57
TAMD63: Charge air cooler (CAC) and insert
1. Screw with drainage hole
2. Plugs over guide balls for CAC insert
TAMD71 and TAMD72
Close the sea cock and drain the water from
the seawater and freshwater systems be-
fore working on the cooling system.
1. Remove the cover plate over the heat exchang-
ers and charge air coolers (CAC).
2. Remove the pipes between the seawater pump
and the heat exchanger or between the CAC and
the reverse gear’s oil cooler.
3. Remove the covers over the heat exchangers
and the CAC. Remove the connecting pipe(s)
between the covers.
4. Remove the clamping rings beneath the hous-
ings. Remove the O-rings at the lower seal.
4. Remove the cooling water hoses to and from the
heat exchanger/charge air cooler (CAC).
5. Remove the heat exchanger from the engine (6
screws).
6. Remove the end cover from the heat exchanger
or CAC (6 mm Allen screw). Remove the O-rings
and intermediate rings.
7. Unscrew plugs (2) over the two guide balls for
the charge air cooler’s insert a few turns (10 mm
Allen screw).
8. Push out the inserts.
Note: The inserts can only be pushed out back-
wards as they have a flange at the rear.
9. Flush and clean the inserts internally and exter-
nally. Use suitable brushes. Also clean the hous-
ings and covers.
Note: Ensure that no contaminants enter the en-
gine’s inlet manifold via the charge air cooler.
Check that the drainage hole in screw (1) at the
back of the charge air cooler is not blocked.
10. Fit the inserts in the housings. Use new sealing
rings.
Note: The intermediate rings should be fitted
with the hole down. Inserts and intermediate
rings can be fitted in only one position due to the
distribution of holes.
11. Fit the end covers using new sealing rings. Tight-
en plugs (2) on the CAC.
12. Fit the heat exchanger on the engine and tighten
it.
13. Connect the engine coolant hoses to the heat
exchanger and CAC. Tighten all hose clamps.
14. Connect the plastic pipe from the thermostat
housing to the heat exchanger.
15. Fit the oil pressure sender and oil pressure
switch.
16. Connect the battery leads.
17. Fill the engine with coolant and vent the system
as described on page 55.
18. Open the sea cock and start the engine. Check
for leaks.
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