TM 9-6115-604-34
NAVFAC P-8-633-34
SECTION VII. MAINTENANCE OF AFTERCOOLER, INTAKE AND EXHAUST MANIFOLDS,
AND
WATER MANIFOLDS
9-41. GENERAL. Each cylinder head exhaust port is connected individually to two three-piece exhaust manifolds. The
outlet of each exhaust manifold connects to a turbocharger, where the high pressure exhaust gas is used to turn a turbine
wheel and impeller. Compressed air from the turbocharger passes through the aftercooler and intake manifold to the
inlet ports of each cylinder head. The aftercooler assembly consists of a housing assembly and two heat exchanger
cores which are connected to the engine cooling system. As it emerges from the turbocharger, the compressed air is at a
very high temperature. The excess heat is absorbed by the aftercooler to provide denser air for more efficient
combustion. Water manifolds connect between each rocker arm housing to carry return coolant from the cylinder heads
to the thermostat housing.
9-42. AFTERCOOLER MAINTENANCE.
a.
Inspect.
(1)
Remove the air crossover housings and connections in accordance with step b, below.
(2)
Use a light to visually inspect both cores (30, Figure 9-78) for evidence of leakage. Pay particular attention
to where the core tubes connect with the adapter connections (17).
(3)
Visually examine the air crossover housings (4), tubes (7), crossover connections (9), covers (28), and
housing (34) for cracks and porosity.
(4)
Check the mounting plates (36) and supports (40) for cracks.
(5)
Inspect all inlet and outlet connections for evidence of coolant leakage.
(6)
If defects are found, repair or replace the defective parts in accordance with steps (b) through (i), below.
(7)
If no defects are found, install the air crossover housings and connections in accordance with step (i),
below.
b.
Remove.
(1)
Drain the cooling system in accordance with the Operator and Organizational Maintenance Manual.
(2)
Remove the turbochargers and the turbocharger oil hose assemblies secured to the aftercooler in
accordance with the Operator and Organizational Maintenance Manual.
(3)
Remove the air control valve assembly and support channels from the aftercooler and remove the air filter
tubing assembly on the engine left side only in accordance with the Operator and Organizational
Maintenance Manual.
(4)
Remove the ether line tubing and the ether jets and associated fittings from the intake manifold crossover
housings in accordance with the Operator and Organizational Maintenance Manual.
(5)
Remove the air bleed hose assemblies to the radiator and the aftercooler in accordance with the Operator
and Organizational Maintenance Manual.
(6)
Remove the capscrews (1, Figure 9-78), lockwashers (2), and washers (3), and remove the crossover
housings (4) by slipping them off of the tubes (7). Remove and discard the gaskets (5).
(7)
Pull out the tubes (7), and remove and discard the packings (8). Remove and discard insulation from tube
(7).
(8)
Remove the crossover connection (9), by removing the capscrews (1), lockwashers (2), and washers (3).
Remove and discard the gaskets (10).
(9)
Remove the capscrews (11) and lockwashers (2) securing the outlet pipes (12) to the outlet connections
(14).
(10)
Remove the hexagon head screws (19) and washers (2) securing the inlet connections (20).
(11)
Remove the capscrews (24) and lockwashers (2), and remove the transfer housing (25), tubes (21), and
inlet connections (20) as an assembly. Discard the gasket (26).
(12)
Remove the capscrews (35), lockwashers (32), and washers (33), and remove the aftercooler assembly
mounting plate (36).
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