GUIDE AS-GAUGE 7C7764 - Caterpillar

Engines: 3612 (S/N: 9RC1-UP; 9FR1-UP; 2NZ1-UP) 3616 (S/N: 1PD1-UP; 1FN1-UP)Introduction
This Special Instruction should be used when you are replacing the standard aftercooler with the High Performance Aftercooler on 3612 Engines and 3616 Engines. The entire instruction should be read and understood prior to beginning work on the engine.Removal Of The Standard Aftercooler
Start by removing the exhaust manifolds from the engine.
Drain the coolant from the engine.
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Remove the bolts that hold the elbow (1) and the elbow (2) to the turbochargers. Remove the elbows from the pipes.
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Remove the pipe (3) and the pipe (4) from the housing (5) .
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Remove the housing (5), the housing (6), and the housing (7) from the rear aftercooler housing.
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Remove the bolts that hold the flanges (8) in place. Remove the flanges and the tube (9) as an assembly.
Remove the bolts and the retainers that hold the tube (10) in place inside of the elbow (11) .
Remove the bolts and spacers (12) that hold the elbow (11) in position. Remove the elbow from the aftercooler and the tube (10) .
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Remove the two pipes (13) and the two pipes (14) from the aftercooler housings.
Remove the bolts that hold the two pipes (15) to the rear aftercooler housing.
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Fasten a hoist to the front aftercooler housing. Remove the bolts from the front aftercooler housing. Remove the front aftercooler housing from the cylinder block. The weight of the aftercooler housing is approximately 236 kg (520 lb).
Fasten a hoist to the rear aftercooler housing (16). Remove the bolts (17) from the rear aftercooler housing. Remove the rear aftercooler housing from the cylinder block. The weight of the aftercooler housing is approximately 236 kg (520 lb).
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Remove the gaskets (18) from the cylinder block.Installation Of The 130-1292 Seal
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Table 1
Required Tools And Parts    
Item    Part Number    Description    Quantity    
A     148-9707     Ring Compressor Pliers     2    
B     148-9705     Seal Ring Compressor     2    
C     148-6443     Ring Insert     1    
D     148-6442     Ring     1    
E     148-6444     Seal Installer     1    
F     148-6445     Seal Driver     1    
1     130-1292     Seals     4    
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Chamfer On Insert
Remove the two 6D-3033 Allen Head Screws from the 148-6443 Ring Insert (C). Place the 130-1291 Pipe (2) on a work bench. Install the insert in the top seal groove of the pipe (2). The insert has a chamfer on one side. It is important to install the insert with the chamfer toward the top of the pipe. This will allow the energized seal to slide evenly over the insert.
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When the insert (C) is installed, place the 148-6444 Seal Installer (E) onto the pipe. Lubricate the seal installer with glycerin.
Place the 130-1292 Seal (1) on the seal installer (E) with the energized spring toward the top of the pipe.
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Use the 148-6442