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Disassembly and Assembly

3406B DIESEL TRUCK ENGINE
Media Number -SEBR0544-03 Publication Date -01/04/1991 Date Updated -13/06/2006

SEBR05440149

Aftercooler Core
SMCS - 1064-011; 1064-012

Remove Aftercooler Core

1. Drain the coolant from the engine.

2. Remove bolts (1) from the adapter. Loosen turbocharger compressor housing clamp (2), and rotate
turbocharger tube (3) out of the way of the aftercooler housing.

3. Put identification marks on the bolts which hold the aftercooler cover in position for installation
purposes. Remove bolts (4) that hold the aftercooler cover to the aftercooler housing. Remove
aftercooler cover (5).

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4. Remove four bolts (6), elbow (7), the two adapters and pipe (8).

5. Remove four bolts (9), elbow (10) and two adapters (11).

6. Remove aftercooler core (12) from aftercooler housing (13).

7. Remove O-ring seals (14) and gaskets (15) if necessary.

Install Aftercooler Core

1. Clean and inspect all parts. Make a replacement of all parts that are worn or damaged.

NOTE: Lubricate all O-ring seals with clean engine oil at assembly.

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2. Install O-ring seals (1). Fasten gaskets (2) to both sides of the aftercooler core flange with 5H2471
Cement.

3. Put aftercooler core (3) in position in the aftercooler housing with the end that has the
identification "Jacket Water, Fresh Air" toward the water inlet end of the aftercooler housing.

4. Install cover (4) on the aftercooler housing. Be sure to install the long bolts in the thru bolt holes.

NOTICE
To prevent damage to the aftercooler core, tighten the bolts that hold
the aftercooler core before tightening the bolts that hold the adapters.

5. Tighten the aftercooler core cover bolts to a torque of 25 ± 7 N·m (18 ± 5 lb.ft.). Tighten the bolts
again after engine is operated to a torque of 25 ± 7 N·m (18 ± 5 lb.ft.).

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6. Install gasket (5) and adapter (6) on the aftercooler housing.

7. Install adapter (7) on adapter (6).

8. Put O-ring seals (8) on pipe (9), and install pipe (9) into elbow (10).

9. Install elbow (11) on pipe (9). Put gasket (12) in position between elbow (11) and adapter (7), and
fasten the elbow to aftercooler housing with four bolts.

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10. Install gasket (13) and adapter (14) on the aftercooler housing.

11. Install adapter (15) on adapter (14).

12. Put O-ring seal (16) in position on tube (17), and install elbow (18) on tube (17). Put gasket (19)
in position between elbow (18) and adapter (15), and fasten the elbow to the aftercooler housing with
four bolts.

13. Rotate turbocharger tube (20) into position. Place a gasket between the aftercooler housing and
adapter, and install the four bolts and nuts that hold it.

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14. Tighten turbocharger clamp nut (21) to a torque of 18 ± 3 N·m (13 ± 2 lb.ft.). Lightly hit all
around the clamp with a soft faced hammer, and tighten the clamp nut again to the same torque
value.

15. Fill the engine with coolant to the correct level. See the Maintenance Guide.

Copyright 1993 - 2017 Caterpillar Inc. Mon Jan 2 12:48:06 UTC+0700 2017
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