Cummins ISX11.9 CM2250 – Service Manual 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  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.

• Disconnect the batteries. Refer to the OEM service manual.
• Drain the coolant. Refer to Procedure 008-018 in Section 8.

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

Remove the turbocharger coolant supply hose from the lubricating oil filter head.

Remove the smaller banjo bolt from the turbocharger electric actuator coolant inlet port and the large banjo bolt from the turbocharger bearing housing coolant inlet port.

Remove and discard all banjo sealing washers.

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

Remove the turbocharger bearing housing coolant return hose from the top of the turbocharger bearing housing and the rocker housing.

Remove and discard all banjo sealing washers.

Remove the turbocharger actuator coolant return hose by removing the banjo from the coolant inlet side of the EGR mass measurement flow assembly, the tube nut at the aftertreatment fuel injector, and the banjo from the turbocharger actuator coolant return port.

Remove and discard all banjo sealing washers.

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.

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

Clean the turbocharger coolant hoses with solvent.

Dry with compressed air.

Check the o-rings for cuts or deformation. Replace as necessary.

Check the turbocharger coolant hoses for cracks or other damage.

Replace if damage is found.

Check the face of the coolant fittings on the engine and on the turbocharger to be sure the o-ring is in place and is not damaged.

A damaged or missing o-ring will result in a coolant leak.

Replace the o-rings as necessary.

CAUTION  Do not bend or kink hoses while tightening. Doing so can damage the lines.

CAUTION  Do not use petroleum products on the turbocharger coolant line o-rings. The o-rings will swell and cause the connection to leak.

Install four new banjo sealing washers on the turbocharger coolant supply hose.

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

Install and tighten the turbocharger actuator return coolant hose to the inlet of the EGR mass measurement flow assembly.

Install and tighten the turbocharger actuator return coolant hose to the turbocharger actuator coolant return port.

NOTE: Use a second wrench to hold the coolant hose coupling while tightening the hose.

Install and tighten the turbocharger actuator return coolant hose to the aftertreatment fuel injector.

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

CAUTION  Do not use petroleum products on the turbocharger coolant hose o-rings. The o-rings will swell and cause the connection to leak.

Install two new sealing washers on the coolant return hose rocker housing connection.

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

NOTE: Use a second wrench to hold the coolant hose coupling while tightening the hose.

Install the turbocharger bearing housing coolant return hose to the top of the turbocharger bearing housing. Tighten the fitting.

Install the turbocharger bearing housing coolant return hose in the rokcer housing. Tighten the banjo fitting.

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

CAUTION  Do not use petroleum products on the turbocharger coolant hose o-rings. The o-rings will swell and cause the connection to leak.

Install four new banjo sealing washers on the turbocharger coolant supply hose.

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

NOTE: Use a second wrench to hold the coolant hose coupling while tightening the hose.

Install and tighten the turbocharger coolant supply hose to the turbocharger bearing housing.

Install and tighten the turbocharger coolant supply hose to the turbocharger actuator.

Install and tighten the turbocharger coolant supply hose to the lubricating oil filter head.

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 engine with coolant. Refer to Procedure 008-018 in Section 8.
• Connect the batteries. Refer to the OEM service manual.
• Operate the engine and check for leaks.