WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

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.

• Disconnect the batteries. Refer to the OEM service manual.
• Drain the cooling system. Refer to Procedure 008-018 in Section 8.

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  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

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.

WARNING  When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury.

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

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 malfunction or any other occasion where oil or debris enters into the aftercooler, the afterccoler must be cleaned.

Inspect the parts for cracks or other damage.

NOTE: Pressure test the aftercooler core.

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.

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

Dry with compressed air.

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

Install and tighten the capscrews.

WARNING  This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.

Install two guide studs in the cylinder heads.

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 illustrated:

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.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

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.

• Fill the cooling system. Refer to Procedure 008-018 in Section 8.
• Connect the batteries. Refer to the OEM service manual.