Disassemble And Assemble Charge Air Cooler; Remove And Install Heat Exchanger - Yanmar BY Series Service Manual

Repair
12/05
13. Connect seawater pipe between heat
exchanger and charge air cooler.
14. Connect seawater pipe between charge air
cooler and hydraulic oil cooler.
15. Start the engine and check for coolant leaks.
Check the level of the coolant and fill as
necessary.
Disassemble and Assemble Charge
Air Cooler
1. Remove charge air cooler from engine. See
Remove and Install Charge Air Cooler on
page 7-12.
2. Remove outlet cover (Figure 7-13, (4)) and
spacer (Figure 7-13, (5)).
Figure 7-13
(5)
(4)
(8)
(7)
Figure 7-13
3. Remove inlet cover (Figure 7-13, (1)).
4. Pull core (Figure 7-13, (3)) from housing.
5. Remove O-rings (Figure 7-13, (2 and 6)).
6. Remove anode (Figure 7-13, (7)) and copper
gasket (Figure 7-13, (8)).
7. NOTICE: NEVER use caustic soda to clean the
components. Use paraffin-based engine
detergent to clean the cooler element.
Thoroughly flush and rinse all components.
8. If any internal deposits remain in the tubes,
consult a local radiator repair shop.
Note: ALWAYS install new O-rings.
9. Install new O-rings (Figure 7-13, (2)) on cooler
core.
BY Service Manual
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© 2009 Yanmar Marine International
10. Install cooler core (Figure 7-13, (3)) and inlet
cover (Figure 7-13, (1)).
11. Install one O-ring (Figure 7-13, (6)) between
core and housing (Figure 7-13, (9)).
12. Install spacer (Figure 7-13, (5)), remaining
O-ring (Figure 7-13, (6)) and outlet cover
(Figure 7-13, (4)).
13. Install new anode (Figure 7-13, (7)) and copper
gasket (Figure 7-13, (8)). See Check and
Replace Anodes on page 7-9.
14. Install charge air cooler. See Remove and
Install Charge Air Cooler on page 7-12.

Remove and Install Heat Exchanger

1. Drain coolant from the engine and heat
exchanger. See Drain and Fill Closed Cooling
System on page 7-10.
2. Drain the seawater system. See Drain and
Refill Seawater Cooling System on page 7-8.
3. Disconnect seawater hoses (Figure 7-14, (1
and 2)) from heat exchanger.
Figure 7-14
(1)
(5)
(4)
Figure 7-14
4. Disconnect coolant hose (Figure 7-14, (3)) and
pipe (Figure 7-14, (4)) from heat exchanger.
5. Remove upper mounting bracket bolts
(Figure 7-14, (5 and 6)).
6. Remove three lower bolts (Figure 7-14, (7)).
7. Remove the heat exchanger.
COOLING SYSTEM
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