.

Install and tighten the four mounting nuts.

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.

• Install a new o-ring, the clamp, and the charge-air cooler elbow to the turbocharger. Refer to Procedure 010-027 in Section 10.
• 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 010-023 in Section 10. Refer to Procedure 010-027 in Section 10.
• Connect the coolant supply and return lines. Refer to Procedure 010-041 in Section 10.
• Install the oil supply line. Refer to Procedure 010-046 in Section 10.
• Install the oil drain lines. Refer to Procedure 010-045 in Section 10.
• Connect the actuator electrical connector.
• Connect the turbocharger speed sensor and compressor inlet temperature sensors. For the ISM engine, see the following procedure in the Electronic Control System Troubleshooting and Repair Manual, Bulletin 4021560. Refer to Procedure 019-390 in Section 19.
• Connect the inlet air pipe to turbocharger compressor inlet and install the exhaust connection. Refer to Procedure 010-024 in Section 10.
• Fill the engine with coolant. Refer to Procedure 008-018 in Section 8.
• Start the engine and verify operation of the turbocharger.
• Check for coolant, oil, and air leaks.

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.

• Install a new o-ring, the clamp and the charge-air cooler elbow to the turbocharger. Refer to Procedure 010-027 in Section 10..
• 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 010-023 in Section 10. Refer to Procedure 010-027 in Section 10.
• Connect the coolant supply and return lines. Refer to Procedure 010-041 in Section 10.
• Install the oil supply line. Refer to Procedure 010-046 in Section 10.
• Install the oil drain lines. Refer to Procedure 010-045 in Section 10.
• Connect the air line to the actuator. Refer to Procedure 010-118 in Section 10.
• Connect the turbocharger speed sensor and compressor inlet temperature sensors. For ISM engines, see the following procedure in the Electronic Control System Troubleshooting and Repair Manual. Refer to Procedure 019-390 in Section 19.
• Connect the inlet air pipe to turbocharger compressor inlet and install the exhaust connection. Refer to Procedure 010-024 in Section 10.
• Fill the engine with coolant. Refer to Procedure 008-018 in Section 8.
• Start the engine and verify operation of the turbocharger.
• Check for coolant, oil, and air leaks.

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.

• Connect the wastegate. Refer to Procedure 010-050 in Section 10.
• Install the oil supply line. Refer to Procedure 010-046 in Section 10.
• Install the oil drain line. Refer to Procedure 010-045 in Section 10.
• Connect the inlet air pipes to turbocharger compressor inlet and install the exhaust connection. Refer to Procedure 010-024 in Section 10.
• Install the new o-ring clamp and charge-air cooler elbow to the turbocharger. Refer to Procedure 010-027 in Section 10.
• Connect the coolant supply and return lines. Refer to Procedure 010-041 in Section 10.
• Fill the engine with coolant. Refer to Procedure 008-018 in Section 8.
• Operate the engine and check for leaks.