ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 010-005   Aftercooler Assembly (Sea Water)

A turbocharger or sea water pump failure can cause damage to the aftercooler assembly.

If a turbocharger failure or a sea water pump failure has occurred, remove the aftercooler element and inspect the element and housing for damage.

Inspect the zinc anodes to make sure they are still in one piece and have not broken.

See the Inspect step within this procedure.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

WARNING  Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system.

CAUTION  Use caution when disconnecting or removing fuel lines, replacing filters and priming the fuel system that fuel is not spilled or drained into the bilge area. Do not drop or throw filter elements into the bilge area. The fuel and fuel filters must be discarded in accordance with local environmental regulations.

CAUTION  Zinc plugs expand and can break off during removal. Inspect the zinc plug to make sure it is in one piece. If not, it must be replaced with a new zinc plug, and the broken pieces must be retrieved from the aftercooler to prevent damage to components downstream in the sea water system.

• Shut off the sea water supply and return line(s). Refer to the OEM service manual.
• Shut off the fuel supply and return lines. Refer to the OEM service manual.
• Disconnect the battery power from the engine. Refer to Procedure 013-009.
• Drain the sea water by removing the zinc anode plug at the bottom of the aftercooler. Refer to Procedure 008-059.
• Loosen the aftercooler top and bottom air connection hose clamps.
• If necessary, remove the aftercooler air discharge connection. Refer to Procedure 010-131.
• Disconnect the aftercooler air inlet connection. Refer to Procedure 010-019.
• If necessary, remove the fuel drain flex hoses at the fuel cooler.
• Remove the fuel cooler clip and mounting capscrew.
• Remove the fuel cooler lower molded sea water hose from the aftercooler. Support the cooler to prevent damage to the fuel lines.
• Loosen the hose clamp on the upper water transfer connection and remove the aftercooler sea water discharge hose.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

WARNING  Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system.

CAUTION  Use caution when disconnecting or removing fuel lines, replacing filters and priming the fuel system that fuel is not spilled or drained into the bilge area. Do not drop or throw filter elements into the bilge area. The fuel and fuel filters must be discarded in accordance with local environmental regulations.

CAUTION  Zinc plugs expand and can break off during removal. Inspect the zinc plug to make sure it is in one piece. If not, it must be replaced with a new zinc plug, and the broken pieces must be retrieved from the aftercooler to prevent damage to components downstream in the sea water system.

• Shut off the sea water supply and return lines. Refer to the OEM service manual.
• Shut off the fuel supply and return lines. Refer to the OEM service manual.
• Disconnect the batteries. Refer to Procedure 013-009.
• Drain the sea water system by removing the plugs at the bottom of the marine gear oil and fuel cooler.
• Remove the aftercooler air box drain plug and drain the condensation from the aftercooler housing core.
• Remove the air crossover and air outlet tube. Refer to Procedure 010-019.
• Remove the sea water lines. Refer to Procedure 008-056.
• Remove the marine gear oil and fuel cooler assembly. Refer to Procedure 008-129.

Loosen the aftercooler mounting capscrews at the flywheel housing (1), the cylinder block (2), and the cylinder head (3).

Remove the aftercooler assembly.

Remove the upper mounting capscrews and loosen the bracket mounting capscrews in the cylinder block.

WARNING  This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component.

Attach a lifting strap and use a suitable hoist to lift the assembly.

Remove the lower mounting capscrews.

Slide the assembly from the bracket and away from the engine.

NOTE: Although the QSC8.3 and QSL9 aftercoolers look different, the following steps will apply to both.

Mark or note the aftercooler inlet and outlet water connection locations.

Remove the zinc plugs from the upper water transfer connection.

Remove the three capscrews and the upper water connection.

CAUTION  The aftercooler core assembly will slide out of the cooler housing when removing the lower aftercooler water connection. To reduce the possibility of damaging the core, lay the aftercooler assembly on its side to remove the connection and the core.

Lay the aftercooler assembly on its side.

The core assembly has two flat sides which must be orientated toward the aftercooler air intake and outlet sides of the aftercooler.

Remove the lower connection cover and the core.

Remove the upper and lower sealing o-rings.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

NOTE: The aftercooler core can be cleaned and tested by a radiator cleaning facility. Ultrasonic cleaner is the preferred method of cleaning.

Use soap and water to clean the aftercooler and end caps.

Dry with compressed air.

Inspect the housing and caps for cracks or other damage.

Inspect the aftercooler housing for deterioration of the sealing surfaces.

Assemble the aftercooler in a vertical position. Install the aftercooler core into the aftercooler housing. Align the marks so one flat side of the core is facing the air inlet side of the housing.

Install a new o-ring around the lower core O.D. Install the water end cap and tighten the capscrews.

Install a new o-ring around the upper core O.D. Install the water end cap and tighten the capscrews.

Install the zinc plugs and tighten.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Pressure test the sea water side of the aftercooler assembly.

Apply 276 kPa [40 psi] air pressure.

Lower the assembly into a tank of water and check for leaks.

Completely dry the aftercooler with compressed air.

Loosely install the aftercooler assembly to the flywheel housing first using two mounting capscrews.

Install the upper capscrews first.

Install the aftercooler to bracket mounting capscrews.

Tighten all capscrews.

Attach a lifting strap and use a suitable hoist to lift the aftercooler assembly into place.

Slide the assembly onto the lower support bracket and install the lower mounting capscrews.

Tighten the capscrews.

Install the upper bracket to the aftercooler mounting capscrews. Tighten all of the upper bracket mounting capscrews finger tight.

Tighten the bracket to the cylinder block mounting capscrews.

Tighten the bracket to aftercooler mounting capscrews.

• Install the fuel cooler lower molded sea water hose to the aftercooler.
• Install the fuel cooler clip and mounting capscrew.
• If removed, install the fuel drain flex hoses at the fuel cooler.
• Connect the aftercooler air inlet connection from the turbocharger.
• Install the aftercooler sea water discharge to marine gear cooler hose and tighten the hose clamps.
• If removed, install the aftercooler air discharge to the intake air connection. Refer to Procedure 010-131.
• Tighten the aftercooler top and bottom air connection hose clamps.
• Connect the battery power to the engine. Refer to Procedure 013-009.
• Open the sea water supply and return line(s). Refer to the OEM service manual.
• Open the fuel supply and return lines. Refer to the OEM service manual.

Operate the engine and check for leaks.

• Install the marine gear oil and fuel cooler assembly. Refer to Procedure 008-129.
• Install the sea water lines. Refer to Procedure 008-056.
• Install the air crossover and air outlet tube. Refer to Procedure 010-019.
• Open the fuel supply and return valves. Refer to the OEM service manual.
• Open the sea water supply and return valves. Refer to the OEM service manual.
• Connect the batteries. Refer to Procedure 013-009.

Operate the engine and check for leaks.