Usage:
Typical Example
1. Remove coolant from the engine.
2. Remove pipe (1) from between the turbocharger and the cover assembly.
3. Loosen clamps (2) and remove oil breather cap (3).
4. Loosen clamp (6) and remove bolts (4) that fasten tube assembly (5) to the aftercooler cover assembly. Remove tube assembly (5).
5. Remove O-ring seal (7) from tube assembly.
Typical Example
6. Remove adapter (8) and gasket from the aftercooler housing.
NOTE: An O-ring seal on each end of the aftercooler core holds adapters (8) and (11) in position.
Typical Example
7. Remove four bolts that fasten tube assembly (9) from the oil cooler bonnet to the aftercooler housing. Loosen hose clamp on the opposite end of tube assembly and remove tube assembly (9) from the aftercooler housing.
8. Remove O-ring seal (10) from the tube assembly.
Typical Example
9. Remove adapter (11) and gasket and disconnect tube assembly (12) from the air fuel ratio control.
Typical Example
10. Remove two bolts (13) that fasten the cover assembly to the housing.
Typical Example
11. Remove the remainder of bolts (15) and cover assembly (14) from the housing.
Typical Example
12. Remove aftercooler core assembly (16) and gasket from the housing. Remove O-ring seals (17) from each end of the core assembly.
Typical Example
13. Remove two bolts (18) on the inside of the aftercooler housing.
Typical Example
14. Disconnect wire (20) from the aftercooler housing switch.
NOTE: Make a note of the location of bolt spacers before removal.
15. Remove bolts (19), housing (21) and gasket from the cylinder head.
Install Aftercooler
NOTE: Inspect all O-ring seals and gaskets and make replacements if necessary.
NOTE: Put a thin layer of clean engine oil on all O-ring seals and in the bores of each adapter.
Typical Example
1. Put aftercooler housing gasket in position on the cylinder head and install aftercooler housing (1). Make a note of the location of two spacers (2) from the remove story.
Typical Example
2. Connect wire (3) to the aftercooler housing switch.
Typical Example
3. Install aftercooler core gasket (6) in position on housing.
4. Install O-ring seals (5) on each end of the aftercooler core (4).
5. Put aftercooler core (4) in position in housing.
Typical Example
6. Install gasket (7) and cover (8) in position on aftercooler core. Be sure all hose and wire clips are in place.
Typical Example
7. Connect tube assembly (9) to cover assembly. Install gasket and adapter (10).
8. Install O-ring seal (11) on tube assembly.
Typical Example
9. Install tube assembly (12) in position. Be sure hose and tube clamps are in place. Install hose on opposite end of tube assembly to the oil cooler bonnet.
Typical Example
10. Install gasket and adapter (13) in cover assembly.
11. Install O-ring seal (14) on tube assembly.
12. Put tube assembly (18) in position on the aftercooler cover assembly and install bolts (17). Tighten hose clamps (19).
13. Install breather cap (16) and tighten bolt to a torque of 14 ± 3 N·m (10 ± 2 lb.ft.). Tighten clamp (15).
Typical Example
14. Install pipe (20) between turbocharger and aftercooler cover assembly.
15. Fill the radiator with coolant to the correct level. See MAINTENANCE MANUAL.