Has anybody removed a KAD42/43 intercooler?

BruceK

BruceK

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Doing maintenance as you do and want to check intercooler. Took top off to view insert but just not enough headroom to remove insert. To add to woes drain plug has corroded badly as it's not brass and snapped off.

So, I have removed (looking at it) bottom right support bracket, mid height LHS nut under manifold. From the top I have removed far right nut and left side nut just before manifold intake.
I would expect one more nut on the far left of the manifold to form a triangle but unless it's hiding behind the oil filter bracket and housing I cant see it.

Intercooler still on quite tight and not sure if this is just sealing gasket or if there is another nut/bolt I am missing or more

circled in red removed. Another at green?

zxjz7F1.jpg


If there is another at green does one really need to remove the entire bracket holding fuel and oil filters and fittings or can it be accessed by some other means?
 
BruceK said:
Doing maintenance as you do and want to check intercooler. Took top off to view insert but just not enough headroom to remove insert. To add to woes drain plug has corroded badly as it's not brass and snapped off.

So, I have removed (looking at it) bottom right support bracket, mid height LHS nut under manifold. From the top I have removed far right nut and left side nut just before manifold intake.
I would expect one more nut on the far left of the manifold to form a triangle but unless it's hiding behind the oil filter bracket and housing I cant see it.

Intercooler still on quite tight and not sure if this is just sealing gasket or if there is another nut/bolt I am missing or more

circled in red removed. Another at green?

zxjz7F1.jpg


If there is another at green does one really need to remove the entire bracket holding fuel and oil filters and fittings or can it be accessed by some other means?
Click to expand...

Remove oil filter, behind filter 2 13mm nuts, the two 13 mm nuts facing towards the head , bottom bracket , 18 mm bolt heads . The pipe from turbo to intercooler .
Sometimes a strap type bracket low down rear of main casing , any others I think there are 5 13mm head nuts in total.
 
Thanks VP, hugely appreciated :encouragement: I will remove filter and inspect further. Was looking at the manifold oil and fuel filter bracket and all hosing in despair. I cant get the oil filter hoses off as there is no clearance for a traditional spanner.
How these people design engine bays on some boats is appalling. :(
 
BruceK said:
Thanks VP, hugely appreciated :encouragement: I will remove filter and inspect further. Was looking at the manifold oil and fuel filter bracket and all hosing in despair. I cant get the oil filter hoses off as there is no clearance for a traditional spanner.
How these people design engine bays on some boats is appalling. :(
Click to expand...

Oil filter off , two nuts , then the fuel filter bracket , just lift up the oil filter head out the way .
 
DavidJ said:
I’ve had my KAD43’s for 18 years and have never checked the intercoolers. It this something I should be doing?
What am I looking for?
Click to expand...

whether the radiator tubes need rodding, whether the radiator fins are clean and not blocked with oil debris from turbo's.

I suffer an annual rise in engine temps late season which I am convinced is barnacle and mussel growth around the drive intakes. But as the boat is out the water I am doing a complete breakdown of the cooling system in case there is an additional issue because diving on the drives and clearing the intake holes is not curing the problem. The cooling system seems marginal and as sea temps rise so do engine temps accordingly, almost degree for degree.
 
Reverse rydlyme flush and take nothing apart :)

I’ve had the intercooler housing off and had to remove the rack the oil/fuel filter is on. I can’t remember why but perhaps I didn’t need to after all. I snapped a drain bolt but it’s so soft, it was easy for a machine shop to drill out the old one and retap.
 
FARSCO said:
Reverse rydlyme flush and take nothing apart :)

I’ve had the intercooler housing off and had to remove the rack the oil/fuel filter is on. I can’t remember why but perhaps I didn’t need to after all. I snapped a drain bolt but it’s so soft, it was easy for a machine shop to drill out the old one and retap.
Click to expand...

I have done that previously with good results but something is off and I need to get to the bottom of it. Reverse flushing coolant also wont clean the radiator fins. Insert must come out to do that.

 
This what mine looked like on 23 year old AD41 engines.
the missing pieces went into the engine and may or may not have caused a siezed cylinder.
had it repaired by a specialist automotive repair company.
Anyway, worth checking!

P1100713.jpg
 
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