3208 INDUSTRIAL ENGINE – Aftercooler

Remove & Install Aftercooler

Start By:

a. remove turbocharger

b. remove air inlet manifold

Fluid Spillage Containment

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to “Tools And Shop Products Guide”, NENG2500 for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

1. Loosen two clamps (1).

2. Disconnect two hoses (2) from the aftercooler housing. Cap and plug all openings immediately.

3. Disconnect fuel vent line (3). Cap and plug all openings immediately.

4. Loosen three hidden bolts (4). (One bolt not shown).

5. Remove five bolts and washers (5).

NOTE: Upon installation, tighten the bolts in Steps 4 and 5 as follows:

a. Tighten bolts marked (3) and (4) in the illustration above, to a torque of 20 ± 7 N·m (15 ± 5 lb ft).

b. Tighten bolts marked (1) thru (8) in the illustration above, by numerical sequence to a torque of 43 ± 7 N·m (32 ± 5 lb ft).

6. Attach lifting slings and a suitable lifting device to aftercooler housing (6). The weight of the aftercooler housing is approximately 25 kg (55 lb).

7. Lift the aftercooler housing up slightly and toward the rear of the engine to gain access to bolts and washers (4).

8. Remove three bolts and washers (4).

9. Remove aftercooler housing (6).

10. Remove fourteen bolts and washers (7).

11. Pull aftercooler core (8) out of aftercooler housing (6).

12. Inspect gasket (9) for wear or damage and replace with a new part if necessary.

13. Inspect seal (10) for wear or damage and replace with a new part if necessary.

NOTE: For installation of the aftercooler, reverse the removal steps.

End By:

a. install air inlet manifold

b. install turbocharger