Turbocharger - Cleaning
The content of this article/image reflects the changes called out by TSB - 09-003-09.
THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED TOOL FOR THIS PROCEDURE.
THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER TO PERFORM THIS PROCEDURE.
StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE.
SUBJECT:
Revised Turbocharger Cleaning Procedure
MODELS:
2007 - 2009 (D1/DH)
DISCUSSION:
This new procedure will work in conjunction with new software available for the Cummins Engine Control Module (ECM) release in November, 2009. When used with scan tool version 10.02 or later, a more robust cleaning of the turbocharger can be achieved. This bulletin provides the revised procedures.
Address any DTC's related to vehicle speed sensor, engine speed sensor, coolant temp sensor, brake pedal switch, transmission, and O2 sensors prior to proceeding with this procedure. Failure to do so may result in the procedure failing to function.
Turbocharger Cleaning Procedure
Parts Required:
Special Tools/Equipment Required:
Warning: Use ONLY Mopar Diesel Turbocharger Cleaner (p/n 68044565AA) to perform this repair. Mopar Diesel Turbocharger Cleaner is a specially made WATER BASED solvent. Use of a flammable, or any low temperature combustible liquid/solvent, may cause severe damage to the engine and exhaust aftertreatment system components. Introduction of a flammable liquid/solvent to the engine intake system may cause engine run away, engine damage, and possible personal injury.
Note: Address any DTC's related to vehicle speed sensor, engine speed sensor, coolant temp sensor, brake pedal switch, transmission, and O2 sensors prior to proceeding with this procedure, Failure to do so may result in the procedure failing to function.
1. Inspect the engine turbocharger to determine if the turbocharger is equipped with a cleaning port. Does the turbocharger have a cleaning port?
a. Yes, proceed to step 2.
b. No, Refer to Service Procedure in TechCONNECT; Serv Info tab > 09 - Engine, 6.7 L Diesel > Turbocharger System > Cleaning > 6.7L turbocharger cleaning procedure - P/U ONLY > install a turbocharger cleaning port, (do NOT install stainless steel plug at this time). After cleaning port has been drilled and tapped, Proceed to Step # 2. Turbocharger Cleaning Port
2. Connect the vehicle tailpipe to the shop exhaust ventilation system. Turn the shop exhaust ventilation system ON.
3. Remove the turbocharger cleaning port access plug (if installed).
4. Located the cleaning tool (hose) and nozzle from the #10142 turbocharger cleaning kit special tool.
Note: The spray nozzle in the #10142 Turbocharger Cleaning Kit uses a very small orifice for the cleaner to pass through. The design of the nozzle is important for the proper application of the chemical. If the orifice in the spray nozzle becomes restricted, carefully inspect and clean the filtering screen at the entrance to the nozzle of any debris. If careful, the nozzle may be partially disassembled for cleaning, should this be needed.
5. Using the #10142 turbocharger cleaning kit, install the nozzle of the turbocharger cleaning tool into the turbocharger cleaning port tapped hole. Use care not to cross thread the tapped hole. Tighten the nozzle to 5.6 Nm (50 in lbs).
6. Place a fender cover over the top of the right battery to isolate/insulate the battery terminal ends from the cleaning tool hose.
Note: In the following steps, DO NO INSTALL cleaner can on the tool. In some instances, the scantool may perform a series of tests that may instruct the technician NOT to clean the turbocharger. The tool is installed prior to warming the engine to precent the technician from having to work on a hot turbocharger. Installing the can on the hose will puncture the can.
7. Using the #10142 turbocharger cleaning kit, install the hose of the turbocharger cleaning tool to the other end of the cleaning nozzle.
8. Route the can tap end of the cleaning tool hose under both cable sleeve of the EGR Cooler By-Pass Valve Assembly so that the cleaning tool hose is held away from the positive battery terminal by the throttle body cable sleeves.
9. Verify that the turbocharger cleaning tool tap cutoff valve is in the CLOSED position, handle 90 degrees to hose. Do not install cleaner can at this time.
10. Make sure the truck is in Park (auto), or Neutral (manual) and the parking brake is ON.
11. Start the vehicle engine and allow to idle and warm. Using the scan tool: From the HOME menu, > PCM, > More Options > System Test > Start > Set engine speed to 2,000 RPM. Follow the prompts > Actuate, then monitor the engine temperature.
12. Continue to run the vehicle engine until engine temperature is ABOVE 82 C° (180 F°).
Note: The engine must be fully warmed (above 82 C°/180 F°) so that the turbocharger and accumulated soot are at the correct higher temperature for this repair to be effective. The exhaust side of the turbocharger will be significantly higher in temperature than the 82 C°/180 F° engine operating temperature.
Note: If the following function does not appear on scantool, ensure scantool software is 10.02 or later. If the scantool has 10.02 or later, the PCM will need to be flashed to the latest available software before proceeding.
13. Using the scan tool: From the "HOME" menu; Select "ECU View" > PCM > Misc. Functions > VG Turbo Cleaning Procedure > Start. Follow the prompts.
14. The prompts in the cleaning process may instruct the technician to clean the turbocharger using a second or third can of cleaner. Use as many cans as requested by scantool, up to 3 cans. If cleaning is ineffective, scan tool may prompt technician to replace turbocharger.
Note: During cleaning process be sure to follow on screen instructions carefully. Specifically do not key off, press accelerator or brake pedal, unplug scantool, release parking brake or put into gear, leave truck unattended, or allow down time between steps unless specified by the scantool. Any of these will result in an ineffective cleaning.
Note: To dispense the full contents of the cleaner correctly, the Mopar Diesel Turbocharger Cleaner can must be UPSIDE DOWN (can nozzle pointing towards the ground). It is necessary that the Mopar Diesel Turbocharger Cleaner is higher than the level of the turbocharger while the cleaner is being dispensed. Suggest hanging the can from the hood latch.
15. After completing the cleaning procedure via the scan tool, remove the #10143 turbocharger cleaning tool from the cleaning tool nozzle.
16. Remove the #10142 cleaning tool nozzle from the housing of the turbocharger.
17. Install the stainless steel Mopar turbocharger cleaning port plug into the cleaning port of the turbocharger. Tighten the plug to 10 Nm (69 in lbs).
Note: The use of the proper Mopar plug is critical. Use of an unapproved plug of different material type and/or thread may cause damage to the turbocharger.
18. Remove the protective fender, cover from the right battery.
19. Perform powertrain verification test to ensure no additional issues.
Note: It is important to perform the complete repair when cleaning a turbocharger. Do not omit any steps in the the cleaning process.