PISTON & ROD GP 1W2200 - Caterpillar

Aftercooler Core
START BY:a. remove instrument panel (marine engine)1. Drain the coolant from the engine.
Marine Engine2. Remove five bolts (1) that hold air inlet manifold (2) to the aftercooler.
Industrial Engine3. Remove the four nuts and washers that hold adapter (4) to the aftercooler. Remove the bolts and cover (3).4. Loosen clamp (6) on the turbocharger.5. Rotate air inlet pipe (5) to move adapter (4) away from the aftercooler. 6. Remove the bolts that hold elbow (7) to the aftercooler, and remove the elbow and pipe (8).
Marine Engine7. Remove tube (10).8. Remove the four bolts that hold elbow (9) to the aftercooler, and remove the elbow. 9. Remove adapters (11) and (12) from each end of the aftercooler. 10. Remove the bolts that hold cover (13) to the aftercooler housing, and remove the cover. 11. Remove aftercooler core (14) from the aftercooler housing. 12. Remove O-ring seals (15) from the ends of aftercooler core (14).Install Aftercooler Core
1. Put O-ring seals (2) in position on aftercooler core (1). Put clean oil on the O-ring seals. 2. Put the gasket in position on aftercooler housing (3), and install aftercooler core (1) in the aftercooler housing. 3. Put gasket (5) in position on the aftercooler core, and install cover (4) and the bolts that hold it to the aftercooler housing. 4. Put adapters (6) and (7) in position in each end of the aftercooler housing. 5. Make sure gasket (9) is in place on the adapter.6. Put a new O-ring seal on pipe (10). Put clean oil on the O-ring seal.7. Put the pipe and elbow (8) in position in elbow (11), and install the bolts that hold elbow (8) to the aftercooler housing.
Marine Engine8. Install a new O-ring seal on pipe (13).9. Put elbow (14) in position on pipe (13), and install the bolts that hold the elbow to the aftercooler housing.10. Install tube (12).
Industrial Engine11. Put a new gasket on each side of the aftercooler cover.12. Rotate air inlet pipe (17) until adapter (15) is in position on the aftercooler cover.13. Put cover (16) in position on the aftercooler cover, and install the bolts.14. Install the washers and nuts that hold adapter (15) to the aftercooler cover.15. Tighten clamp (18) on the turbocharger.
Marine Engine16. Put the gasket and air inlet pipe (19) in position on the aftercooler cover, and install the five bolts that hold it.17. Fill the engine with coolant to the correct level. See the Maintenance Guide.END BY:a. install instrument panel (marine engine)