Cummins ISX11.9 CM2250 – Service Manual 010-033   Turbocharger

Remove the protective caps and heavy tape from the Air Handling Clean Care Kit, Part Number 4919799, used to cover open points in the air handling system.

WARNING  Remove the plastic shipping plugs in the turbocharger bearing housing for the oil supply and oil drain. Failure to remove the oil supply shipping plug will damage the turbocharger. Failure to remove the oil drain shipping plug will damage the oil compressor seal. Engine oil can be sucked through the air intake system and cause engine acceleration and overspeeding that can result in a fire, an explosion, and extensive property damage.

Remove the plastic shipping plugs from the oil drain and oil supply holes located in the turbocharger bearing housing.

Install the oil supply fitting. Refer to Procedure 010-046 in Section 10.

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.

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.

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 turbocharger and actuator coolant lines when lifting the turbocharger.

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

Install a new gasket, the turbocharger, and the four mounting nuts. Be sure the mounting spacers are properly positioned.

Tighten the mounting nuts. After all four mounting nuts are tightened, tighten the first mounting nut again.

If installing a new turbocharger, it may be necessary to rotate the turbocharger compressor housing to properly align with the charge-air cooler piping.

Rotate the turbocharger compressor housing by loosening the V-band between the turbocharger bearing housing and the turbocharger compressor housing.

Rotate the turbocharger compressor housing to properly align with the charge-air cooler piping.

Tighten the V-band clamp.

WARNING  The turbocharger speed sensor harness must be tied up and away from any heat sources and hard or sharp surfaces. Failure to do so will cause damage to the harness.

WARNING  Do not install cable ties directly over the sensor connector. Doing so can damage the connector. Tie the speed sensor wiring harness on either side of the connectors.

Use cable ties to secure the turbocharger actuator harness and the turbocharger speed sensor harness away from any heat sources and hard or sharp surfaces.