N14 Base Engine Troubleshooting and Repair Manual – 010-001   Aftercooler

WARNING  Coolant can be toxic. Dispose of in accordance with local environmental regulations.

Drain the cooling system. Refer to Procedure

008-018-005.

Remove the air crossover connection or tube.

Remove the support clamps from the aftercooler transfer tubes.

Remove the hoses from the aftercooler coolant inlet and outlet connections.

Remove the air compressor air inlet tube.

Remove the AFC signal tube and any other hoses which are attached to the aftercooler housing
(turbocharger boost pressure, etc.).

Remove one mounting capscrew and washer at each end of the housing.

Install a guide stud in each capscrew mounting hole.

NOTE: Two guide studs are required to support the aftercooler assembly during removal.

Remove the remaining mounting capscrews and washers.

WARNING  Because this assembly weighs more than 23 kg [50 lbs], two people or a hoist will be required to lift the aftercooler assembly to avoid personal injury.

Remove the aftercooler assembly.

Remove the gaskets.

Remove the coolant inlet connection.

Remove the coolant outlet connection.

Remove the capscrews and washers which secure the aftercooler to the housing.

Remove the aftercooler core from the housing.

Remove the strip seal.

Steam clean the parts, and dry with compressed air.

NOTE: Clean the aftercooler core with a solvent or chemical which will

not harm copper or aluminum.

If the engine experiences a turbocharger failure or any other occasion where oil or debris is put into the aftercooler, the afterccoler

must be cleaned.

Visually inspect the parts for cracks or damage.

NOTE: Pressure test the aftercooler core. Refer to Procedure

010-001-013.

Remove and disassemble the aftercooler assembly. Refer to Procedure

010-001-002.

Install the hose (1), the hose clamps (2), and the solid pipe plug (3) on the water outlet pipe.

Install the hose (4), the hose clamps (5), and the water inlet tube (6) on the water inlet pipe.

Install the hose (7), the hose clamps (8), and the air pressure gauge (9).

Connect the air pressure gauge to a regulated air supply, and apply 276 kPa [40 psi] air pressure.

Submerge the core or aftercooler assembly in a tank of water heated to 80°C [180°F].

If air bubbles appear, the core is damaged. Replace the core or aftercooler assembly.

Remove the core or aftercooler assembly from the water tank.

Remove the test equipment.

Dry with compressed air.

Assemble and install the aftercooler. Refer to Procedure

010-001-026.

Install a new strip seal and the aftercooler cover to the housing.

Install and tighten the capscrews.

Install two guide studs in the cylinder heads.

WARNING  Because its assembly weighs more than 23 kg [50 lbs], two people or a hoist will be required to lift the aftercooler assembly to avoid personal injury.

Install new gaskets, and install the aftercooler assembly on the guide studs.

Install the capscrews and washers.

Remove the guide studs, and install the remaining two capscrews and washers.

Tighten the capscrews in the sequence shown to the following:

Install the coolant inlet and the outlet connections.

Tighten the hose clamps.

Install the air compressor air inlet tube.

Install the AFC signal tube and any other hoses which are attached to the aftercooler housing
(turbocharger boost pressure, etc.).

Install the air crossover connection or tube.

Fill the cooling system. Start the engine, and check for leaks. Refer to Procedure

008-013-028.