Section 10 - Air Intake System - Group 10 Page 10-a

Section 10 - Air Intake System - Group 10

Section Contents
Page
Aftercooler Assembly .................................................................................................................................... 10-3
Assemble .................................................................................................................................................... 10-5
Clean ......................................................................................................................................................... 10-4
Disassemble ............................................................................................................................................... 10-4
Exploded View............................................................................................................................................. 10-3
Inspect for Reuse ....................................................................................................................................... 10-4
Aftercooler Coolant Tube ............................................................................................................................... 10-6
Clean ......................................................................................................................................................... 10-6
Inspect for Reuse ....................................................................................................................................... 10-6
Air Crossover ................................................................................................................................................. 10-7
Clean ......................................................................................................................................................... 10-7
Inspect for Reuse ....................................................................................................................................... 10-7
Air Intake System - General Information ....................................................................................................... 10-1
Preparatory ................................................................................................................................................. 10-1
Charge Air Cooler (CAC) ................................................................................................................................ 10-8
Clean ......................................................................................................................................................... 10-8

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Inspect for Reuse ....................................................................................................................................... 10-8
Leak Test .................................................................................................................................................... 10-9
Service Tools.................................................................................................................................................. 10-2
Air Intake System......................................................................................................................................... 10-2
Turbocharger Heat Shield............................................................................................................................. 10-11
Clean ........................................................................................................................................................ 10-11
Marine Applications ............................................................................................................................... 10-11
Inspect for Reuse ...................................................................................................................................... 10-11
Marine Applications ............................................................................................................................... 10-11
Install ........................................................................................................................................................ 10-11
Marine Applications ............................................................................................................................... 10-11
Remove .................................................................................................................................................... 10-11
Marine Applications ............................................................................................................................... 10-11
Turbocharger, Water-Cooled......................................................................................................................... 10-10
Clean ........................................................................................................................................................ 10-10
Inspect for Reuse ...................................................................................................................................... 10-10
 Air Intake System - General Information
Section 10 - Air Intake System - Group 10 Page 10-1

Air Intake System - General Informa-

tion
Preparatory
The combustion air system consists of air intake system,
turbocharger (A), air crossover (C), and aftercooler assem-
bly (D).
The aftercooler assembly (or intake manifold) to cylinder
head mounting capscrews are covered by rubber sleeves.
The rubber sleeves are located on the top mounting
capscrews at the cylinder head. These sleeves prevent
capscrew damage by keeping dirt and water off of the
threads. These sleeves must be replaced during rebuild.

All QSK19 engines have turbochargers. The turbochargers

also have water cooled bearing housings. This gives the
turbocharger increased working life by reducing the harm
of hot shutdowns.
The turbocharger uses exhaust gas energy to turn the
turbine wheel. This turbine wheel drives a compressor

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impeller that provides pressurized air to the engine for
combustion.
QSK19 engines can have either JWAC (jacket water after
cooled) air cooling systems, or LTA (low temperature after-
cooling) air cooling systems. These systems use engine
coolant to cool the inlet air between the turbocharger and
the engine. Refer to the coolant flow diagrams.

Rail Applications
Because the QSK19 Rail engine uses an air-to-air after-
cooler, there is no aftercooler element in the intake mani-
fold that uses coolant to cool the intake air. The intake
housing is a one-piece component that contains an inlet
duct. This air-to-air aftercooler has a turbocharger outlet
elbow which is unique to all QSK19 air-to-air cooled engines.
Service Tools
Page 10-2 Section 10 - Air Intake System - Group 10

Service Tools
Air Intake System

The following special tools are recommended to perform procedures in this section. The use of these
tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins
Authorized Repair Location.

Tool No. Tool Description Tool Illustration

Manometer
Used to measure air inlet restriction.
ST-1111-3

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Dial depth gauge
Used to check for proper nozzle ring crush or end clearance
checks on turbochargers.
ST-537
 Aftercooler Assembly (010-002)
Section 10 - Air Intake System - Group 10 Page 10-3

Aftercooler Assembly (010-002)

Exploded View

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1. Gasket, Intake Manifold 15. Screw, Captive Washer Cap
2. Seal, Grommet 16. Gasket, Exhaust Manifold
3. Retainer, Seal 17. Screw, Hex Flange Head Cap
4. Gasket, Connection 18. Spacer, Mounting
5. Screw, Captive Washer Cap 19. Gasket, Aftercooler Housing
6. Seal, Rectangular Ring 20. Gasket, Aftercooler Cover
7. Screw, Captive Washer Cap 21. Screw, hexagon Head Cap
8. Seal, O-ring 22. Manifold, Exhaust
9. Plug, Threaded 23. Connection, Air Crossover
10. Plug, Threaded 24. Cover, Aftercooler
11. Seal, O-ring 25. Manifold, Exhaust
12. Screw, Captive Washer Cap 26. Core, Aftercooler
13. Screw, Captive Washer Cap 27. Housing, Aftercooler
14. Washer, Plain
Aftercooler Assembly (010-002)
Page 10-4 Section 10 - Air Intake System - Group 10

Clean
WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer’s recommendations
for use. Wear goggles and protective clothing to avoid
personal injury.
Use solvent to clean the exterior of the aftercooler assem-
bly.
NOTE: Use a solvent that will not harm copper.
Use solvent to clean the elements.

Inspect for Reuse

Inspect the aftercooler for reuse. Look into the cylinder
head ports and into the aftercooler for indications of coolant
leakage.

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Use a hose with a plugged with a pipe plug to plug one
water tube as shown.
Attach an air line and gauge to the remaining tube.
Pressure check the element.
Apply air pressure and check for leaks.

Air Pressure
kPa psi
415 MAX 60
NOTE: Heating the tank water to 50°C (120°F) will improve
the test results.

Disassemble
Remove the capscrews, seal retainer (3), gaskets (4), and
seals (5). Discard the seals and gaskets.
 Aftercooler Assembly (010-002)
Section 10 - Air Intake System - Group 10 Page 10-5

Remove the aftercooler cover capscrews and cover.

Remove the element and gaskets.

Inspect the cover and intake manifold gasket surfaces for
damage.
Inspect the threaded holes for damage.
Discard the gaskets.

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Assemble
Install the element and two new gaskets.

Install the aftercooler cover and capscrews.

Do not tighten the capscrews until after the seals are
installed.
Aftercooler Coolant Tube (010-006)
Page 10-6 Section 10 - Air Intake System - Group 10

Use engine oil to lubricate the seals.

Install the seal on the retainer.
Use clean engine oil to lubricate the O.D. of the water
bosses on the aftercooer element.
Slide the gasket on the water bosses. Slide the seal and
retainer on the tube.
Install the capscrews, and tighten.
Torque Value: 35 N•m [25 ft-lb]

Install the 24 capscrews.

Tighten using the following steps and values.
Torque Value:
Step 1 35 N•m [25 ft-lb]
Step 2 50 N•m [35 ft-lb]

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Aftercooler Coolant Tube (010-006)
Clean
WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer’s recommendations
for use. Wear goggles and protective clothing to avoid
personal injury.
Use solvent to clean the aftercooler water inlet and outlet
tubes.
Dry with solvent.
Use a wire brush to clean the hose sealing surfaces.

Inspect for Reuse

Inspect the aftercooler water tubes for damage.
 Air Crossover (010-019)
Section 10 - Air Intake System - Group 10 Page 10-7

Air Crossover (010-019)

Clean
WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer’s recommendations
for use. Wear goggles and protective clothing to avoid
personal injury.
Use solvent to clean the air crossover.
Use compressed air to dry the air crossover.

Marine
WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer’s recommendations
for use. Wear goggles and protective clothing to avoid

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personal injury.
Use solvent to clean the parts.
Use compressed air to dry the parts.

Inspect for Reuse

Inspect the air crossover for cracks, breaks, holes, and
worn bolt holes.

Marine
NOTE: The Marine air crossover hose (3) is a different
material hose than the standard QSK19 hose.
Inspect the crossover tube for cracks.
Inspect the bore for any blockage.
Inspect the o-ring grove on the mounting flange and the
hose clamps (4) for any wear or damage.
Charge Air Cooler (CAC) (010-027)
Page 10-8 Section 10 - Air Intake System - Group 10

Charge Air Cooler (CAC) (010-027)

Clean
If the engine experiences a turbocharger failure or any
other occasion where oil or debris is put into the CAC,
(charge air cooler) the CAC must be cleaned.
Remove the CAC piping and CAC from the vehicle. Refer
to the manufacturer’s instructions.

CAUTION
Do not use caustic cleaners to clean the CAC. Damage
to the CAC will result.
Flush the CAC internally with solvent in the opposite di-
rection of normal air flow. Shake the CAC and lightly tap

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on the end tanks with a rubber mallet to dislodge trapped
debris. Continue flushing until all debris or oil is removed.
NOTE: Be sure the tubes are in the vertical direction when
flushing.
If the debris cannot be totally removed from the CAC, the
CAC must be replaced.

CAUTION
The CAC must be rinsed, dried and free of solvent, oil
and debris or engine damage will result.
After the CAC has been thoroughly cleaned of all oil and
debris with solvent, wash the CAC internally with hot soapy
water to remove the remaining solvent. Rinse thoroughly
with clean water.
Blow compressed air through the inside of the CAC in the
opposite direction of normal air flow until the CAC is dry
internally.

Inspect for Reuse

Visually inspect the CAC for cracks, holes or damage.
Inspect the tubes, the fins and the welds for tears, breaks
or other damage. If any damage causes the CAC to fail the
air leak check, the CAC must be replaced.
NOTE: Always clean and inspect the CAC piping and hoses
prior to installation.
 Charge Air Cooler (CAC) (010-027)
Section 10 - Air Intake System - Group 10 Page 10-9

Leak Test
WARNING
To prevent possible injury if either plug blows off during
the test, secure safety chains on the test plugs to any
convenient capscrew on the radiator assembly. This
test must not be performed without securely fastened
safety chains.
To check the CAC for cracked tubes or header, remove the
inlet and outlet hoses from the cooler. The CAC does not
have to be removed from the chassis.
Install a plug or cap over the outlet side of the cooler. Install
a pressure gauge and a regulated shop air supply line with
a shutoff valve to the inlet side of the cooler.

Apply air pressure to the cooler until the pressure gauge

reads a steady 207 kPa [30 psi] of air pressure.
Shut off the air flow to the cooler and start a stopwatch at
the same time. Record the leakage at 15 seconds.
If the pressure drop is 34 kPa [5 psi] or less in 15 seconds,

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the cooler is okay.
If the pressure drop exceeds 34 kPa [5 psi] in 15 seconds,
check all connections again.

Determine if the pressure drop is caused by a leak in the

CAC or from a leaky connection. Use a spray bottle filled
with soapy water applied to all hose connections, and watch
for bubbles to appear at the location of the leak.
If the pressure drop is caused by a leaky connection, repair
the connection and repeat the test. If the leak is within the
CAC, repeat the test to verify the accuracy of the pressure
drop measurement. Similar pressure drop readings must
be obtained at least three consecutive tests before the
reading can be considered accurate.
NOTE: If a CAC leaks more than 34 kPa [5 psi] in 15
seconds, it will appear as a major leak in a leak tank.

If the pressure drop is greater than 34 kPa [5 psi] in 15

seconds, the CAC must be replaced.
Refer to the manufacturer’s repair manual for replacement
instructions.
NOTE: Charge air coolers are not designed to be 100%
leak free. If the pressure drop is less than 34 kPa [5 psi] in
15 seconds, then the CAC does not need to be replaced.
Turbocharger, Water-Cooled (010-037)
Page 10-10 Section 10 - Air Intake System - Group 10

Turbocharger, Water-Cooled (010-037)

Clean
WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer’s recommendations
for use. Wear goggles and protective clothing to avoid
personal injury.
CAUTION
Tape or plug all openings to prevent solvent or steam
from entering the oil cavities in the turbocharger.
Use steam to clean the turbocharger.

Inspect for Reuse

Check the exterior of the turbocharger for damage.
Check the wheel for fretting and broken vanes.
Use a dial indicator to measure the turbocharger end clear-
ance.

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Measure the end clearance.

Turbocharger End Clearance

mm in
0.05 MIN 0.002
0.13 MAX 0.005
NOTE: If the end clearance exceeds the specifications, the
turbocharger must be replaced or rebuilt. Refer to the
Turbocharger Service Repair Manual, Bulletin No. 3580999,
for rebuild instructions.

Use your hand to push the impeller end of the shaft toward
the housing.
Use a wire type gauge to measure the clearance between
the impeller and the housing at the minimum clearance
point.

Holset HX82 Turbocharger

mm in
Compressor Impeller 0.15 MIN 0.006
0.45 MAX 0.018
Turbine Wheel 0.20 MIN 0.008
0.55 MAX 0.210
NOTE: If the clearance exceeds the specifications, the
turbocharger must be replaced or rebuilt. Refer to the
Turbocharger Service Repair Manual, Bulletin No. 3580999,
for rebuild instructions.
 Turbocharger Heat Shield (010-076)
Section 10 - Air Intake System - Group 10 Page 10-11

Turbocharger Heat Shield (010-076)

Remove
Marine Applications
CAUTION
Do not remove insulation from inside of turbocharger
heat shield. Insulation is permanently affixed to the
heat shield.
Remove the turbocharger heat shield mounting capscrews.
Remove the turbocharger heat shield.

Clean
Marine Applications
WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer’s recommendations

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for use. Wear goggles and protective clothing to avoid
personal injury.
Use solvent to clean the turbocharger heat shield.
NOTE: Take care not to damage the turbocharger heat
shield insulation.

Inspect for Reuse

Marine Applications
Inspect the turbocharger heat shield for cracks, holes, and
damaged bolt holes.

Install
Marine Applications
Install the turbocharger heat shield.
Install and tighten the turbocharger heat shield mounting
capscrews.
Torque Value: 35 N•m [25 ft-lb]
Turbocharger Heat Shield (010-076)
Page 10-12 Section 10 - Air Intake System - Group 10

NOTES

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