(/qs3/pubsys2/xml/en/manual/4021528/4021528-titlepage.

html)

General Information
with Mechanically Actuated Injector
All K38 and K50 engines are turbocharged. All turbochargers on K38 and K50 engines are oil
cooled and lubricated. The engine can have two or four turbochargers.

If the engine has four turbochargers, the two that are mounted on the exhaust manifold are
the high-pressure turbochargers, and the two that are mounted on the support brackets are
the low-pressure turbochargers.

The correct turbocharger assembly must be installed. Many turbochargers appear the same
physically, but contain different internal parts. If the wrong turbocharger assembly is installed,
the performance of the engine will be less than specification, or the engine will be damaged
due to excessive pressure and temperature in the cylinders.
K38 and K50 engines can contain turbochargers that are manufactured by Holset®, Brown
Boveri®, or AiResearch®. In some cases turbochargers from two different vendors are on the
same engine. One of the dataplates that is attached to the turbocharger identifies the vendor,
the turbocharger model, and the Cummins® part number. Cummins Inc. identifies the
turbocharger by the part number, not the model nomenclature.

This manual does not contain information to rebuild the turbocharger. See the following
turbocharger rebuild manuals:

Model Number and

Manufacturer Bulletin
Description
HC5A Turbocharger Shop
Holset® 3810243
Manual
HT100 Series Turbocharger
Holset® 3810386
Shop Manual
Brown Boveri®
Brown Boveri® 3810235
Turbocharger Manual
T18A, Turbocharger Rebuild
AiResearch® 3379091
Manual
Two oil supply hoses are installed on K38 and K50 engines. The length of the hose for KT38,
KTA38, and KTA50 engines is 1295 mm [51 in]. The length of the hose for KTTA38 and
KTTA5O engines is 1092 mm [43 in].
The turbocharger oil drain assembly for the K38 is shorter on engines with dry type exhaust
manifolds than on engines with wet type exhaust manifolds. The turbocharger oil drain
assembly for the K50 is the same as that installed on the K38 with a wet type exhaust
manifold.
The method for connecting the turbocharger oil drain to the cylinder block was changed.
Engines with an engine serial number (ESN) of 33106693 and greater have a flange and an
o-ring seal type connection that is secured with a capscrew. Engines with an ESN of
33106692 and lower have a 90 degree fitting with pipe threads.

A revised turbocharger compressor wheel was released for KTA50-G engines in September,
1985, ESN First 33110070.

Turbochargers with a hose nipple on the compressor discharge and a hose type air crossover
were released for use in production on the KTA38 engines in September 1986, ESN First
33111500.

A chamfer was added to the diffuser plate on HC5A turbochargers to allow oil drain back to
the sump in February, 1987, ESN First 33111870.

A revised profile, turbocharger mounting gasket was released in August, 1987, ESN First
33112713.

A turbocharger oil drain hose that is manufactured of flexible hose is available for engines built
previously with a one or two piece steel tube for the oil drain hose. The two piece steel tube
that is connected by a hump hose is available for service on engines that have AiResearch®
turbochargers only.

The KTTA50 low-pressure turbocharger oil drain hose and drain location was changed in
1988, to provide a better downhill return to the cylinder block. The revised oil drain hose
routing also requires a revised turbocharger support, which is modified to provide clearance
for the new oil drain hose and a different clamp to retain the oil drain hose.

The revised hose drains the oil to drillings on the top deck at the front of the right bank and the
left of the rear bank of the cylinder block. The holes used are partially covered by the
turbocharger support. This support requires modification or replacement.

The mounting capscrew for the flange and o-ring seal type turbocharger drain hose
connection was changed from 0.250 inch -20 UNC to 0.375 inch -16 UNC. The cylinder block
with the smaller holes requires a spacer, Part Number 3177195, between the connection
flange and the cylinder block at the left bank rear location. If the spacer is not installed, an oil
leak will result because the o-ring seal will not be in the bore correctly.

The flange on the turbocharger oil drain hose that fits to the turbocharger is different for
Holset® and AiResearch® turbochargers. The oil drain hose flange is different for the Brown
Boveri® type turbocharger. If the model of turbocharger is changed, the oil drain hose must
be changed.

A K50 turbine housing with a thickened flange between the capscrew holes to reduce flange
distortion was released in February 1988, ESN First 33114833. This is for the K50 pulse
exhaust manifolds only.
 Longer studs, nuts, and spacers were released for the K50 pulse exhaust manifold in May,
1989, ESN First 33115948.

The K50 turbocharger mounting flange was completely thickened to improve gasket reliability.
The spacer is no longer required for K50 pulse exhaust manifold engines produced in
February, 1990, ESN First 33117281.

The K50 pulse exhaust manifold received a boss to allow use of capscrews in place of studs
on engines produced from February, 1990, ESN First 33117392.

A steel oil supply fitting replaced the brass fitting to prevent torque loss/loosening on engines
produced from February, 1990, ESN First 33117392.

A steel oil supply fitting replaced the brass fitting to prevent torque loss/loosening on engines
produced from September 1990, ESN First 33118322.

The Holset® HT100 low-pressure turbocharger replaced the Brown Boveri® RR151
turbocharger for C1800B and K2000 engines in January 1991, ESN First 33119163.

Note : The HT100 turbocharger can not be used to replace the Brown Boveri®
Model RR153 that is used on the KTTA50-C1800A engines.
The Holset® HX80 water-cooled turbocharger design was revised in 1997, to allow for the use
of GAS fittings on all coolant passage openings in the casting. O-ring seal fittings are less
prone to leakage, and are easier to remove and install. The diffuser plate was also changed to
a “sunk wheel” design.

Preparatory Steps
with Mechanically Actuated Injector

 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.

 WARNING 

To reduce the possibility of personal injury, avoid direct

contact of hot oil with your skin.

Disconnect the batteries. Refer to the OEM service

manual.
Turn the air OFF to the air starter, if equipped, and tag
the valve closed. Refer to Procedure 012-022 in Section
12. (/qs3/pubsys2/xml/en/procedures/102/102-012-
022.html)
Drain the cooling system to a point below the
turbochargers. Refer to Procedure 008-018 in Section 8.
(/qs3/pubsys2/xml/en/procedures/28/28-008-018-tr.html)
Remove the coolant supply and return lines. Refer to
Procedure 010-041 in Section 10.
(/qs3/pubsys2/xml/en/procedures/28/28-010-041.html)

with Electronically Actuated Injector

 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.
  WARNING 

To reduce the possibility of personal injury, avoid direct

contact of hot oil with your skin.

Disconnect the batteries. Refer to the OEM service

manual.
Turn the air OFF to the air starter, if equipped, and tag
the valve closed. Refer to Procedure 012-022 in Section
12. (/qs3/pubsys2/xml/en/procedures/102/102-012-
022.html)
Drain the cooling system to a point below the
turbochargers. Refer to Procedure 008-018 in Section 8.
(/qs3/pubsys2/xml/en/procedures/28/28-008-018-tr.html)
Remove the coolant supply and return lines. Refer to
Procedure 010-041 in Section 10.
(/qs3/pubsys2/xml/en/procedures/28/28-010-041-tr.html)
Remove the oil supply lines. Refer to Procedure 010-
046 in Section 10.
(/qs3/pubsys2/xml/en/procedures/28/28-010-046-tr.html)
Remove the oil drain lines. Refer to Procedure 010-045
in Section 10. (/qs3/pubsys2/xml/en/procedures/28/28-
010-045-tr.html)

Remove
with Mechanically Actuated Injector

Note : The turbochargers, mounting hardware, and

connections are not the same for all models of K38
and K50 engines. Because the parts are different,
procedures are given for removal of the following
turbochargers.
KT38, KTA38, and KTA50 with Center Mount Aftercooler
KTTA38 Low-Pressure
KTTA50 Low-Pressure
K2000E Low-Pressure
KTTA38, KTTA50, K1500E, K1800E and K2000E High-
Pressure, and KT38, KTA38, and KTA50 with Outboard
Aftercoolers
Note : The oil inlet and drain hose routing and clamps
can be different than shown, depending on the age of
the engine.
KT38, KTA38, and KTA50 with Center Mount Aftercooler

Note : The illustrations show a KTA38. The KTA50

has a longer connection between the turbocharger
and the aftercooler.
Older engines can have a spacer for the capscrew (23).
Keep the spacer for future assembly.

Detach the oil drain hose from the cylinder block. Remove
the o-ring seal (21).

Discard the seal.

Detach the oil drain hose from the turbocharger. Remove the
gasket (17).
Discard the gasket.

Check the hose (18) for damage. Discard the part if it is

damaged.

Detach the oil inlet hose (16). Removal of the fitting (15) and
the o-ring seal (14) is not required unless they are damaged.

Remove any support clamps from the hose.

Remove the hose. Check the hose for damage. Discard the
part if it is damaged.

Newer engines have a hose and clamps between the

turbochargers and air transfer housings.

The clamps are special high strength parts.

Loosen the hose clamps (2).

Older engines have retaining straps.

Remove the capscrews and the retaining straps (10).

Check the straps for damage. Discard the part if it is

damaged.
  WARNING 

The 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.

Remove the four capscrews (8) and nuts (9).

Remove the turbocharger and gasket.

Discard the gasket.

On newer engines, remove the clamps and the hose.

Discard the hose.

Check the clamps for damage. Discard the part if it is

damaged.

On older engines, remove the tube (5). Remove the o-ring

seals (4).

Discard the seals.

Remove the dust seal (3).

If the dust seal is hard or soaked with oil, discard the part.

KTTA38 Low Pressure:

Remove the oil drain hose (30). Remove the gasket (29) and
the o-ring seal (33).

Discard the gasket and seal.

Check the hose for damage. Discard the part if it is

damaged.
Detach the oil inlet hose (16). The removal of the fitting (15)
and the o-ring seal (14) is not required unless damaged.

Remove any support clamps from the hose. Remove the

hose.

Check the hose for damage. Discard the part if it is

damaged.

 WARNING 

The 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.

Remove the four capscrews (27) and the nuts (28).

Remove the turbocharger and the gasket.

Discard the gasket.

Loosen the hose clamps (24). Remove the clamps and the
hose (23) from the high-pressure turbocharger air
connection.

Remove the air connection (21) from the high-pressure

turbocharger. Remove the o-ring seals (19).

Discard the seals.

Remove the dust seal (22). If the dust seal is hard or soaked
in oil, discard the part.

Remove the four capscrews (12) and nuts (18). The heavy
washers (13) and capscrews are special heat resistant parts.

Remove the exhaust connection (11) and the exhaust outlet

pipe (10).
Remove the v-band clamp (8) and the exhaust outlet
connection (9).

Remove the six capscrews (7). The heavy flat washers (5)
are special. Remove the support plate (4).

Remove the socket head capscrew (3). Remove the

turbocharger support legs (1).

KTTA50 Low-Pressure

The Brown Boveri®, Model RR151, turbochargers contain

metric fasteners for the oil connection plates.

Remove the oil drain hose (48).

Remove the gasket (47) and o-ring seal (51).

Discard the gasket and seal.

Check the hose for damage. Discard the part if it is

damaged.

Some Brown Boveri® turbochargers do not contain the

adapter plates for the oil inlet.

Detach the oil inlet hose. The adapter plates (44) and fittings
do not require removal.

Remove any support clamps. Remove the hose.

Check the hose for damage. Discard the part if it is
damaged.

Remove the four capscrews (40) and nuts (42). Remove the
gasket.

Discard the gasket.

Remove the two capscrews (35) that hold the exhaust side
of the turbocharger to the support bracket.

Remove the two capscrews (31) and nuts (34) that hold the
intake support bracket to the turbocharger support bracket.

 WARNING 

The 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.

Remove the low-pressure turbocharger (16).

Loosen the hose clamps (12). Pull the intake connection

pipe (15) from the high-pressure turbocharger. Remove and
discard the o-ring seals (13) and the hose (11). Remove the
dust seal.

If the dust seal is hard or soaked with oil, discard the part.
Remove the exhaust connection (11) and outlet pipe (10).

Remove the v-band clamp (8) and the exhaust outlet GRAPHIC NOT FOUND
connection (9).

Remove the six capscrews (7). Remove the turbocharger

support bracket (4).

Remove the socket head capscrews (3). Remove the

turbocharger bracket support legs (1).

K2000E Low-Pressure:

Remove the oil drain hose (60). Remove the gasket (59) and
o-ring seal (63).

Discard the gasket and seal.

Check the hose for damage. Discard the part if it is

damaged.

Detach the oil inlet hose. Removal of the fitting, plate, (56)
and gasket (55) is not required.

Remove any support clamps from the hose. Remove the

hose.

Check the hose for damage. Discard the part if it is

damaged.
Remove the heat shield (blanket) from the interstage air
hose.

Loosen the two T-bolt clamps (45) on the air intake pipe (47)
and the compressor inlet.

Remove the four capscrews (49) and nuts (52) that hold the
air intake pipe (47) to the turbocharger compressor outlet.

Remove the air intake pipe (47).

Check the pipe for damage. Discard the part if it is damaged.

Loosen the v-band clamp (8).

Remove the four capscrews (12) and nuts (14) that hold the
two exhaust connections (9 and 11).

Remove the four capscrews (40) and nuts (42) that hold the
exhaust connection to the turbine housing.
Remove the exhaust connection.

Remove the two capscrews (31) and nuts (25) that hold the
bracket (32) to the connection (26).

Remove the two capscrews (43) and the nuts (34) that hold
the bracket (32) to the support bracket (4).

 WARNING 

The 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.

Remove the two capscrews (35) and nuts (38) that hold the
turbocharger exhaust outlet connection to the bracket.

Remove the turbocharger.

KTTA38, KTTA50, K1500E, K1800E and K2000E High-

Pressure, and KT38, KTA38, and KTA50 with Outboard
Aftercoolers

If the engine being serviced is a KT38, KTA38, or KTA50,

record the direction of the turbocharger exhaust outlet and
mark the exhaust manifolds for location. This will aid the
assembly process as the exhaust can be either front out or
rear out.
 Detach the oil drain hose from the cylinder block. Remove
the o-ring seal (9).

Discard the o-ring seal.

Check the hose for damage. Discard the part if it is
damaged.

Detach the oil drain hose from the turbocharger. Remove

any support clamps and the hose. Remove the gasket (5).

Discard the gasket.

Check the hose for damage. Discard the part if it is
damaged.

Removal of the fitting (15) and the o-ring (14) is not

required.

Detach the oil inlet hose. Remove any support clamps.

Remove the hose.

Check the hose for damage. Discard the part if it is

damaged.

 WARNING 

The 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.

Remove the four capscrews (3) and the nuts (4). Remove
the turbocharger and gasket.

Discard the gasket.

with Electronically Actuated Injector

Remove the low-pressure turbocharger air intake and
bracket.
Remove the low-pressure turbocharger exhaust adapter and
bracket.

Remove the eight nuts, plain washers, nuts, capscrews and GRAPHIC NOT FOUND
p-clips from the air transfer connections.

Remove the air transfer connections and discard the

gaskets.

Note : Note the orientation of the capscrews and nuts

in the transfer tube prior to removal. The capscrews
must be installed in the same orientation during
installation.
Remove the eight nuts, plain washers, and capscrews, and
remove the air transfer piping. Discard the gaskets.

 WARNING  GRAPHIC NOT FOUND

The 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.

Remove the low-pressure turbochargers.

Loosen and remove the clamps and hoses connecting the

turbochargers to the intake manifold.
 Remove the clamps from the high-pressure turbocharger
and air transfer connection.

Remove the air transfer from the high-pressure turbocharger.

Remove the four capscrews, nuts, and washers and remove

the exhaust outlet connection from the high-pressure
turbocharger.

Remove the exhaust outlet clamp and outlet connection from

the turbocharger.

Remove the four mounting capscrews, nuts and washers

from each high-pressure turbocharger.

Gas Compression

 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.

Remove the mounting capscrews and lock washers.

Remove the turbocharger and gasket.

Discard the gasket.

Clean
 CAUTION 
Tape or plug all openings to prevent solvent or steam
from entering the oil cavities in the turbocharger.

This procedure applies to all models of turbocharger on K38

and K50 engines. See General Information at the beginning
of this section.

 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 
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
can cause serious personal injury.

Use solvent or steam. Clean the exterior of the turbocharger.

Inspect for Reuse
Inspect the turbine and compressor wheels for fretting and
broken vanes.

Use a dial depth gauge, Part Number ST-537, or a dial

indicator to measure the axial motion (end-to-end).

Compressor Impeller Axial End Clearance

mm in
Holset®
HC5,
HC5A, 0.025 MIN 0.001
(127 mm
wheel)
  0.152 MAX 0.006
Holset®
HC5,
HC5A, 0.025 MIN 0.001
(130 mm
wheel)
  0.152 MAX 0.006
Holset®
HX80/HX8 0.025 MIN 0.001
5
  0.152 MAX 0.006
Holset®
HX82/HX8 0.025 MIN 0.001
3
  0.152 MAX 0.006
Holset®
0.035 MIN 0.001
HE800
  0.115 MAX 0.005
Holset®
0.050 MIN 0.002
HT100
  0.152 MAX 0.006
Make sure the movement is within the MIN/MAX Total
Indicator Readings (TIR) values shown above.
Note : If the end clearance exceeds the
specifications, the turbocharger must be replaced or
rebuilt. Contact a Cummins® Authorized Repair
Location. Reference the HC5A Turbocharger Shop
Manual, Bulletin 3810243, or the HT100 Series
Turbocharger Shop Manual, Bulletin 3810386, for
rebuild instructions.

Measure the radial clearance (side-to-side) at the

compressor nose, using a dial gauge.

Compressor Impeller Radial Clearance

mm in
Holset®
HC5,
HC5A, 0.228 MIN 0.009
(127 mm
wheel)
  0.686 MAX 0.027
Holset®
HC5,
HC5A, 0.228 MIN 0.009
(130 mm
wheel)
  0.762 MAX 0.03
Holset®
HX80/HX8 0.254 MIN 0.01
5
  0.787 MAX 0.031
Holset®
HX82/HX8 0.254 MIN 0.010
3
  0.787 MAX 0.031
Holset®
0.254 MIN 0.010
HE800
  0.787 MAX 0.031
Holset®
0.254 MIN 0.01
HT100
  0.813 MAX 0.032
Make sure the movement is within the MIN/MAX TIR values
shown above.

Note : If the clearance exceeds the specifications, the

turbocharger must be replaced or rebuilt. Contact a
Cummins® Authorized Repair Location. See HC5A
Turbo Shop Manual, Bulletin 3810243, or HT100
Series Turbocharger Shop Manual, Bulletin 3810386,
for rebuild instructions.

Note : Check the model of turbocharger installed on

the engine, this is for: BrownBoveri®, Model RR-153
and RR-151.
To measure axial clearance, use Part Number ST-537, Dial
Depth Gauge, or a dial indicator. Measure the axial motion.

BBC (RR-151) and (RR-153) End Clearance

mm in
0.09 MIN 0.004
0.13 MAX 0.005

If the end clearance exceeds the specifications, the

turbocharger must be replaced or rebuilt. Use the following
manual for rebuild instructions. Reference the BrownBoveri®
Turbocharger Manual, Bulletin 3810235.

Note : The compressor and turbine casings do not

require removal to measure the radial clearance. The
parts shown are removed for clarity.
Use a feeler gauge to measure the radial clearance.

BBC (RR-151) and (RR-153) Bearing

Radial Clearance
mm in
RR-153   0.55 MAX 0.021
RR-151   0.75 MAX 0.030

If the radial clearance exceeds the specification, the part

must be replaced or rebuilt. Use the following manual for
rebuild instructions. Reference the BrownBoveri®
Turbocharger Manual, Bulletin 3810235.
Note : Check the model of turbocharger installed on
the engine, this is for: AiResearch™, Model T-18A.
Use a dial indicator to measure the end clearance.

AiResearch™ T-18A End Clearance

mm in
0.10 MIN 0.004
0.23 MAX 0.009

If the end clearance exceeds the specifications, the

turbocharger must be replaced or rebuilt. Use the following
manual for information concerning rebuild instructions.
Reference the Turbocharger Component Shop Manual,
Bulletin 3379091.

AiResearch® Method One:

Check the radial clearance of both the compressor impeller

and turbine wheel.

Use your hand to push the compressor impeller or turbine

wheel toward the housing.

Use a feeler gauge that is not more than 13 mm [0.5 in]

wide. Measure the clearance between the impeller and the
housing at the minimum clearance point.

AiResearch® T-18A Impeller and Turbine Wheel

Radial Clearance
mm in
0.08 MIN 0.003
0.18 MAX 0.007

If the clearance exceeds the specifications, the turbocharger

must be replaced or rebuilt. Use the following manual for
information concerning rebuild instructions. Reference the
Turbocharger Component Shop Manual, Bulletin 3379091.

AiResearch® Method Two:

To measure the direct bearing radial clearance on the T-18A,

place a dial indicator through the oil drain hole as illustrated.
Be sure the indicator touches the highest part of the shaft.

Move the turbine and compressor wheels by hand to the

upper and lower limits.
 AiResearch® T-18A Bearing Radial Clearance
mm in
0.20 MIN 0.008
0.46 MAX 0.018

If the clearance exceeds the specifications, the turbocharger

must be replaced or rebuilt. Use the following manual for
information concerning rebuild instructions. Reference the
Turbocharger Component Shop Manual, Bulletin 3379091.

All models:

After the turbocharger has been checked:

Lubricate the bearings with engine oil through the oil

inlet fitting
Cover all openings to prevent entry of dirt until installed
on the engine.

Note : Check the model of the turbocharger installed

on the engine. This is for: Honeywell®, all models.
Specifications for checking radial and axial clearance are
not available.

Inspect for signs of contact between the turbocharger vanes

and housing.

Check the bearing system for wear:

Hold both ends of the turbocharger shaft and rotate the

shaft while applying pressure down on the compressor
side and up on the turbine side. It should rotate freely
and there should be no contact between the
compressor wheel and the compressor housing, or the
turbine wheel and the turbine housing.

Replace the turbocharger if any malfunctions are identified.

Disassemble
Remove the o-ring and discard.
If the compressor cover has an inlet baffle it can be removed
with a flat tip screwdriver. Pry the retaining ring up and
remove the retaining ring.

 CAUTION 
Use caution in handling the turbine blades. The turbine
blades can be easily damaged when the turbine
housing is removed.

Remove the turbine housing by bending the lock plate tabs

away from the capscrew heads.

Remove the capscrews.

Make sure the turbine wheel rotates freely inside the turbine
housing. Tap on the turbine housing with a mallet to separate
the turbine housing from the bearing housing.

Remove the oil supply fittings and the coolant lines from the
center housing assembly.

Discard the o-rings.

Clean and Inspect for Reuse
 WARNING 

Some solvents are flammable and toxic. Read the

manufacturer's instructions before using.

 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.

Clean the compressor cover and turbine housing in parts

cleaner to loosen deposits.

 WARNING 

Wear appropriate eye and face protection when using

compressed air. Flying debris and dirt can cause
personal injury.

Dry the compressor housing with compressed air.

Use a soft bristle brush to remove heavy scale deposits.

Wash and dry the parts after brushing.

 CAUTION 

Do not use compressed air to dry or spin the turbine

wheel as this can cause damage to the turbocharger
bearing system.
If chemical and brush cleaning is not effective, bead blast
with plastic abrasive media, Part Number 3822735, or
equivalent.

Wash and dry parts after bead blasting.

The center housing rotating assembly can be cleaned with
electrical contact cleaner, Part Number 3824510, or
equivalent.

Do not spray contact cleaner into the oil and coolant ports.

Inspect the compressor cover for cracks, dents, and other

damage.

Inspect the inside of the compressor cover for signs of

scoring or damage from the compressor wheel. Replace the
compressor cover, if damaged.

Inspect the turbine housing for cracks and damage. Cracks

larger than 10 mm [0.39 in] can cause an exhaust leak.
Replace the turbine housing if damage is found.

Follow the criteria shown in the illustration.

Minor cracks in the turbine housing internal wall, where

exhaust gas flow enters the turbine wheel, is an acceptable
condition. The turbine housing can be reused.

Inspect the turbine housing for signs of contact with the

turbine wheel. Damaged turbine housings must be replaced.
Inspect the center housing rotating assembly for any signs of
cracks, damaged threads, or other damage.

Rotate the turbine wheel by hand to make sure it spins

freely.

Replace the center housing rotating assembly if it is

damaged or does not spin freely.

Inspect the compressor wheel for damage, broken, or bent

blades.

Do not attempt to repair or straighten the blades. Instead,

replace the center housing rotating assembly.

Inspect the turbine wheel for damaged, broken, or bent

blades.

Do not attempt to repair or straighten the blades. Instead,

replace the center housing rotating assembly.

Measure
Use a dial depth gauge, Part Number ST-537, or a dial
indicator to measure the axial motion (end-to-end).

Compressor Impeller Axial End Clearance

mm in
Holset®
HC5,
HC5A, 0.025 MIN 0.001
(127 mm
wheel)
  0.152 MAX 0.006
 Holset®
HC5,
HC5A, 0.025 MIN 0.001
(130 mm
wheel)
  0.152 MAX 0.006
Holset®
HX80/HX8 0.025 MIN 0.001
5
  0.152 MAX 0.006
Holset®
0.050 MIN 0.002
HT100
  0.152 MAX 0.006

Make sure the movement is within the MIN/MAX TIR values

shown above.

Replace the center housing rotating assembly if the axial

clearance is not within specifications.

Measure the radial clearance (side-to-side) at the

compressor nose, using a dial gauge.

Compressor Impeller Radial Clearance

mm in
Holset®
HC5,
HC5A, 0.228 MIN 0.009
(127 mm
wheel)
  0.686 MAX 0.027
Holset®
HC5,
HC5A, 0.228 MIN 0.009
(130 mm
wheel)
  0.762 MAX 0.03
Holset®
HX80/HX8 0.254 MIN 0.01
5
  0.787 MAX 0.031
 Holset®
0.254 MIN 0.01
HT100
  0.813 MAX 0.032

Make sure the movement is within the MIN/MAX TIR values

shown above.

Replace the center housing rotating assembly if the radial

clearance is not within specifications.

Assemble
 CAUTION 
Use caution when handling the turbine blades. The
turbine blades can be easily damaged when installing in
the turbine housing.

Assemble the center housing rotating assembly on to the

turbine housing.

Lubricate the threads of the new capscrews with anti-seize

compound, Part Number 3824732, or equivalent.

Install the capscrews, with new lock plates, to the

turbocharger turbine housing.

Torque Value:  20.3  n•m    [ 180 in-lb ]

Use a hammer and punch to fold the locking plate onto the
flat of the capscrew, to prevent loosening.

Assemble the inlet baffle into the compressor cover and

secure with a retaining ring. Hold one end of the retaining
ring in the groove. Press the remainder of the retaining ring
 into position. Use a flat tip screwdriver to make sure the
retaining ring is correctly seated in the compressor cover
groove.

Note : The HX83 Turbocharger uses a titanium

compressor wheel. The edge of the wheel is very
sharp. Handle the compressor wheel with care.
Assemble the compressor housing new o-ring on the
turbocharger.

 CAUTION 

Do not damage the compressor wheel blades during

assembly.

Assemble the v-band clamp and compressor cover onto the

turbocharger.

Place the v-band clamp in position.

Tighten the v-band clamp.

Torque Value:  12  n•m    [ 106 in-lb ]

Make sure the compressor wheel and turbine wheel rotate

freely.
Install
with Mechanically Actuated Injector

 CAUTION 

Check to be sure the correct turbocharger assembly is

installed. The turbocharger assembly number is on the
dataplate that is mounted on the turbocharger. Compare
the assembly number with the number in the Control
Parts List (CPL) Manual with the corresponding CPL for
the engine being serviced. Many turbochargers appear
the same physically, but contain different parts. If the
wrong turbocharger assembly is installed, the
performance of the engine will be less than
specification, or damage can result to the engine due to
excessive cylinder pressure and temperature.

The turbochargers, mounting hardware, and connections are

different for various models of K38 and K50 engines.
Because of the different parts, installation procedures are
given for:

KT38, KTA38, and KTA50 Turbochargers with Center

Mount Aftercooler
KTTA38 and KTTA50 High-Pressure, and KT38, KTA38,
and KTA50 Turbochargers with Outboard Aftercoolers
KTTA38 Low-Pressure Turbochargers
KTTA50 Low-Pressure Turbochargers
K2000E, K1800E and K1500E High-Pressure
Turbochargers
K2000E Low-Pressure Turbochargers

During turbocharger installation, it is often necessary to

adjust the angle of the bearing housing oil drain and the
angle of the compressor housing outlet. Instructions for
these adjustments are described following the procedure for
the KTTA50 Low-Pressure Turbocharger.

Oil inlet and drain hose routing and clamps can be different
than shown because of the age of the engine. Be sure the oil
hoses have the correct clamps installed to prevent damage
from vibration or heat from another part.

KT38, KTA38, and KTA50 Turbochargers with Center Mount

Aftercooler
Note : The illustrations show a KTA38. The KTA50
has a longer connection between the aftercooler
housing and the turbocharger. The procedure is the
same for these models.
Newer engines have a hose and clamps to connect the
turbocharger to the aftercooler connection. Older engines
have a tube with a dust seal and two o-ring seals to connect
the turbocharger to the aftercooler connection.

The clamps are special to allow a higher torque. Standard T-

bolt type clamps can loosen and allow an air leak.

Newer Engines:

Install the hose (1) and clamps (2) on the aftercooler

connection. Do not tighten the clamps.

Some of the newer K50 engines have a hose and heavy

duty clamps installed over the tube and o-ring as shown in
the next picture.

Older Engines:

Install the dust seal (3) and o-ring seals (4) on the tube (5).

Use vegetable oil. Lubricate the o-ring seals.

Install the tube in the bore of the aftercooler housing. Push

the tube into the bore until it touches the step in the bore.

 WARNING 
The 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.

Install the gasket (6) on the exhaust manifold. The gasket

must be installed so that the raised bead on the gasket is
toward the turbocharger.

Install the turbocharger (7). Push the compressor housing

into the hose or on the hose.

The capscrews (8) with nuts (9) are manufactured from heat
resistant material. If heat resistant capscrews are not
installed, the parts will fail, causing an exhaust leak.
 Apply an anti-seize compound on the threads of the
capscrew.

Install the four capscrews (8) with the nuts (9).

Torque Value:
Capscrews  40  n•m    [ 30 ft-lb ]

Some of the compressor housing is not shown removed for

clarity.

Check the angle of the oil drain and the alignment of the
compressor housing to the aftercooler connection. If the
angle or alignment is not correct, adjust the turbocharger oil
drain angle, or adjust the turbocharger compressor housing
alignment, described later in this section.

Newer Engines:

Tighten the clamps (2).

Torque Value:
K38   9  n•m    [ 80 in-lb ]
The K50 requires a special clamp.

Torque Value:
K50  15  n•m    [ 133 in-lb ]

Older Engines:

Install the parts.

Retaining plates (10)

Flat washers (11)
Lock washers (12)
Capscrews (13).

Torque Value:
Capscrews  16  n•m    [ 142 in-lb ]

Note : Holset® turbochargers have a fitting that has

straight threads and requires an o-ring seal.
AiResearch® turbochargers have a fitting with pipe
threads. The torque value is the same for both types
of the fittings.
Install the o-ring seal (14) on the oil inlet fitting (15). Install
the fitting.
Torque Value:
Oil Inlet Fitting  35  n•m    [ 26 ft-lb ]
Connect the turbocharger oil inlet hose (16) to the fitting.

Install the clamps for the oil inlet hose.

The other end of the oil inlet hose must be connected to a
fitting in the cylinder block. Refer to Procedure 001-026 in
Section 1. (/qs3/pubsys2/xml/en/procedures/28/28-001-026-
tr.html)

Install the parts.

Gasket (17)
Hose (18)
Lock washers (19)
Capscrews (20).

Torque Value:
Capscrews  40  n•m    [ 30 ft-lb ]

Newer engines have a flange and an o-ring seal type oil

drain hose as shown. The newer hose connects to the
cylinder block with a capscrew. Older engines have a hose
that has a tubing nut and connects to the block with a fitting
that has pipe threads.

If a flange and an o-ring type connection is installed on an

older block, a spacer is required between the hole in the
block for the capscrew and the flange. If the spacer is not
installed, an oil leak will result.

Install the o-ring seal (21) on the hose flange.

Use vegetable oil. Lubricate the seal.

Install the flange, the lock washer (22), and the capscrew
(23).

Torque Value:
Flange Capscrews  40  n•m    [ 30 ft-lb ]
Repeat this procedure to install the other turbocharger and
connect the oil hoses.

KTTA38 and KTTA50 High-Pressure, and KT38, KTA38, and

KTA50 Turbochargers with Outboard Aftercoolers

The turbochargers must be mounted on the correct engine

bank.
 KTTA38 and KTTA50 High-Pressure:

The turbocharger on the left bank must be installed with the

compressor housing pointed toward the front of the engine.
The turbocharger on the right bank must be installed with
the turbine housing pointed toward the front of the engine.

KT38, KTA38, and KTA50 with Outboard Aftercoolers:

The turbine housing on both turbochargers must point the

same direction, either toward the front of the engine or
toward the rear of the engine so that the exhaust piping will
fit the application.

 WARNING 

The 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.

Note : The turbochargers for the K50 engine with

pulse type exhaust manifolds are to be mounted with
four studs and nuts, not capscrews and nuts. The
torque value is the same. Some K38 engines do not
require the nuts.
The gasket must be installed so that the raised bead on the
gasket is toward the turbocharger.

Install the gasket (1) on the exhaust manifold.

Apply an anti-seize compound on the threads of the

capscrews or studs (3).

Install the turbocharger (2), the capscrews or studs (3), and

the nuts (4), if required.

Torque Value:
Turbocharger Capscrews  40  n•m    [ 30 ft-lb ]

Note : Some of the compressor housing is shown

removed for clarity.
Check the angle of the oil drain. The alignment of the
compressor housing to the air crossovers can not be
checked until the aftercooler assembly is installed. If the
angle is not correct, adjust the turbocharger oil drain angle,
described later in this section.
 Note : Holset® turbochargers have a fitting that has
straight threads and requires an o-ring seal.
AiResearch® turbochargers have a fitting with pipe
threads. The torque value is the same for both types
of fittings.
Install the o-ring seal (14) on the oil inlet fitting (15). Install
the fitting.

Torque Value:
Oil Inlet Fitting  35  n•m    [ 26 ft-lb ]
Connect the turbocharger oil inlet hose (16) to the fitting.

Install the clamps for the oil inlet hose.

The other end of the oil inlet hose must be connected to a

fitting in the cylinder block. Refer to Procedure 001-026 in
Section 1. (/qs3/pubsys2/xml/en/procedures/28/28-001-026-
tr.html)

Install the parts.

Gasket (5)
Hose (6)
Lock washers (7)
Capscrews (8).

Torque Value:
Capscrews  40  n•m    [ 30 ft-lb ]

Install the o-ring seal (9) on the hose flange.

Use vegetable oil. Lubricate the seal.

Install the flange in the bore of the block. Install the lock
washer (10) with the capscrew (11).

Torque Value:
Flange Capscrews  40  n•m    [ 30 ft-lb ]
Repeat this procedure to install the other turbocharger and
connect the oil hoses.

KTTA38 Low-Pressure Turbochargers

Note : The engine has two low-pressure
turbochargers. The illustrations show the installation
of one turbocharger. It is recommended that the two
low-pressure turbochargers be installed at the same
time.
 The engine has six turbocharger supports. Two are mounted
on the front of the right bank and two on the rear of the left
bank. One is mounted on the front of the left bank and one
on the rear of the right bank.

Install the turbocharger supports (1) and the lock washers

(2), with the socket head capscrews (3).

Torque Value:
Turbocharger Support Capscrews  270  n•m    [ 199 ft-lb ]

Do not tighten the clamps or fasteners to final torque until

the torque value is given. Tighten the parts enough to hold
them together, but loose enough to allow the parts to be
moved for alignment.

Install the parts.

Bracket (4)
Flat washers, heavy (5)
Lock washers (6)
Capscrews (7).

There are six each of the flat washers, lock washers, and
capscrews.

Install the v-band clamp (8) and the exhaust outlet

connection (9).

Apply an anti-seize compound to the slip-joints of the

exhaust outlet connection (9), exhaust outlet pipe (10), and
the turbocharger connection (11).
Install the pipe (10) to the connection (9). Install the
connection (11) in the pipe (10).

Apply an anti-seize compound on the threads of the

capscrews (12).

Install the four capscrews (12) through the connection and

bracket.

Install the heavy flat washers (13), the lock washers (17),
and the nuts (18).

Install the large o-ring seal (19) and the small o-ring seal
(20) on the air inlet pipe (21).

Install the dust seal (22) on the air inlet pipe.

Use vegetable oil. Lubricate the o-ring seals.

Install the air inlet pipe in the high-pressure turbocharger.

Install the hose (23) and the two T-bolt clamps (24) on the air
inlet pipe and high-pressure turbocharger.

 WARNING 
The 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.

The gasket must be installed so that the raised bead on the

gasket is toward the turbocharger

Install the gasket (25).

Install the low-pressure turbocharger (26). Push the

compressor housing on the air inlet pipe.

Apply an anti-seize compound to the threads of the

capscrews (27).

Install the four capscrews (27) and lock nuts (28).

 Note : Some of the compressor housing is shown
removed for clarity.
Check the angle of the oil drain. Check the alignment of the
compressor housing to the air inlet pipe. If the angle or
alignment is not correct, see Turbocharger, Oil Drain Angle,
Adjust, or Turbocharger, Compressor Housing Alignment,
Adjust, described in this section.

Tighten the six capscrews (7) that hold the bracket to the
supports.

Torque Value:
Bracket to Supports  90  n•m    [ 66 ft-lb ]

Tighten the four capscrews (12) and nuts (18) that hold the
connection to the bracket.

Torque Value:
Connection to Bracket  90  n•m    [ 66 ft-lb ]

Tighten the four capscrews (27) and nuts (28) that hold the
turbocharger to the connection.

Torque Value:
Turbocharger Connection  40  n•m    [ 30 ft-lb ]

Tighten the v-band clamp (8).

Torque Value:
V-band Clamp  7  n•m    [ 62 in-lb ]
Use a mallet. Tap around the clamp to be sure it is seated.

Torque the clamp nut to the same torque value.

Continue tapping and tightening the clamp until the nut does
not turn at the specified torque after tapping.
 Tighten the two T-bolt clamps (24).

Torque Value:
T-bolt Clamps  9  n•m    [ 80 in-lb ]

Note : Holset® turbochargers have a fitting that has

straight threads and requires an o-ring seal.
AiResearch® turbochargers have a fitting with pipe
threads. The torque value is the same for both types
of fittings.
Install the o-ring seal (14) on the oil inlet fitting (15). Install
the fitting.

Torque Value:
Oil Inlet Fitting  35  n•m    [ 26 ft-lb ]
The other end of the oil inlet hose must be connected to a
fitting in the cylinder block. Refer to Procedure 001-026 in
Section 1. (/qs3/pubsys2/xml/en/procedures/28/28-001-026-
tr.html)

Install the following parts.

Gasket (29)
Hose (30)
Lock washers (31)
Capscrews (32).

Torque Value:
Capscrews  40  n•m    [ 30 ft-lb ]

Note : Some older KTTA38 engines equipped with

AiResearch® low-pressure turbochargers have a
drain hose that has two pieces connected by a
temperature resistant hump hose.
Install the o-ring seal (33) on the hose flange.

Use vegetable oil. Lubricate the seal.

Install the flange, the lock washer (34), and the capscrew
(35).

Torque Value:
Flange Capscrews  40  n•m    [ 30 ft-lb ]

KTTA50 Low-Pressure Turbochargers

 Note : The engine has two low-pressure
turbochargers. The illustrations show the installation
of one turbocharger. It is recommended that the two
low-pressure turbochargers be installed at the same
time.
The engine has six turbocharger supports. Two are mounted
on the front of the right bank, and two are on the rear of the
left bank. One is mounted on the front of the left bank, and
one on the rear of the right bank.
Install the turbocharger supports (1), the lock washers (2),
and the socket head capscrews (3).

Torque Value:
Turbocharger Support Capscrews  270  n•m    [ 199 ft-lb ]

Do not tighten the clamps or fasteners to final torque until

the torque value is given. Tighten the parts enough to hold
them together, but loose enough to allow the parts to be
moved for alignment.

Install the bracket (4), the six lock washers (6), and the six
capscrews (7).

Install the v-band clamp (8) and the exhaust outlet GRAPHIC NOT FOUND
connection (9).

Apply an anti-seize compound to the slip-joints of the

exhaust outlet connection (9), the exhaust outlet pipe (10),
and the turbocharger connection (11).

Install the pipe (10) on the outlet connection (9). Install the
connection (11) in the pipe (10).

Install the hose (11) and the two T-bolt clamps (12) on the
high-pressure turbocharger.

Install the two o-ring seals (13) and the dust seal (14) on the
air inlet pipe (15).

Use vegetable oil. Lubricate the o-ring seals.

Install the air inlet pipe in the high-pressure turbocharger.

 CAUTION 
 KTTA50 engines equipped with LOG type exhaust
manifolds must have Brown-Boveri Corporation
(BBC®), Model Number 153, turbochargers. KTTA50
engines with PULSE type exhaust manifolds must have
BBC®, Model Number RR 151, turbochargers. Be sure
the correct turbochargers are installed, or damage to
the engine can result.

 CAUTION 
Newer BBC® RR 153 turbochargers have fastener
threads that are U.S. Customary inch. Older BBC® RR
153 turbochargers have fastener threads that are metric
millimeter. The fastener threads in all BBC® RR 151 are
metric millimeter. Be sure the correct fasteners are
installed or the parts can be damaged.

Note : The exhaust and intake adapters for the BBC®

RR 153 and RR 151 appear the same, but have
different dimensions. Be sure to install the correct
part.
Apply an anti-seize compound to the bore of the low-
pressure turbocharger (16) for the exhaust outlet connection
(17), and the threads of the capscrews (19) and (20).

The connection must be installed as shown so that the

flange with two holes aligns with the bracket.

The two capscrews (19) are longer than the six capscrews
(20).

Install the exhaust outlet connection (17), the lock washers

(18), and the capscrews (19) and (20).

Torque Value:
Exhaust Outlet Connection Capscrews  40  n•m    [ 30 ft-lb ]

Install the parts on the air intake connection (26).

Capscrews (21)
Bracket (22)
Flat washers, heavy (23)
Lock washers (24)
Nuts (25).

Install the o-ring seal (27) in the groove on the connection

(26).
 Use engine oil or lubriplate to secure the seal in the groove.

Install the parts on the low-pressure turbocharger.

Connection (26)
Flat washers (28)
Lock washers (29)
Capscrews (30).

Tighten only the capscrews (30).

Torque Value:
Capscrews  25  n•m    [ 18 ft-lb ]

 WARNING 

The 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.

Use a hoist and lifting strap. Put the turbocharger (16) in

position and push the compressor housing on the air pipe.

Install the capscrews (31) through the heavy flat washers

(32), and the brackets (22) and (4).

Install the heavy flat washers (32), lock washers (33), and
the nuts (34).

Apply an anti-seize compound to the threads of the

capscrews (35).

Install the two capscrews (35) through the exhaust outlet

connection (17) and the bracket (4).

Install the heavy flat washers (36), the lock washers (37),
and the nuts (38).

The gasket must be installed so that the raised bead on the

gasket is toward the turbocharger.

Install the gasket (39) between the turbocharger turbine

housing and the exhaust connection.
 Apply an anti-seize compound to the threads of the
capscrews (40).

Install the four capscrews (40) through the holes in the

turbine housing, the gasket, and the connection.

Install the lock washers (41) and the nuts (42).

Note : Some of the compressor housing is shown

removed for clarity.
Check the angle of the oil drain. Check the alignment of the
compressor housing to the air inlet pipe. If the angle or
alignment is not correct, see Turbocharger, Oil Drain Angle,
Adjust, or Turbocharger, Compressor Housing Alignment,
Adjust, described in this section.

Tighten the six capscrews (7) that hold the bracket to the
supports.

Torque Value:
Bracket to Supports  90  n•m    [ 66 ft-lb ]

Tighten the two capscrews (35) and nuts (36) that hold the
turbocharger exhaust outlet connection to the bracket.

Torque Value:
Exhaust Outlet Connection to Bracket  90  n•m    [ 66 ft-lb ]

Note : Be sure the bracket (32) is flat against the

flange on the air inlet connection.
Tighten the two capscrews (43) and the nuts (34) that hold
the air intake connection (32) to the bracket (4).

Torque Value:
Air Intake Connection to Bracket  40  n•m    [ 30 ft-lb ]

Tighten the two capscrews (31) and the nuts (25) that hold
the bracket (32) to the connection (26).
Torque Value:
Bracket Capscrews  40  n•m    [ 30 ft-lb ]

Tighten the four capscrews (40) and nuts (42) that hold the
exhaust connection to the turbine housing.

Torque Value:
Exhaust Connection Capscrews  90  n•m    [ 66 ft-lb ]

Tighten the v-band clamp (8).

Torque Value:
V-band Clamp  7  n•m    [ 62 in-lb ]
Use a mallet. Tap around the clamp to be sure it is seated.

Tighten the clamp nut to the same torque value.

Continue tapping and tightening the clamp until the nut does
not turn at the specified torque after tapping.

Tighten the two T-bolt clamps (45) on the air inlet pipe.

Torque Value:
T-bolt Clamps  7  n•m    [ 62 in-lb ]

 CAUTION 

Be sure the correct capscrews are installed. If the

wrong capscrews are installed, failure of the part can
result.

Note : Newer BBC® RR153 turbochargers have a

fitting that is threaded directly into the bearing
housing. Older BBC® RR 153 turbochargers require
an adapter plate, Part Number 3176567, and a
gasket, Part Number 3176568, attached to the
bearing housing with two capscrews.
 Note : All BBC® RR 151 turbochargers have an
adapter plate and gasket. The adapter plate and
gasket are different than on the older BBC® RR 153
turbochargers.
Install the parts for the turbocharger oil inlet.

Gasket (55)
Plate (56)
Lock washers (57)
Capscrews (58).
Torque Value:
Oil Inlet Capscrew  40  n•m    [ 30 ft-lb ]
If the fitting is not installed in the plate, install the oil inlet
fitting.

Torque Value:
Fitting Torque  35  n•m    [ 26 ft-lb ]
Connect the turbocharger oil inlet hose.

The other end of the oil inlet hose must be connected to a

fitting in the cylinder block. Refer to Procedure 001-026 in
Section 1. (/qs3/pubsys2/xml/en/procedures/28/28-001-026-
tr.html)

Install the parts for the turbocharger oil drain.

Gasket (47)
Hose (48)
Lock washers (49)
Capscrews (50).

Torque Value:
Oil Drain Capscrews  40  n•m    [ 30 ft-lb ]
Install the o-ring seal (51) on the hose flange.

Use vegetable oil. Lubricate the seal.

Install the flange, the lock washer (52), and the capscrews
(53) in the proper holes in the cylinder block.

Torque Value:
Oil Drain Flange Capscrews  40  n•m    [ 30 ft-lb ]

K2000E and K1800E High-Pressure Turbochargers

The K2000E uses Holset® HC5A High-Pressure

Turbochargers (2), the HT100 Low-Pressure Turbochargers
(1) installation is described later in this section.
 The K1800E engine is single stage turbocharged and does
not use the turbocharger interstage connections or
assembly procedures as does the K2000E.

The K1800E engine uses Holset® HX85 turbochargers (1).

Note : The high-pressure turbochargers (2) are

mounted to the exhaust manifold using four
capscrews (3) and nuts (4). These capscrews and
nuts are manufactured from high strength stainless
steel that has high temperature capability. Do not
substitute with lower quality parts.

The gasket must be installed with the raised bead (2) toward
the turbocharger.

Install the gasket (1) on the exhaust manifold.

Coat the threads of the capscrews with anti-seize

compound.

Install the turbocharger (2), capscrews (3) and nuts (4).

Torque Value:
Turbocharger Mounting Capscrews  40  n•m    [ 30 ft-lb ]

Note : Some of the compressor housing has been

removed for clarity.
Check the angle of the oil drain and the alignment of the
compressor housing to the air crossovers (this can not be
checked until the aftercooler assemblies are installed).

If the angle is not correct, the bearing housing must be

rotated in relation to the turbine housing. Adjust the
turbocharger oil drain angle.

If the alignment is correct or after the adjustment, lock the

bearing housing to the turbine casing lockplate tabs.

Connect the turbocharger oil inlet hose (16) to the fitting

(15).
 Install the clamps for the oil inlet hose.

The other end of the oil inlet hose must be connected to a

fitting in the cylinder block. Refer to Procedure 001-026 in
Section 1. (/qs3/pubsys2/xml/en/procedures/28/28-001-026-
tr.html)

Install the gasket (5), hose (6), lock washers (7) and two
capscrews (8) to the turbocharger oil drain.

Install the o-ring seal (9) on the hose flange. Use engine oil
to lubricate the seal. Install the flange in the bore of the
block. Install the lock washer (10) and the capscrew (11).

Torque Value:
Oil Inlet Capscrews  40  n•m    [ 30 ft-lb ]
Repeat the procedure to install the other turbocharger and
connect the oil supply and the drain hose.

K2000E Low-Pressure Turbochargers

The K2000E engine contains two low-pressure

turbochargers. This illustration shows the installation of only
one turbocharger. The recommendation is to install both low-
pressure turbochargers at the same time.

The K2000E engine contains six turbocharger supports. Two

of each of the supports are mounted on the front of the right
bank and rear of the left bank. One of each of the supports is
mounted on the front of the left bank and rear of the right
bank.

Install the turbocharger supports (1), and the lock washers

(2), and the socket head capscrews (3).

Torque Value:
Turbocharger Support Capscrews  270  n•m    [ 199 ft-lb ]

Note : From this point on, do not tighten the clamps

or fasteners to their final torque unless the torque
value is given. Tighten only enough to allow the parts
to move for alignment.
 Install the bracket (4), six lock washers (6), and six
capscrews (7).

Install the v-band clamp (8) and exhaust outlet connection

(9).

Apply anti-seize compound to the threads of the capscrews

(12). Install the gasket (10), capscrews (12), lock washers
(13), and nuts (14).

Use anti-seize compound to coat the slip joints of the

exhaust pipe (11) and the turbocharger connection (16).

Install the turbocharger connection (16) on the exhaust pipe

(11).

After all interstage connections are in place, there must be a

minimum of 3.18 mm [0.125 inch] expansion space between
connections (11 and 16).

The gap can be adjusted by moving the low-pressure

turbocharger or low-pressure turbocharger mounting
bracket.

Use anti-seize compound to coat the bore on the low-

pressure turbocharger (22) for the exhaust outlet connection
(17), and the threads of the capscrews (19 and 20).

The bracket (21) must be oriented to provide proper

turbocharger alignment.

Note : The two capscrews (19) are longer than the six
capscrews (20).
Install the exhaust outlet connection (17), lock washers (18),
and capscrews (19 and 20).

Torque Value:
Exhaust Outlet Capscrews  40  n•m    [ 30 ft-lb ]
 Install the two capscrews (31), bracket (32), heavy flat
washer (23), lock washers (24), and nuts (25) on the air
intake connection.

Install the o-ring seal (27) in the groove on the connection

(26). Use engine oil or Lubriplate® to hold the seal in the
groove.

Install the connection (26), four flat washers (28), lock

washers (29), and capscrews (30), on the low-pressure
turbocharger. Tighten only the four capscrews (30).

Torque Value:
Air Intake Connection Capscrews  40  n•m    [ 30 ft-lb ]

Use a hoist and lifting strap to position the turbocharger and

to align the capscrew holes in the brackets.

Install the capscrews (43) through the heavy flat washer (44)
and both brackets (32 and 4). Install the heavy flat washers
(44), lock washers (33) and the nuts (34).

Use anti-seize compound to coat the threads of the

capscrews (35).

Install the two capscrews (35) through the exhaust outlet

connection (17) and the bracket (4). Install the heavy flat
washers (36), lock washers (37), and nuts (38).

The raised bead on the gasket (39) must be toward the

turbocharger.

Install the gasket (39) between the turbocharger turbine

housing and the exhaust connections (16).

Use anti-seize compound to coat the threads of the

capscrews (40).

Install the four capscrews (40) through the holes in the

turbine housing, gasket, and connection.

Install the lock washers (41) and nuts (42).

Slide one T-bolt clamp (45) and hose (46) over the end of the
intake pipe (47). Slide the hose on far enough to install the
pipe. Install the second clamp (45) over the compressor
outlet.
 Position the intake pipe (47) between the turbochargers and
insert the gasket (48). Secure the flanges with four bolts
(49), flat washers (50), lock washers (51), and nuts (52).

Note : Some of the compressor housing has been

removed for clarity.
Check the angle of the oil drain. Check the alignment of the
compressor housing to the air inlet pipe.

If the angle or alignment is not correct, the bearing housing

must be rotated in relation to the turbine housing. See
Turbocharger, Compressor Housing Alignment, Adjust and
Turbocharger, Oil Drain Angle Alignment, Adjust, described
in this section.

Prior to any of the capscrews being tightened, check to be

sure there is a minimum of 3.18 mm [0.125 in] expansion
space at the slip joints on both exhaust interstage
connections.

Tighten the six capscrews (7) that hold the bracket to the
supports.

Torque Value:
Support Bracket Capscrews  95  n•m    [ 70 ft-lb ]

Tighten the two capscrews (35) and nuts (38) that hold the
turbocharger exhaust outlet connection to the bracket.

Torque Value:
Bracket Capscrews  95  n•m    [ 70 ft-lb ]

The bracket (32) must be flat against the flange on the air
inlet connection.

Tighten the two capscrews (43) and nuts (34) that hold the
bracket (32) to the support bracket (4).

Torque Value:
Air Inlet Connection Capscrews  40  n•m    [ 30 ft-lb ]
 Tighten the two capscrews (31) and nuts (25) that hold the
bracket (32) to the connection (26).

Torque Value:
Bracket Connection Capscrews  40  n•m    [ 30 ft-lb ]

Tighten the four capscrews (40) and nuts (42) that hold the
exhaust connection to the turbine housing.

Torque Value:
Exhaust Connection Capscrews  95  n•m    [ 70 ft-lb ]
Tighten the three capscrews (19) that hold the bracket (21)
to the exhaust outlet connection (17).

Torque Value:
Exhaust Outlet Connection Capscrews  40  n•m    [ 30 ft-lb ]

Tighten the four capscrews (12) and nuts (14) that hold the
two exhaust connections (9 and 11).

Torque Value:
Exhaust Outlet Connections  95  n•m    [ 70 ft-lb ]

Tighten the v-band clamp.

Torque Value:
V-Band   9  n•m    [ 80 in-lb ]
Use a mallet. Tap all around the clamp to make sure it is
seated.

Tighten the clamp nut to the same torque value.

Continue tapping and tightening the clamp until the nut will
not turn at the specified torque after tapping.

Tighten the four capscrews (49) and nuts (52) that hold the
air intake pipe (47) to the turbocharger compressor outlet.

Torque Value:
Intake Pipe Capscrews  40  n•m    [ 30 ft-lb ]
  CAUTION 

The hoses and T-bolt clamps of the air intake system

are of heavy duty design to withstand temperatures and
pressures to which they are exposed. Only specified
parts are to be used. The clamps can be removed and
tightened again a maximum of three times. The torque
retention on the nut will be beyond reuse after this. At
this time, a second nut MUST be added to double lock
the nut or a new clamp MUST be used.

Center the hose (46) over the high-pressure turbocharger

compressor inlet and the pipe (47). Secure the two T-bolt
clamps (45).

Note : Do not position the clamps over the hose

beads. The clamps must be positioned between the
hose beads and the end of the hose. A portion of the
hose must extend outside the clamp.
Tighten the two T-bolt clamps (45) on the air intake pipe (47)
and the turbocharger compressor inlet.

Torque Value:
Intake Pipe Clamps  8  n•m    [ 71 in-lb ]
These clamps need to be tightened again after the engine
has operated a few hours.

Wrap the interstage air hose with a heat shield (blanket). The
blanket is secured by placing the eyelets that are located on
each end of the blanket over the hose clamp T-bolts. Use flat
washers and nuts on the T-bolts to retain the heat shield.

Install the gasket (55), plate (56), lock washers (57), and
capscrews (58) for the low-pressure turbocharger oil inlet.

Torque Value:
Low-Pressure Turbocharger Oil Inlet  25  n•m    [ 18 ft-lb ]
Install the oil inlet fitting.

Torque Value:
Oil Inlet Fitting  35  n•m    [ 26 ft-lb ]
 Connect the turbocharger oil inlet hose.

The other end of the oil inlet hose must be connected to a

fitting in the cylinder block. Refer to Procedure 001-026 in
Section 1. (/qs3/pubsys2/xml/en/procedures/28/28-001-026-
tr.html)

Install the gasket (59), the hose (60), the lock washers (61),
and the capscrews (62) for the low-pressure turbocharger oil
drain.

Torque Value:
Turbocharger Oil Drain  25  n•m    [ 18 ft-lb ]
Install the seal (63) on the hose flange. Use engine oil to
lubricate the seal. Install the flange, lock washer (64) and the
capscrews (65) in the proper holes in the cylinder block.

Torque Value:
Hose Flange  40  n•m    [ 30 ft-lb ]
Note : The turbocharger oil drain line must run
downhill from the turbocharger to the cylinder block.

with Electronically Actuated Injector

 WARNING 

The 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.

Note : The word “OUT”, or raised bead on the gasket

must be positioned toward the turbocharger.
Lift the high-pressure turbochargers, using approved lifting
straps, and place them onto the middle mounting pads with
the air outlets facing outboard.

Install the capscrews, washers, and nuts, and tighten.

Torque Value:
Turbocharger Mounting Capscrews and Nuts  45  n•m    [
33 ft-lb ]

Install the exhaust outlet and clamp.

 Apply anti-seize compound, Part Number 3824397, or
equivalent to both ends of the exhaust interstage piping
flanges.

Install both halves of the exhaust interstage using new

gaskets.

Apply anti-seize compound, Part Number 3824397, or

equivalent to the mounting capscrews.

Tighten the exhaust outlet connection clamp.

Torque Value:
Hose Clamp  8  n•m    [ 71 in-lb ]
Install the capscrews, washers and nuts finger tight to allow
for alignment.

Install the hose and clamps (with tightening screws facing

downward) to the inlet side of the turbocharger.

Tighten the hose clamp closest to the turbocharger inlet.

Torque Value:
Hose Clamp  8  n•m    [ 71 in-lb ]
Install the intake air piping into the hose and loosely tighten
the clamp to allow for alignment.

 WARNING  GRAPHIC NOT FOUND

The 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.

Lift the low-pressure turbochargers, using approved lifting

straps, onto the mounting pads and align them with the
interstage air transfer connections.
 Install new steel gaskets between the outer low-pressure
turbocharger and the outer low turbocharger exhaust
connection. Check that the raised beads on the gaskets are
facing the outer turbocharger.

Install the capscrews, washers and nuts in the same

orientation noted prior to removal and hand tighten.

Check the alignment and tighten the capscrews.

Torque Value:
Exhaust Connection Capscrews and Nuts  95  n•m    [ 70 ft-lb
]

Install a new paper gasket between the air intake connection GRAPHIC NOT FOUND
and the turbocharger and install the capscrews, washers and
nuts. Hand tighten only to allow for alignment.

Add the p-clip to the top right capscrew. Do not tighten this
bolt until the oil supply line is installed.

Once alignment is checked, tighten the capscrews.

Torque Value:
Air Intake Connection Capscrews and Nuts  48  n•m    [ 35 ft-
lb ]
Check that all air transfer connections are aligned and
tighten the interstage hose clamps.

Torque Value:
Interstage Hose Clamp  8  n•m    [ 71 in-lb ]

Install the air intake and bracket onto the low-pressure

turbocharger and trolly assembly.

Apply anti-seize compound, Part Number 3824394, or

equivalent, to the mounting capscrews and install.

Tighten all capscrews with the exception of the two

capscrews not connected to the mounting bracket.

Torque Value:
Air Intake Capscrews  48  n•m    [ 35 ft-lb ]

Apply anti-seize compound, Part Number 3824394, or

equivalent, to the rear turbocharger outlet flange and install
the exhaust adapter and bracket onto the low-pressure
turbocharger and trolly assembly.
 Apply anti-seize compound, Part Number 3824394, or
equivalent, to the eight mounting capscrews and install.

Torque Value:
Exhaust Adapter Capscrews  48  n•m    [ 36 ft-lb ]

Finishing Steps
with Mechanically Actuated Injector

 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 

Some state and federal agencies have determined that

used engine oil can be carcinogenic and cause
reproductive toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used engine oil.
If not reused, dispose of in accordance with local
environmental regulations.

 WARNING 

Coolant is toxic. Keep away from children and pets. If

not reused, dispose of in accordance with local
environmental regulations.

Fill the cooling system. Refer to Procedure 008-018 in

Section 8. (/qs3/pubsys2/xml/en/procedures/28/28-008-
018-tr.html)
Turn the air ON to the air starter, if equipped. Refer to
Procedure 012-022 in Section 12.
(/qs3/pubsys2/xml/en/procedures/102/102-012-
022.html)
 Connect the batteries. Refer to the OEM service
manual.

with Electronically Actuated Injector

 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 oil drain lines. Refer to Procedure 010-045 in

Section 10 (/qs3/pubsys2/xml/en/procedures/28/28-010-
045-tr.html).
Install the coolant supply and return lines. Refer to
Procedure 010-041 in Section 10
(/qs3/pubsys2/xml/en/procedures/28/28-010-041-
tr.html).
Fill the cooling system. Refer to Procedure 008-018 in
Section 8 (/qs3/pubsys2/xml/en/procedures/28/28-008-
018-tr.html).
Turn the air ON to the air starter, if equipped. Refer to
Procedure 012-022 in Section 12.
(/qs3/pubsys2/xml/en/procedures/102/102-012-
022.html)
Connect the batteries. Refer to the OEM service
manual.

Last Modified:  11-Aug-2021