48 Sundancer Aftercooler Maintenance

Discussion in 'Sport Yachts/Yachts' started by jeffrey vargas, Dec 7, 2019.

  1. jeffrey vargas

    jeffrey vargas Active Member

    144
    Feb 4, 2019
    Sacramento, Ca
    2008 Sea Ray Sundancer 48
    Cummins QSC 8.3
    I thought I'd post this in case anyone might need some info on the aftercooler maintenance on a 2008, 48 Sundancer. I pulled my port side aftercooler today for routine maintenance. I bought this boat last March and it had no record of ever having the aftercoolers actually taken off and sent for maintenance. It did have records of having acid flushes done and the engines run great with no temp issues at all. When I bought the boat, I knew I was going to do this regardless just because of all the horror stories I'd heard from not doing it. Also, the boat has now been in freshwater for 9 months so I'll probably never have to do this again and wanted to document the maintenance for the next owner (when I move up..lol). I had the hardest time finding any 48 Sundancer that had maintenance records for this. Anyhow, after removing and opening the aftercooler up, I was shocked at how good it looked. I took a flashlight and shined it down the tubes and everyone of them was clear. Regardless, I'm going to have the core removed, cleaned and then the unit pressure tested. Now, my biggest concern is how the hell am I going to get back behind the Starboard engine to do it. Also, the most difficult part to this was removing the fuel/oil cooler. It has to be removed to get to the bolts for the aftercooler. I'll also be sending that in for maintenance while I'm at it. Let me know if you have any questions, I'd be glad to help!
     

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    douglee25 and carterchapman like this.
  2. ocgrant

    ocgrant Well-Known Member GOLD Sponsor

    623
    Dec 31, 2006
    Miami / Ft Lauderdale
    H2O Therapy
    2006 Sundancer 48
    Cummins QSC
    I am in the market for one of these now and looked at one today and was wondering the same thing.... How do you get to the starboard side cooler. Does the floor come up easily?
     
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  3. jeffrey vargas

    jeffrey vargas Active Member

    144
    Feb 4, 2019
    Sacramento, Ca
    2008 Sea Ray Sundancer 48
    Cummins QSC 8.3
    No, taking the floor up would be a last resort. Way too much work even though it would make getting to the starboard side easy. My plan is to get my really skinny nephew back there and show him what to do. The fuel/oil cooler is the most difficult part simply because the oil lines connect behind the oil cooler. Also, I'm thinking I'm going to disassemble the exhaust side of the turbo so I can both inspect the turbo and try to move the exhaust tube further starboard for extra room. I can assure you, if you're looking for a 48 Sundancer and they haven't done this, you're gong to have to do it. Also, climb back behind the water cooler and take a really good look at the sanitation hoses and also inspect them at the Vacuflush pumps. If the hoses haven't been replaced, you're going to have to do this. I rebuilt my entire sanitation system about a month ago. It was incredibly difficult. 100X more difficult than Aftercoolers. I was able to rebuild the whole system from bowls back to the tank for about $1700. I gave my nephew $500. I'd have to say this is an easy $5k job or more if you have it done. I removed the water heater and bow thruster batteries just so it would be easier to move around. Also gave me the opportunity to paint that entire area and look at the area where the strut is bolted through the hull. Hope this helps...Let me know if you need more info.
     

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