REMOVE AND INSTALL PROCEDURES

INTERNATIONAL MAXXFORCE DT 9 AND 10

MOUNTING ENGINE ON ENGINE STAND

ENGINE PREPERATION
Clean Engine

1. Disconnect the negative battery cable.

2. Cap all engine openings to prevent water and degreasing agents from entering engine.

3. Cover exposed electrical connectors and the ECM using plastic and duct tape.

4. Use an appropriate detergent mixed in the correct ratio and apply to engine using a hot
pressure washer or similar cleaning equipment.

Drain Coolant

Coolant Drain Plug

1. Place a coolant drain pan under the oil system module.

2. Remove M16 coolant drain plug from the bottom of the oil system module. Open radiator
cap to allow system to drain quicker.

3. Remove and discard coolant drain plug O-ring.

4. Install a new O-ring on the coolant drain plug.

5. After coolant has drained, install coolant drain plug in the oil system module.
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 6. Tighten coolant drain plug to special torque.

7. Recycle or dispose of coolant according to applicable regulations.

Drain Oil

Oil Drain Plug Removal

1. Place an oil drain pan beneath the oil drain plug.

2. Remove the oil pan drain plug and discard O-ring.

3. Inspect drain plug and replace if necessary.

4. Install a new O-ring on the oil drain plug.

5. After oil has drained, lubricate oil drain plug O-ring with clean engine oil and install oil
drain plug in the oil pan.

6. Tighten oil drain plug to special torque.

7. Recycle or dispose of oil according to applicable regulations.

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REMOVAL
Electrical Connections

Boost Control Harness and Electrical Connections

1. Turbocharger wastegate actuator connector—vacuum line

2. Connector wire clip lock
3. Turbocharger 2 Wastegate Control (TC2WC) valve 2-pin connector
4. M5 x 16 socket head bolt (2)
5. Insulator—high temperature plastic (2)
6. Exhaust Gas Temperature (EGT) connector
7. Interstage Cooler (ISC) inlet duct
8. Exhaust Gas Temperature (EGT) sensor
9. Turbocharger air inlet duct connector—vacuum line

1. Remove boost control harness assembly and Turbocharger 2 Wastegate Control

(TC2WC) Valve. See Boost Control Harness Assembly and Turbocharger 2 Wastegate
Control (TC2WC) Valve.

2. Disconnect connector from Exhaust Gas Temperature (EGT) sensor. See Exhaust Gas
Temperature (EGT) Sensor.

3. Move engine wiring harness to the side so components can be removed to mount the
Engine. Stand Bracket to the crankcase.

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Aftertreatment / Turbocharger Disconnection Points

Aftertreatment / Turbocharger Disconnection Points (Typical)

1. Exhaust brake valve

2. Exhaust brake tube
3. Exhaust clamp
4. Actuator brake assembly
5. Exhaust brake under rail housing

NOTE: The following procedure is correct for vehicles equipped with either the exhaust under
rail brake assembly or the exhaust over rail brake assembly.

1. Loosen the exhaust clamp so it will slide off onto the exhaust brake under rail housing.

2. Loosen the 5/16 nut and the 37-degree nut on the exhaust brake tube. Remove tube; do
not discard.
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Turbocharger Oil Supply Tube Assembly and Heat Shield

Turbocharger Oil Supply Tube Assembly

1. Turbocharger oil supply tube nut

2. Fitting and O-ring (with screen)
3. Oil supply tube assembly
4. M6 x 12 bolt

1. Remove turbocharger oil supply tube nut from fitting and O-ring (with screen) on the oil
cooler housing.

2. Remove M6 x 12 bolt securing turbocharger oil supply tube assembly retainer to EGR
cooler.

Oil Supply Tube at Low-Pressure Turbocharger Assembly

1. M6 x 16 bolt
2. Oil supply tube assembly

3. Remove M6 x 16 bolt securing oil supply tube assembly to low-pressure turbocharger.

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 Oil Supply Tube at High-Pressure Turbocharger Assembly

1. M6 x 16 bolt
2. Oil supply tube assembly

4. Remove M6 x 16 bolt securing oil supply tube assembly to high-pressure turbocharger.

5. Remove oil supply tube assembly.

6. Remove and discard two oil supply tube O-rings.

7. Install Disposable Air and Fuel Caps on the ends of the turbocharger oil supply tube and
on the oil supply ports of the turbocharger and oil system module turbo oil supply
adapter.

Turbocharger Heat Shield

1. M8 x 12 bolt (3)
2. M8 x 27 bolt (hi temp)
3. Turbocharger heat shield
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 8. Remove one M8 x 27 bolt.

9. Remove three M8 x 12 bolts. Remove turbocharger heat shield from turbocharger.

ISC Inlet Elbow and Intercooler

ISC Inlet Elbow

1. Interstage cooler inlet duct

2. Hose T-bolt / coil spring clamp
3. M6 x 30 bolt (2)
4. ISC inlet elbow

1. Remove two M6 x 30 bolts securing the Interstage Cooler (ISC) inlet elbow to the
interstage cooler assembly.

2. Loosen nut on hose spring clamp and turn the ISC inlet elbow away from the interstage
cooler assembly.

Turned ISC Inlet Elbow and Disengaged Elbow Deaeration Hose

1. Hose T-bolt / coil spring clamp (2)

2. Interstage cooler
3. Heat exchanger clamp
4. Deaeration hose elbow
5. O-ring
6. ISC inlet elbow
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 3. Loosen heat exchanger clamp on deaeration hose elbow and pull up elbow to disengage
from intercooler assembly.

4. Remove and discard ISC inlet elbow O-ring.

Interstage Cooler Mounting Bolts

5. Loosen and remove four M8 x 110 bolts securing the interstage cooler to the valve
cover. Remove interstage cooler from engine.

Turbocharger Oil Drain Tubes and Turbocharger

Turbocharger Oil Drain Tubes

1. M10 nut special thread (5)

2. Low-pressure turbocharger
3. High-pressure turbocharger oil drain tube
4. Breather tube assembly
5. Breather tube assembly worm gear clamp
6. Turbocharger oil drain tube worm gear clamp (2)
7. M8 x 25 bolt
8. Low-pressure turbocharger oil drain tube
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 1. Remove M8 x 25 bolt securing turbocharger oil drain tubes.

2. Loosen turbocharger oil drain tube worm gear clamps and disconnect drain tubes (high
and low-pressure) from the turbocharger and crankcase breather.

3. Loosen breather tube assembly worm gear clamp. Disconnect breather tube assembly
from crankcase breather.

Turbo Lifting Bracket Mounting Location

4. Install Turbo Lifting Bracket onto the turbocharger. Install the lifting bracket and secure
using the two front bolt holes used to secure the turbocharger heat shield.

5. Attach a hoist to the Turbo Lifting Bracket, then loosen and remove five M10 nuts
securing turbocharger to the exhaust manifold.

6. Remove turbocharger assembly and discard gasket.

7. Remove the High Fin Density EGR Cooler and Components and the Interstage Inlet
Duct Assembly.

Oil Filter

Oil Filter

1. Oil filter (spin-on)

2. Oil cooler module assembly

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 1. Place an oil drain pan under the oil filter.

2. Rotate oil filter counterclockwise with an oil filter wrench and remove oil filter.

3. Remove oil filter gasket and discard, if stuck to the oil cooler module assembly.

4. Recycle or dispose of oil and filter with gasket, according to applicable regulations.

Oil System Module Assembly

Oil Cooler Module and Coolant Return Tube

1. Oil cooler module assembly

2. M8 x 30 bolt (11)
3. Coolant return tube assembly
4. Tube support
5. M8 x 30 stud bolt

1. Place a drain pan under the oil cooler module assembly.

2. Loosen, do not remove, one M8 x 30 bolt securing the closest tube support to the oil
cooler module.

3. Remove, do not discard, one M8 x 30 stud bolt from the oil cooler module.

4. Remove ten M8 x 30 bolts securing the oil cooler module to the crankcase. Pull the oil
cooler module slightly away from the crankcase, then pull back to remove the oil cooler
module from the coolant return tube.

5. Discard O-ring from the coolant return tube.

6. Recycle or dispose of oil and coolant according to applicable regulations.

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MOUNTING ENGINE STAND BRACKET AND ENGINE
Mounting Engine Stand Bracket

Engine Stand Bracket and Engine Stand

1. Engine Stand
2. Square plate (top)
3. Class 10.9 M16 bolt (8)
4. Engine Stand Bracket
5. Class 10.9 M8 bolt (9)
6. Square plate (bottom)

1. Install bottom square plate on the Engine Stand using two Class 10.9 M16 bolts and
tighten to standard torque.

2. Match Engine Stand Bracket holes with bolt holes in the exhaust side of the crankcase
and install 11 appropriately sized Class 10.9 M8 bolts.

3. Tighten all 11 bolts to standard torque.

4. Raise or lower the engine to the approximate height of the Engine Stand.

5. Install two Class 10.9 M16 bolts through the bottom square plate and Engine Stand
Bracket. Install two Class 10.9 M16 nuts and washers on bolts and finger tighten.

6. Install the top square plate on the Engine Stand using two Class 10.9 M16 bolts and
tighten to standard torque.

7. Raise or lower the engine as needed to match the engine plate to the Engine Stand.

8. Install two Class 10.9 M16 bolts and washers securing the top plate to the engine stand.
Tighten eight M16 bolts to standard torque.

9. Slowly release tension from engine hoist.

10. Remove hoist safety chain hooks from engine lifting eyes.
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NOTE: When installing components back onto engine, be sure to use new gaskets, seals, and
O-rings.

SPECIAL TORQUE

Coolant drain plug, M16 ................................................................................. 21 N·m (15 lb·ft)

Oil pan drain plug ........................................................................................... 68 N·m (50 lb·ft)

SPECIAL SERVICE TOOLS

Disposable Air and Fuel Caps ........................................................................ ZTSE4891

Engine Stand Bracket .................................................................................... ZTSE4940
Engine Stand ................................................................................................. OTC1750A
Oil filter wrench .............................................................................................. Obtain locally
Turbo Lifting Bracket ...................................................................................... ZTSE4942

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