DISC AS 9R2478 - Caterpillar

Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 2
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Illustration 1 g00580321
Disconnect line (1) that runs to the exhaust bypass for the turbocharger.
Remove four bolts (2) and the nuts on the air inlet from the turbocharger.
Illustration 2 g00580361
View from the top of the engine
Remove two bolts (3) and the retainers from outlet pipe (4) of the aftercooler.
Illustration 3 g00580403
Remove two bolts (5) from the bracket that holds outlet pipe (4) to the aftercooler.
Remove two bolts (6) from the bracket that holds inlet pipe (8) to the aftercooler.
Disconnect fitting (7).
Illustration 4 g00580433
Remove bolt (9) and the retainer from inlet pipe (8).
Remove outlet pipe (4) and inlet pipe (8) from the aftercooler. Plug all openings immediately.
Illustration 5 g00580439
Remove four bolts (10) and the nuts that attach the elbow of the engine throttle control to the aftercooler.
Illustration 6 g00580793
Install Tool (A) and attach a suitable lifting device to the aftercooler.
Illustration 7 g00580797
The exhaust heat shields are removed for the photos only.
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.
Lift the aftercooler off the engine. Note: Ensure that the oil lines and the water lines for the turbocharger are not damaged.
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.
Remove bolts (12) that hold the water outlet on the aftercooler in order to clean the aftercooler.
Illustration 8 g00597710
Use a suitable sized rod to clean aftercooler core (13), if necessary.
Use the following steps if the mounting plate for the aftercooler must be removed.
Remove the fuel control actuator from the mounting plate. Refer to Disassembly and Assembly, "Fuel Control Actuator - Remove and Install" for the correct procedure.
Illustration 9 g00580834
View from the top of the engine
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.
Remove two nuts (14) and the bolts.
Remove the mounting plate. Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 2
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Inspect the condition of the seals and the gaskets. Replace the seals and the gaskets, if necessary.
Use the following steps to install the mounting plate for the aftercooler, if necessary:
Illustration 10 g00580834
View from the top of the