ISM, ISMe, and QSM11 – 010-041   Turbocharger Coolant Hoses

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

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.

• Disconnect the batteries. Refer to Procedure 013-009.
• Drain the coolant. Refer to Procedure 008-018.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

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.

• Disconnect the batteries. Refer to Procedure 013-009.
• Remove the turbocharger oil supply line. Refer to Procedure 010-045.
• Remove the oil drain lines from the turbocharger. Refer to Procedure 010-046.
• Drain the coolant. Refer to Procedure 008-018.

Use a second wrench to hold the coolant line coupling while loosening the line.

Remove the turbocharger coolant supply line (bottom) from the EGR coolant supply tube.

Remove the turbocharger return (top) line from the water manifold and the turbocharger.

NOTE: Use a second wrench to hold the coolant line coupling while loosening the line.

Remove the turbocharger coolant supply line from the bottom of the turbocharger and the EGR cooler coolant supply tube.

Remove and discard the banjo sealing washers.

Remove the turbocharger actuator coolant supply line from the bottom of the turbocharger bearing housing by removing the retaining nut, the banjo bolt, and washers from the actuator.

Remove the adapter.

Remove and discard the banjo sealing washers.

NOTE: Use a second wrench to hold the coolant line coupling while loosening the line.

Remove the turbocharger coolant return line from the top of the turbocharger and the water manifold housing.

Remove and discard the banjo sealing washers.

Remove the turbocharger actuator coolant return line (1) from the turbocharger coolant out fitting adapter (2) by loosening the retaining nut (3) and the banjo bolt and washers (4).

Remove the coolant supply and return fittings from the turbocharger bearing housing if replacing it with a new component. (Service turbochargers are not supplied with these fittings.)

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

Clean the turbocharger coolant lines with solvent.

Dry with compressed air.

Check the o-rings for cuts or deformation. Replace if damage is found.

Check the turbocharger coolant lines for cracks or other damage. Replace if damage is found.

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

Clean the turbocharger coolant lines with solvent.

Dry with compressed air.

Check the o-rings and banjo washers for cuts or deformation. Replace if damage is found.

Check the turbocharger coolant lines for cracks or any other damage. Replace if damage is found.

Check the face of the coolant fittings on the engine and on the turbocharger to make sure the o-ring is in place and is not damaged. A damaged or missing o-ring will result in a coolant leak.

CAUTION  Do not bend or kink hoses while tightening. Doing so may damage the line.

CAUTION  Do not use thread sealant on fittings. doing so can possibility damage internal components.

CAUTION  Check the face of the coolant fitting on the engine and on turbocharger to make sure o-ring is in place and is not damaged. A damaged or missing o-ring will result in a coolant leak.

Use a second wrench to hold the coolant line coupling while tightening the line.

Install the turbocharger coolant supply line to the EGR supply line and the turbocharger and the return lines to the water manifold and turbocharger.

CAUTION  Do not use petroleum products on the banjo sealing washers. The sealing material will swell and cause the connection to leak.

Install the coolant inlet and outlet fitting adapters into the turbocharger bearing housing.

Lubricate the banjo sealing washers with clean engine coolant, soapy water, or vegetable oil.

Install the banjo washers on each side of both coolant return tube ports.

Install the turbocharger actuator coolant return line (1) to the turbocharger coolant outlet fitting (2) by installing the retaining nut (3). Do not torque.

Install the banjo bolt. Tighten the banjo bolt and washers (4).

Tighten the turbocharger coolant outlet retaining nut (3).

Install the turbocharger coolant return line on top of the turbocharger and the water manifold housing.

CAUTION  Do not use petroleum products on the banjo sealing washers. The sealing material will swell and cause the connection to leak.

Lubricate the banjo sealing washer with clean engine coolant, soapy water, or vegetable oil.

Install the banjo washers on each side of both coolant supply tube ports.

Install the turbocharger coolant supply line to the bottom of the turbocharger bearing housing by installing the retaining nut (1). Do not torque.

Install the turbocharger actuator coolant supply banjo bolt (2).

Tighten the turbocharger coolant supply retaining nut (1).

Install the coolant supply line.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Fill the cooling system. Refer to Procedure 008-018.
• Connect the batteries. Refer to Procedure 013-009.
• Operate the engine and check for leaks.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Install the turbocharger oil supply line. Refer to Procedure 010-045. and 010-046.
• Install the .oil drain lines to the turbocharger. Refer to Procedure 010-046.
• Fill the coolant. Refer to Procedure 008-018.
• Connect the batteries. Refer to Procedure 013-009.
• Operate engine and check for leaks.