GE

Marine

Engine Air Inlet System, 7FDS

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and 7FDM Diesel Engines

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Doc No. GEK−76735 (MI−95100−001), Rev. A
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MI−95100−001A
GEK−76735A, Engine Air Inlet System

© 2008 General Electric Company. All rights reserved. The information contained in this
publication is the property of General Electric Company and is disclosed in confidence. This
publication is intended for use by GE customers solely for purposes of operating and performing
routine maintenance of purchased or licensed GE products, and it shall not be reproduced,
redistributed, retransmitted, translated, abridged, adapted, condensed, revised or otherwise
modified, in any form, in whole or in part, or used for any other purpose, or disclosed to third
parties, without the express written consent of GE.

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GE and Customer agree that the information contained herein does not purport to cover all details

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or variations in GE products or to provide for every possible contingency with installation, operation
or maintenance. Should further information be desired or should particular problems arise that are

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not covered sufficiently for the user’s purposes, the matter should be referred to General Electric

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Company. Any applicable Federal, State or local regulations or company safety or operating rules
must take precedence over any information or instructions given in the Technical Documentation.

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GE has no obligation to keep the material up to date after the original publication.
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GENERAL ELECTRIC COMPANY EXPLICITLY DISCLAIMS ALL WARRANTIES OF ACCURACY,
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MERCHANTABILITY OR FITNESS FOR ANY PURPOSE IN CONNECTION WITH THIS PUBLICATION AND
USE THEREOF.
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If you are not an authorized recipient of this publication, you are hereby notified that any perusal,
use, distribution, copying or disclosure is strictly prohibited. If you have received this publication in
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error, please immediately return to GE at the following address: GE Transportation, Technical

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Publications Department, Building 14, 2901 East Lake Rd., Erie, PA 16531.
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 MI−95100−001A
Engine Air Inlet System, GEK−76735A

CONTENTS
Page
1. DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. TURBOCHARGER AIR DISCHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1. 7S1700 SERIES TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. INTERCOOLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. AIR INLET MANIFOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.1. TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.2. INTERCOOLER CLEANING COMPOUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1. DESCRIPTION

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The turbocharger, driven by the exhaust gases from the diesel engine, compresses cleaned and filtered air, which

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then flows through air discharge elbows to intercoolers on each side of the engine. The intercoolers allow some of the

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heat from compression of the air to pass to cooling water.

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From the intercoolers, the air flows through the sectional air inlet manifolds on each side of the engine to the cylin-

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ders. These manifolds consist of lightweight castings bolted to each cylinder, with connecting sheet−metal tubes
sealed by O−rings under clamping flanges. This eliminates the need for the precise alignment of cylinder assemblies,
air inlet manifolds and intercoolers.
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2. TURBOCHARGER AIR DISCHARGE
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2.1. 7S1700−SERIES TURBOCHARGER

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For a diesel engine with a 7S1700−series turbocharger, the air discharge pipes connecting the turbocharger with
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the intercoolers must be slid into the intercooler opening prior to the application of the intercooler or turbocharger to the
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engine.
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Assemble the two air discharge pipes between the turbocharger and the intercoolers as follows:
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CAUTION: Do NOT use GE Part 115X1268 black O−rings on the air discharge elbow; they will not with-
stand the higher air temperatures.
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1. Lubricate four new green Viton O−rings (GE Part 115X1902−2) with high−temperature FS1292* grease (GE
Part 147X2428). This reduces the probability of O−ring damage during installation, and provides high−tem-
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perature lubrication during operation. Apply the O−rings to four clamp rings.

2. Apply two clamp rings − one facing the intercooler and the other facing the turbocharger − over the portion of
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each air discharge pipe extending out of the intercooler.

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3. Slide both air discharge pipes into the turbocharger discharge elbows, centering each between the turbochar-
ger and respective intercooler as evidenced by the beads being visible at each side.

4. Apply high−temperature anti−seize thread compound (GE Part 41A213226) to the three bolts for each clamp
ring. Using flat washers, install all clamp ring bolts finger−tight. Then torque all bolts to the torque given in
DATA Section.

5. Apply high−temperature anti−seize thread compound (GE Part 41A213226) to the end of two studs. Ensure
the use of the latest stud design; look for “8” marked on the end of the stud. Assemble two nuts onto each stud,

Revisions are indicated by margin bars.

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MI−95100−001A
GEK−76735A, Engine Air Inlet System

with flat washers on the outboard side of each nut. Install one stud in each intercooler in line with the turbochar-
ger flange cutout, and run one nut and washer each up against the intercooler and the turbocharger flange until
they are snug. Torque the nuts at the intercooler to the torque given in DATA Section.

6. Install a flat washer and nut on the outer end of each stud, and run these washers and nuts up against the
turbocharger flange. Using two wrenches, simultaneously tighten the two nuts on each stud uniformly against
the sides of the turbocharger flange in a locking fashion. Then advance the torque on the nut on the outside of
each flange to the torque given in DATA section, holding the nut on the inside of the flange with the wrench to
keep the stud from turning.

3. INTERCOOLERS

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The diesel engine is equipped with two intercoolers which alter the temperature of the air supplied to the cylinders.

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This air, heated by compression in the turbocharger, passes horizontally through the intercooler core. Heat is re-

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moved from the air and carried away by engine cooling water which flows through the tubes in the core in three passes:
up, down and up again. (At idle or at light loads in cold weather, the air may be warmed by heat transferred from the

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water.) Figure 1 illustrates the ECC intercooler.

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Each intercooler has a steel fabricated case enclosing a tube and fin−type radiator core. The radiator core is per-

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manently mounted in the case. Water headers at the top and bottom of the intercooler are removable to permit clean-
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ing and repair of tubes.
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Each intercooler should be inspected periodically for dirt build−up in the air passages of the core. If allowed to
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accumulate in the intercoolers because of poor filter maintenance, the dirt will restrict air flow to the cylinders, resulting
in high cylinder temperatures, a smoky exhaust and loss of horsepower.
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To inspect the intercoolers, remove the air discharge fittings between the turbocharger and intercoolers, and ob-
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serve the condition of the core fins through the inlet opening. A very light coating of oily dust is normal.
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Intercoolers also should be inspected for damage and degradation of the core. The core face at the air inlet is prone
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to separation and breakage of the aluminum fins. The intercoolers have built−in air baffles to protect this area of the
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core.
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The preferred method of cleaning intercoolers is to remove the top and bottom headers. Upon removing the lower
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header, inspect the tube inlets to the first water pass for erosion. Erosion indications are pits on the inside of the tube
and tube recession from the gasket surface. If any tube end has receded more than 0.13 in. (3,3 mm) from the gasket
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surface, or has individual pits deeper than 0.025 in. (0,64 mm) [half of the wall thickness], the intercooler should be
replaced.
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CAUTION: The intercooler core fins are copper; therefore, do NOT subject the cores to cleaning agents
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which are harmful to copper.

Completely immerse the case and core in a tank containing an appropriate agitated cleaning solution, followed by a
thorough rinse of the case and core with clean water. Tubes should be cleaned by running a wire brush through each
tube to remove water treatment build−up. See DATA Section for recommended cleaning compounds.

Intercooler lower headers should be inspected for cracks around the bolt flange and between the water inlet and
outlet ports. Cracked headers should not be reused.

Intercooler cases with cracked welds should be unit−exchanged for repair, as field re−welds rarely last long, and
can lead to tubes loosening in the case and subsequent internal water leaks.

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 MI−95100−001A
Engine Air Inlet System, GEK−76735A

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Figure 1. Intercooler.
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Intercooler upper headers with the 2.0 in. (51 mm) water outlet hole should be bushed with the 1.5 in. (38 mm)
inside−diameter orifice washer to reduce the opening to the current standard.
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Before the top and bottom headers are re−applied, the intercooler core should be tested for leaks in the core tubes.
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Construct and apply gasketed blanking plates over the air openings with one plate adapted for an air hose connection.
With the intercooler case completely immersed in clean water, apply regulated air pressure of 30 psi (207 kPa) maxi-
mum to the core. Inspect the case and tubes for leaks as indicated by air bubbles. For later repair, mark the location of
leaks using a wax crayon.

Leaks in the intercooler core tubes may be repaired by plugging both ends of the leaking tubes with solder or by
drilling out the tube and applying a pipe plug. If leaks develop in more than ten percent of the tubes in any one of the
three sections determined by the water flow path, renew the intercooler.

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MI−95100−001A
GEK−76735A, Engine Air Inlet System

4. AIR INLET MANIFOLDS

Air inlet manifold clamp−ring bolts must be kept tight to avoid air leaks (Figure 2).

BOLTS* TO FLAT
CYLINDER WASHER*

GASKET

PIPE

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CYLINDER
SECTION

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AIR INLET
BETWEEN

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CYLINDERS

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CLAMP O−RING
RING SEAL

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BOLT HERE

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WATER INLET
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CAST INTAKE
MANIFOLD SECTION
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* NEW DESIGN USES NY−LOCK BOLTS WITHOUT

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WASHERS.
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Figure 2. Air Inlet Manifold Body Installed on Cylinder.

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Current production uses O−rings that are still black in color, but with a yellow dot or strip. These yellow color−coded
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O−rings have higher temperature capability, and therefore an extend service life.
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CAUTION: NEVER re−use O−rings; always replace a removed O−ring with a new O−ring.
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When assembling sections of the air inlet manifold − such as after a cylinder replacement − care should be taken to
assure that the sealing O−rings are in place, and that the interconnecting tubes are properly centered as evidenced by
the beads being visible at each side (Figure 3).
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 MI−95100−001A
Engine Air Inlet System, GEK−76735A

OBSERVE POSITION OF BEADS

TO INDICATE THAT TUBE IS
CENTERED DURING ASSEMBLY CLAMP
RING

CAST AIR INLET

MANIFOLD

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SECTION

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Figure 3. Air Inlet Manifold.

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5. DATA

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5.1. TORQUE VALUES
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lb−ft. Nm
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5.1.1. 7S1700−Series Turbocharger

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Bolts, Air Discharge Pipe Clamp Ring 30−35 41−47

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Nuts, Air Discharge Elbow Stud 55−60 75−81

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5.1.2. Air Inlet Manifolds

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Bolts, Inlet Manifold Section to Cylinder 55−60 75−81

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Bolts, Inlet Manifold Clamp Ring 35−40 47−54

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5.2. INTERCOOLER CLEANING COMPOUNDS

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(Non−caustic cleaning compounds recommended for aluminum and galvanized steel − use according to direc-
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tions supplied by the manufacturer of the cleaning compound.)

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Manufacturer Product
Oakite Products, Inc. Oakite Composition No 111
Pennsalt Chemicals Corp. Pennsalt Delchem Super CR
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Pennsalt Cleaner 44
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Magnus Chemical Co., Inc. Magnusol

Turco Products, Inc. Turco Mulsirex

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MI−95100−001A

REV 09−04, DJS

NEW 04−04, DJS
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GEK−76735A, Engine Air Inlet System

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