G3500 Engines Caterpillar

Removal Procedure

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Illustration 1	g00580321

1. Disconnect line (1) that runs to the exhaust bypass for the turbocharger.

2. Remove four bolts (2) and the nuts on the air inlet from the turbocharger.
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   Illustration 2	g00580361
   View from the top of the engine

3. Remove two bolts (3) and the retainers from outlet pipe (4) of the aftercooler.
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   Illustration 3	g00580403

4. Remove two bolts (5) from the bracket that holds outlet pipe (4) to the aftercooler.

5. Remove two bolts (6) from the bracket that holds inlet pipe (8) to the aftercooler.

6. Disconnect fitting (7).
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   Illustration 4	g00580433

7. Remove bolt (9) and the retainer from inlet pipe (8).

8. Remove outlet pipe (4) and inlet pipe (8) from the aftercooler. Plug all openings immediately.
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   Illustration 5	g00580439

9. Remove four bolts (10) and the nuts that attach the elbow of the engine throttle control to the aftercooler.
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   Illustration 6	g00580793

10. Install Tool (A) and attach a suitable lifting device to the aftercooler.
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    Illustration 7	g00580797
    The exhaust heat shields are removed for the photos only.

11. Remove eight bolts (11) that hold the aftercooler to the mounting plate. There are four bolts on the rear of the aftercooler and four bolts that are on the front of the aftercooler.

12. Lift the aftercooler off the engine.

    Note: Ensure that the oil lines and the water lines for the turbocharger are not damaged.

13. Remove the O-ring seal that is on the air inlet of the aftercooler. Remove the gasket that is on the air outlet of the aftercooler.

14. Remove bolts (12) that hold the water outlet on the aftercooler in order to clean the aftercooler.
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    Illustration 8	g00597710

15. Use a suitable sized rod to clean aftercooler core (13), if necessary.

16. Use the following steps if the mounting plate for the aftercooler must be removed.

    1. Remove the fuel control actuator from the mounting plate. Refer to Disassembly and Assembly, "Fuel Control Actuator - Remove and Install" for the correct procedure.
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       Illustration 9	g00580834
       View from the top of the engine

    2. Remove four bolts (15) and the spacers from the base of the mounting plate. There are two bolts that are on the front of the mounting plate and two bolts that are on the rear of the mounting plate.

    3. Remove two nuts (14) and the bolts.

    4. Remove the mounting plate.

Installation Procedure

1. Inspect the condition of the seals and the gaskets. Replace the seals and the gaskets, if necessary.

2. Use the following steps to install the mounting plate for the aftercooler, if necessary:
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   Illustration 10	g00580834
   View from the top of the engine

   1. Position the mounting plate on the engine. Install two bolts (14) and the nuts.

   2. Install spacers and four bolts (15) in the base of the mounting plate.

   3. Install the fuel control actuator on the mounting plate. Refer to Disassembly and Assembly, "Fuel Control Actuator - Remove and Install" for the correct procedure.
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   Illustration 11	g00580793

3. Install Tool (A) and attach a suitable lifting device to the aftercooler. Position the aftercooler on the engine.

   Note: Ensure that the oil lines and the water lines for the turbocharger are not damaged.

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   Illustration 12	g00580797
   The exhaust heat shields are removed for photos only.

4. Install eight bolts (11) that hold the aftercooler to the mounting plate. There are four bolts on the rear of the aftercooler and four bolts on the front of the aftercooler.
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   Illustration 13	g00580439

5. Install four bolts (10) and the nuts that attach the elbow of the engine throttle control to the aftercooler.
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   Illustration 14	g00580433

6. Install inlet pipe (8) and outlet pipe (4) on the aftercooler.

7. Install the retainer and bolt (9) on inlet pipe (8).
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   Illustration 15	g00580403

8. Connect fitting (7) on the line that runs from the water manifold to the turbocharger.

9. Install the bracket and two bolts (6) that hold inlet pipe (8) to the aftercooler.

10. Install the bracket and two bolts (5) that hold outlet pipe (4) to the aftercooler.
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    Illustration 16	g00580361
    View from the top of the engine

11. Install the retainers and two bolts (3) for outlet pipe (4) of the aftercooler.
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    Illustration 17	g00580321

12. Install four bolts (2) and the nuts on the air inlet from the turbocharger.

13. Connect line (1) that runs to the exhaust bypass for the turbocharger.

14. Fill the cooling system to the correct level with coolant. Refer to the Operation and Maintenance Manual for the correct procedure.