Cooling System. Table of Contents. Section 6C - Models with Closed Cooling. Models with Closed Cooling

Transcription

1 Cooling System Moels with Close Cooling Tle of Contents Setion 6C - Moels with Close Cooling Speifitions...6C-2 Generl Informtion... 6C-2 Desription...6C-2 Full Loop Close Cooling Systems...6C-3 Hlf Loop Close Cooling Systems... 6C-3 Sternrive Moels with Close Cooling... 6C-3 Alph Moels with Close Cooling... 6C-3 Brvo Moels with Close Cooling...6C-3 SeCore Moels...6C-3 Instlling the Y Fitting... 6C-5 Instlling the Sewter Supply Hose...6C-5 Coolnt... 6C-5 Coolnt Reommentions... 6C-5 Mintining Coolnt Level... 6C-6 Pressure Cp Mintenne n Testing... 6C-6 Testing the Close Cooling System... 6C-7 Testing Coolnt for Alklinity... 6C-7 Pressure Testing the System... 6C-7 Sewter Pressure Test... 6C-8 Testing for Cyliner He Gsket Lek...6C-9 Thermostt...6C-9 Thermostt Housing Exploe View...6C-9 Thermostt Removl... 6C-9 Thermostt Testing...6C-10 Thermostt Instlltion... 6C-10 Chnging Coolnt... 6C-11 Close Cooling Setion... 6C-11 Drining... 6C-11 Clening the Cooling System... 6C-12 Het Exhnger Assemly... 6C-13 Het Exhnger Assemly Exploe View...6C-13 Testing Internl Leks...6C-13 Blokge...6C-13 Removl... 6C-13 Disssemly... 6C-14 Clening n Inspetion... 6C-15 Repir... 6C-15 Instlltion... 6C-15 6 C 90-8M AUGUST 2013 Pge 6C-1

2 Speil Tools Computer Dignosti System (CDS) 4520 Bosh Automotive Servie Solutions Monitors ll eletril systems for proper funtion, ignostis, n lirtion purposes. For itionl informtion, priing, or to orer the Computer Dignosti System ontt: Bosh Automotive Servie Solutions Moun R Attn: Powersport ASR Wrren, MI or ll: USA Cn Europe Austrli (03) Speifitions Sewter Inlet Reommentions Desription Minimum flow Minimum pressure t full flow (If restritions re present, the reing oul e inurte.) Speifition 106 L/min (28 gl/min) t 4000 RPM 138 kp (20 psi) t 4000 RPM Close Cooling System Cpity Desription Coolnt volume in engine, het exhnger, n exhust mnifols Sewter volume in onuits n tue sie of het exhnger Speifition 19.5 L (20.5 US qt) 4.3 L (4.5 US qt) Coolnt Speifition Desription Prt Numer Extene Life Coolnt 5/100 (ornge olor) K1 Thermostt Desription Speifition Thermostt operting temperture 77 C (170 F) Pressure Cp Desription Pressure p rting Speifition 110 kp (16 psi) Generl Informtion Desription The ooling system is ompose of two seprte susystems: the sewter system n the lose ooling system. The sewter system is similr in funtion to the fn use in n utomoile euse it sors het from the lose ooling system s it psses through the het exhnger. The lose ooling system is similr in funtion to the rest of the ooling system in n utomoile. The oolnt reovery system keeps the reservoir full. Norml oolnt overflow into the reovery ottle is pproximtely 230 ml (7.8 fl oz) uring wrm up. The oolnt reovery system rws oolnt k into the reservoir from the reovery ottle s the engine ools. While there is oolnt in the reovery ottle, the reservoir shoul remin ompletely full. If not, there is vuum lek, usully t the hose leving the reservoir or the gsket uner the reovery filler p. Pge 6C M AUGUST 2013

3 Within the het exhnger, the oolnt (ntifreeze) flows roun the outsie of the ooling tues, while sewter flows through the insie of the ooling tues. Full Loop Close Cooling Systems Full loop lose ooling systems use n ethylene glyol mixture to ool the engine n exhust mnifols. The hot glyol mixture is irulte through the het exhnger tues, engine lok, n exhust mnifol wter jkets. Het trnsfer ours when ool rw wter from the se pump flows through the het exhnger n is ishrge into the exhust strem t the exhust elows. All urrent proution MerCruiser engines equippe with lose ooling kits use full loop systems. Hlf Loop Close Cooling Systems Hlf loop lose ooling systems use n ethylene glyol mixture to ool the engine lok. The hot glyol mixture is irulte through the het exhnger tues n engine lok wter jkets. Het trnsfer ours when ool rw wter from the se pump flows through the het exhnger n is ishrge into the exhust strem t the exhust elows. NOTE: Refer to Setion 6D Wter Flow Digrms for full loop n hlf loop ooling system flow igrms. Sternrive Moels with Close Cooling Alph Moels with Close Cooling Alph sternrive moels with lose ooling re equippe with sewter pump on the engine. However, through the hull or through the trnsom sewter pikup is lso require in orer to meet the minimum flow speifitions. Brvo Moels with Close Cooling NOTE: Brvo moels with lose ooling require through the hull or through the trnsom pikup in ition to the sternrive wter inlets in orer to meet the minimum flow speifitions. When itionl wter inlets re use, Y fitting is instlle into the engine sewter pump. Dul sewter pikup for Brvo moels with lose ooling - Engine sewter pump - 10 m (4 in.) hose, from sewter pump inlet to Y fitting port - Y fitting port to wter inlet t trnsom - Y fitting port to through the hull or through the trnsom sewter pikup Moels operte ove the 50th prllel of the Northern Hemisphere or elow the 50th prllel of the Southern Hemisphere o not require the ul sewter pikup with Brvo sternrive on lose ooling moels. Remove the Y fitting t the sewter pump inlet. Instll sewter supply hose tht meets MerCruiser speifitions. Cut the hose to fit from the trnsom inlet fitting to the sewter pump inlet. SeCore Moels Some SeCore moels o not require through the hull or through the trnsom sewter pikup to meet the minimum flow speifitions. Refer to Sewter Pikups for SeCore Sternrive Engine Moels. SeCore Brvo One n Brvo Three Moels The SeCore Brvo One n Brvo Three engine pkges o not require through the hull or through the trnsom sewter pikup in ition to the sternrive wter pikups if: The sternrive gerse hs ul wter pikups The ot is ple of 64 km/h (40 mph) with the ot fully loe n operte within the speifie operting rnge. NOTE: If through the hull or through the trnsom sewter pikup is not to e instlle, refer to Instlling the Sewter Supply Hose. 90-8M AUGUST 2013 Pge 6C-3

4 SeCore Brvo Two Moels The SeCore Brvo Two engine pkges must hve through the hull or through the trnsom sewter pikup in ition to the sternrive sie wter pikups. Instll the Y fitting t the engine's sewter pump inlet. Refer to Instlling the Y Fitting. Sewter Pikups for SeCore Sternrive Engine Moels Bot spee with the ot fully loe n operte within the speifie operting rnge SeCore Brvo hs sie wter pikup SeCore Brvo hs ul wter pikup Through the hull or through the trnsom sewter pikup 64 km/h (40 mph) or greter Not require. Refer to Instlling the Sewter Supply Hose Less thn 64 km/h (40 mph) Require. Refer to Instlling the Y Fitting km/h (40 mph) or greter Require. Refer to Instlling the Y Fitting Any spee Moels operte ove the 50th prllel of the Northern Hemisphere or elow the 50th prllel of the Southern Hemisphere Not require. Refer to Instlling the Sewter Supply Hose Pge 6C M AUGUST 2013

5 Instlling the Y Fitting Moels with Close Cooling Engine moels tht require through the hull or through the trnsom sewter pikup require Y fitting t the engine sewter pump inlet port. The Y fitting irets the sewter from the sternrive n through the hull or through the trnsom sewter pikup to the engine's sewter pump to meet the minimum flow speifitions. Typil Y-fitting instlltion - Engine sewter pump - 10 m (4 in.) Hose, from sewter pump inlet to Y fitting port - Y fitting port to wter inlet t trnsom - Y fitting port to through the hull or through the trnsom sewter pikup NOTE: For moels not ftory equippe with Y fitting, refer to Merury Prts Ctlog, Close Cooling Systems (Brvo) to orer the speifie Y fitting, sewter supply ulk hose, n hose lmps tht meet MerCruiser speifitions. 1. Cut 10 m (4 in.) piee of the supply hose n onnet it to the sewter pump inlet n the Y fitting port. 2. Instll sewter supply hose onto the Y fitting port n the sternrive's wter inlet t the trnsom. Cut off ny exess hose. 3. Instll sewter supply hose onto the Y fitting port n the through the hull or through the trnsom sewter pikup. Cut off ny exess hose. 4. Properly seure ll hoses to ll fittings to prevent wter leking into the ot. Instlling the Sewter Supply Hose For engine moels not using through the hull or through the trnsom sewter pikup: 1. If pplile, remove the Y fitting t the sewter pump inlet. 2. Instll sewter supply hose tht meets MerCruiser speifitions to the engine's sewter pump inlet. 3. Route the sewter supply hose iretly to the sewter inlet fitting on the trnsom. Cut off ny exess hose. 4. Properly seure the hose t oth ens to prevent wter leking into the ot. NOTE: For moels not ftory equippe with sewter supply hose, refer to the Merury Prts Ctlog, Stnr Cooling Systems (Brvo) to orer the speifie ulk hose, hose lmps, n quik onnet fittings tht meet MerCruiser speifitions. NOTE: For moels with quik onnetion fittings, refer to Brvo Sewter Inlet Fitting Connetion in Setion 2B. Coolnt 8485 Coolnt Reommentions IMPORTANT: Alohol se or Methnol se ntifreeze or plin wter re not reommene for use in the lose ooling setion of the ooling system t ny time. NOTE: All ftory instlle lose ooling systems ome fille with Extene Life Coolnt. This ntifreeze requires rining n repling every five yers or 1000 hours of opertion, whihever omes first. For est results ny top off flui use shoul e Extene Life Coolnt. If Extene Life Coolnt is unville, ny type of ethylene glyol se ntifreeze my e use, ut it will require the rining n repling of the oolnt every two yers or 400 hours of opertion, whihever omes first. In res where the possiility of freezing oes not exist, it is permissile to use solution of rust inhiitor n wter (mixe to mnufturer's reommentions). 90-8M AUGUST 2013 Pge 6C-5

6 Mintining Coolnt Level Coolnt reovery ottle - Cp - "ADD" n "FULL" mrks 1. Before strting the engine, ensure tht oolnt is visile in the oolnt reovery ottle. 2. If oolnt is not visile:. Chek the lose ooling system (inluing the oolnt reovery system) for leks.. Mke ny neessry repirs.. Refill the system with the reommene oolnt solution. 3. If oolnt is visile: Strt the engine n operte it until it rehes its norml operting temperture.. Chek the oolnt level in the oolnt reovery ottle. The oolnt level must e etween the "ADD" n "FULL" mrks on the front of the ottle.. If the oolnt level is low, remove the fill p from the oolnt reovery ottle n the require mount of oolnt solution. Refer to Coolnt Reommentions.! CAUTION A suen loss of pressure n use hot oolnt to oil n ishrge violently resulting in serious injury from urns. Allow the engine to ool own efore removing the oolnt pressure p. 4. Osionlly, ensure tht the oolnt reovery system is funtioning properly y removing the pressure p from the het exhnger n heking the level. The oolnt level shoul e up to the ottom of the het exhnger filler nek. If it is low, exmine the entire lose ooling setion (espeilly the oolnt reovery system) for leks, n mke ny neessry repirs. IMPORTANT: When reinstlling the pressure p, tighten it until it ontts the stops on the filler nek. Pressure Cp Mintenne n Testing IMPORTANT: Reple the pressure p if the engine overhets. The pressure p is esigne to mintin pressure of pproximtely its rte pity one the engine hs ttine operting temperture. The p shoul e lene, inspete, n pressure teste t regulr intervls or whenever the p is suspete of not mintining the proper pressure.! CAUTION A suen loss of pressure n use hot oolnt to oil n ishrge violently resulting in serious injury from urns. Allow the engine to ool own efore removing the oolnt pressure p. 1. Crefully remove the pressure p from the reservoir or the het exhnger. 2. Wsh the p with len wter to remove ny eposits or eris from the seling surfes. 3. Inspet the gsket (if equippe) n the ruer sel on the p for ters, uts, rks, or other signs of eteriortion. Reple the gsket, if mge. 4. Reple the p if the ruer sel is mge. Pge 6C M AUGUST 2013

7 5. Chek the onition of the loking ts on the p. Reple the p if the ts re ent or rke. Moels with Close Cooling - Loking ts (one not shown) - Ruer sel - Gsket Using ooling system pressure tester, test the p to ensure tht it releses t the proper pressure n oes not lek. Refer to the tester instrutions. The p must relieve pressure t 110 kp (16 psi) n must hol the rte pressure for 30 seons without going elow 75.8 kp (11 psi). Reple the p if it fils to fll within these limits. IMPORTANT: Before instlling the p, exmine the lower insie seling surfe in the filler nek to ensure tht it is perfetly smooth n free of eris. Also, inspet the m lok flnges on the sies of the filler nek to ensure tht they re not ent Coolnt reovery pssge - Seling surfes 7. Instll the p on the reservoir or the het exhnger. Testing the Close Cooling System Testing Coolnt for Alklinity! CAUTION A suen loss of pressure n use hot oolnt to oil n ishrge violently resulting in serious injury from urns. Allow the engine to ool own efore removing the oolnt pressure p. The oolnt shoul e hnge per the mintenne sheule (refer to Setion 1C Mintenne) n shoul e heke for lklinity t lest one etween hnge intervls. To hek the oolnt for lklinity, proee s follows: 1. Otin pink litmus pper from lol soure. 2. Allow the engine to ool, remove the pressure p from the het exhnger, n insert one en of the litmus pper into the oolnt. 3. If the pink litmus pper turns lue, the oolnt is lkline n oes not nee to e reple. 4. If the pink litmus pper remins pink, the oolnt is not lkline n must e reple. Refer to Chnging Coolnt. Pressure Testing the System 50072! CAUTION A suen loss of pressure n use hot oolnt to oil n ishrge violently resulting in serious injury from urns. Allow the engine to ool own efore removing the oolnt pressure p. 90-8M AUGUST 2013 Pge 6C-7

8 If the oolnt setion of the lose ooling system is suspete of leking or not holing suffiient pressure, n no visile signs of lekge n e foun, perform the following test: 1. Remove the pressure p from the het exhnger or the reservoir. 2. Clen, inspet, n pressure test the pressure p. 3. Clen the insie of the filler nek to remove ny eposits or eris. 4. Exmine the lower insie seling surfe for mge. The surfe must e perfetly smooth to hieve goo sel etween it n the ruer sel on the p. 5. Ensure tht the loking ms on the sies of the filler nek re not ent or mge. 6. Ajust the oolnt level to 25 mm (1 in.) elow the filler nek. 7. Atth n utomotive type ooling system pressure tester to the filler nek n pressurize the lose ooling setion to mount speifie. Pressure Cp Rting Amount of Pressure Applie to Close Cooling System 110 kp (16 psi) 138 kp (20 psi) 8. Oserve the guge reing for pproximtely two minutes; the pressure shoul not rop uring this time. If the pressure rops, proee with the following steps until lekge is foun. 9. While mintining the speifie pressure on the lose ooling setion, inspet the externl portion of the ooling system (for exmple, hoses, gskets, rin plugs, petoks, ore plugs, n irulting pump sel) for lekge. Also listen losely for uling or hissing. 10. Test the het exhnger. Sewter Pressure Test IMPORTANT: This test pplies only to moels with lose ooling. IMPORTANT: The ot must e in the wter for this test. 1. Connet the omputer ignosti system (CDS). Computer Dignosti System (CDS) Bosh Automotive Servie Solutions 2. Strt the engine. When the engine is t norml operting temperture, shift into forwr ger. 3. Avne the throttle to 4000 RPM. 4. Chek the sewter pressure with CDS. If the sewter pressure oes not meet speifition, further testing is require. Desription Minimum pressure (moels with lose ooling) Speifition 138 kp (20 psi) t 4000 RPM 5. If no lekge oul e foun in the ove steps, the engine is leking internlly. Leking my e use y one or more of the following: Loose yliner he olts or mge gsket Loose intke mnifol olts or mge gsket Loose exhust elow or istriution lok retining nuts or mge gsket Crke or porous yliner he or lok Crke or porous exhust mnifol 6. Proee s follows until the lotion of the internl lek is foun.. Strt the engine.. Pressurize the system to the previously speifie mount n oserve the pressure guge on the tester. If the neele in the guge virtes, the ompression or the omustion is leking into the lose ooling setion from lek in the omustion hmer.. Stop the engine.. Remove the sprk plugs, exmining eh for the presene of oolnt. A sprk plug tht is perfetly len or hs milky pperne is n inition of n internl lek. e. Drin the oil from the engine n exmine it for oolnt. Oil will usully e milky if oolnt is present. If oolnt is present, remove the engine from the ot n remove the oil pn. With the engine in the upright position, repressurize the lose ooling setion to the previously speifie mount n exmine the internl surfes of the engine to lote the lek. f. If no lekge n e foun in the ove steps, the entire engine must e isssemle n inspete for leks. Pge 6C M AUGUST 2013

9 Testing for Cyliner He Gsket Lek Moels with Close Cooling A leking he gsket will use omustion gs to e fore into the ooling system. The mixture of oolnt n tiny ir ules is poor het onutor n will overhet n engine quikly. Compression tests or ooling system pressure hek normlly will not etet the lek euse the test pressure is fr elow the omustion pressures tht use the lek. An effetive test is s follows: IMPORTANT: Operte the ot in the wter for this test. It is est to operte the engine t or ove ruising spee uring this test. Usully file he gsket will not use the engine to overhet elow ruising spee. 1. Instll ler plsti hose etween the reservoir n the oolnt reovery ottle. Use 91 m (3 ft) long hose for this test. 2. Route this hose so tht "U" is forme. 3. Put enough oolnt into the hose to fill the enter 127 mm (5 in.) of the U shpe. 4. Oserve the U shpe while the engine is operting. During ile n wrm up: Some oolnt n ir will leve the reservoir. At ruising spee ( RPM): Coolnt n ir leving the reservoir shoul stop fter pproximtely five minutes operting t given RPM. A leking he gsket will proue ir uling through the U shpe, going to the oolnt reovery ottle. The frequeny n size of the ules will epen on the size of the lek. At higher spees (4000+ RPM): Norml opertion is the sme s esrie ove. A file he gsket will use the ules to ome fster n my e ompnie y violent, intermittent ursts of oolnt. Do not onfuse norml wrm up expnsion with file he gsket. Norml wrm up proues n intermittent flow of oolnt tht will stop within pproximtely five minutes t given RPM. A he gsket lek will not stop; the one thing tht mrks file he gsket is the ontinue pssge of ir. This my e ompnie y violent, intermittent ursts of oolnt leving the reservoir. If oolnt flows evenly from the reservoir t ruising spee, something other thn the he gsket is using the engine to overhet. Thermostt Thermostt Housing Exploe View Gsket 2 - Thermostt housing 3 - Temperture sener 4 - Air vent 5 - Thermostt 6 - Thermostt sel 7 - Thermostt housing over 8 - Temperture sensor 9 - Plug 10 - Vlve for wter heter (TKS moels) Thermostt Removl Refer to the exploe view. 1. Drin the oolnt from the engine. 2. Disonnet the hose from the thermostt housing over. 3. Remove the thermostt housing over olts, the over, n the sel. 4. Remove the thermostt from the thermostt housing. 90-8M AUGUST 2013 Pge 6C-9

10 Thermostt Testing 1. Remove the thermostt. 2. Ple the thermostt on loks in ontiner. 3. A wter to the ontiner until it overs the thermostt. 4. Het the wter. 5. Stir the wter onstntly to voi pplying iret het to the thermostt. - Wooen loks - Stirring ro - Thermometer - Thermostt 6. Oserve the thermostt n hek the temperture when the thermostt fully opens. If the temperture is not within speifitions, then reple the thermostt. Thermostt Instlltion 1. Remove the thermostt housing n the gskets. Disr the gskets. 2. Clen the gsket surfes on the thermostt over, the thermostt housing, n the intke mnifol. 3. Position the gsket on the intke mnifol. Ple the thermostt housing on the gsket. 4. Tighten the srews to speifition. Desription Nm l in. l ft Thermostt housing to intke srew Instll the sel onto the thermostt flnge. 6. Instll the thermostt into the thermostt housing. 7. Instll the thermostt over. Tighten the srews to speifition. e Thermostt housing - Thermostt - Thermostt housing sel - Thermostt housing over e - Thermostt housing over srew (2) Desription Nm l in. l ft Thermostt over srew Connet the hoses. Tighten the hose lmps seurely. 9. Supply ooling wter, strt the engine, n inspet for leks. Pge 6C M AUGUST 2013

11 Chnging Coolnt Close Cooling Setion Moels with Close Cooling The engine n exhust setions of lose ooling system shoul remin fille yer roun with the reommene oolnt solution. Do not rin the lose ooling setion for storge, s this will promote rusting of internl surfes. If the engine will e expose to freezing tempertures, fill the lose ooling setion with Extene Life Coolnt or n ethylene glyol ntifreeze n wter solution. Follow the mnufturer's reommene proportions to protet the engine to the lowest temperture to whih it will e expose. If neessry, hnge the oolnt using the oolnt speifie in Coolnt Reommentions. Chnge Intervls If the lose ooling system is ftory instlle, rin n flush the oolnt from the lose ooling system t lest every five yers or 1000 hours of opertion, whihever omes first. Chnge the oolnt whenever exhust gses hve entere the system. If the system is not ftory instlle or hs h nti freeze other thn Extene Life Coolnt e, it must e hnge every two yers or 400 hours of opertion, whihever omes first. Drining! CAUTION A suen loss of pressure n use hot oolnt to oil n ishrge violently resulting in serious injury from urns. Allow the engine to ool own efore removing the oolnt pressure p. IMPORTANT: A wire shoul e inserte into rin holes to ensure tht foreign mteril is not ostruting the rin holes. On some moels with two piee petok, removl of the petok my e require so tht wire n e inserte ompletely into the rin hole. IMPORTANT: The engine must e s level s possile to ensure the omplete rining of the ooling system. IMPORTANT: The lose ooling setion must e kept fille yer roun with reommene oolnt. If the engine will e expose to freezing tempertures, ensure tht the lose ooling setion is fille with Extene Life Coolnt or n ethylene glyol ntifreeze n wter solution properly mixe to protet engine to lowest temperture to whih it will e expose. 1. Remove the pressure p from the oolnt tnk. 2. On the port n stror sies of the engine lok, remove the lok pipe plugs. Drin the oolnt into proper ontiner. 3. On the port n stror sies of the engine lok, remove the oolnt hoses from the ottom of the exhust mnifols. Drin the oolnt into proper ontiner. e Port n stror sie similr - Engine lok - Engine lok rin plug - Oil pn - Exhust mnifol e - Exhust mnifol oolnt hose M AUGUST 2013 Pge 6C-11

12 4. Remove the hose from the het exhnger to the wter irulting pump t the pump onnetion. Drin the oolnt into proper ontiner. - Hose from het exhnger to wter irulting pump - Wter irulting pump 5. After the oolnt hs rine ompletely, reinstll the lok pipe plug n hoses. Seurely tighten the lmps. 6. Remove the oolnt reovery ottle from the mounting rket n rin the oolnt into proper ontiner. Clening the Cooling System Close-Cooling Setion Clen the lose ooling setion t lest one every five yers or whenever erese ooling effiieny is experiene. A goo gre utomotive ooling system lening solution my e use to remove rust, sle, or other foreign mteril. Alwys follow the mnufturer's instrutions for the lener. If the lose ooling setion is extremely irty, pressure flushing evie my e use to flush out remining eposits. Flushing shoul e one in the opposite iretion of the norml oolnt flow to llow wter to get ehin eposits n fore them out. Refer to the instrutions tht ompny the flushing evie for the proper hookup n flushing proeure. Sewter Setion The ooling effiieny of n engine with lose ooling is epenent upon het trnsfer through the tues within the het exhnger. During engine opertion, ontminnts within the sewter (suh s slt, silt, or lime) ollet on the insie of the tues, reuing het trnsfer n reuing the effiieny of the het exhnger. It is reommene tht the sewter setion of the het exhnger e lene s speifie or whenever erese ooling effiieny is suspete. Refer to Het Exhnger Assemly. Pge 6C M AUGUST 2013

13 Het Exhnger Assemly Het Exhnger Assemly Exploe View Moels with Close Cooling e f g h i - Het exhnger rket - Het exhnger rket p - Het exhnger - Het exhnger p e - Air pump f - Air vent plug n O ring g - Air pump rket (lter style) h - Air mnifol srews n wshers (2) i - Air mnifol j - Het exhnger to het exhnger rket lmp ssemly (2) k - Het exhnger rket olt l - Het exhnger rket loknuts (3) j k l Testing Internl Leks An internl lek will llow oolnt to enter into the sewter iruit when the lose ooling iruit is pressurize. 1. Remove sewter hose from the exhnger. Do not rin the exhnger. 2. Pressurize the lose ooling iruit to kp (16 20 psi) with ritor tester. 3. If sewter egins to flow from the sewter hose fitting of the het exhnger, there is lek. Blokge IMPORTANT: Sewter flows through the tues in the exhnger. Coolnt/ntifreeze flows roun the tues. 1. Remove the en ps n inspet for ny lokge in the sewter iruit, suh s roken impeller les or wees. 2. Remove the lose ooling iruit hoses n inspet the tues just insie the nipples. Beuse the omplete exhnger nnot e inspete, the het exhnger shoul e reple if lokge is suspete. Removl NOTE: The het exhnger oes not hve to e remove for lening. 1. Allow the engine to ool. 90-8M AUGUST 2013 Pge 6C-13

14 2. Drin the sewter from the engine. 3. Drin the oolnt from the engine. 4. If pplile, remove eh ir line from the ir mnifol y pressing on the fitting n pulling the line out. - Relese lotion - Air line fitting - Air line 5. Remove the hoses from the het exhnger. 6. Remove the two lrge hose lmps fstening the het exhnger to the engine. 7. Remove the het exhnger. Disssemly IMPORTANT: Do not remove the ir pump n ir pump rket if they re mounte to the engine omprtment. 1. Remove the ir pump from the ir pump rket. 2. If the ir pump rket is seure with hesive, o not remove the rket. e f 3. If the ir pump rket is seure y srews, remove the ir pump rket. g h Mounte on top of het exhnger n seure with hesive - Het exhnger - O ring - Air vent plug - Het exhnger p e - Air pump rket (lter style) f - Air pump g - Air mnifol srews n wshers h - Air mnifol e f g h i Mounte on front ege of het exhnger n seure with srews - Het exhnger - Het exhnger p - O ring - Air vent plug e - Air pump rket (erly style) f - Air pump rket srews g - Air pump h - Air mnifol srews n wshers i - Air mnifol Remove the ir mnifol. Pge 6C M AUGUST 2013

15 5. Remove the srews tthing the en p to the het exhnger. 6. Remove the en ps n gskets. - Het exhnger - Gsket - En p - Seling wsher Clening n Inspetion Clen the ol gsket mteril n selnt from the surfes. Do not nik or gouge the surfes. 2. Use long ro n wire rush to len out het exhnger tues. 3. Inspet eh prt for rks or other mge. Reple s neessry. 4. Clen n pint the exterior surfes s require to prevent orrosion. Repir IMPORTANT: Brze with BCUP 2 ro or silver soler. Do not melt the other joints uring repir. 1. Internl leks n e repire y rzing shut the ens of the leking tue. This is only temporry fix euse usully nother tue will strt leking fter short perio of time n this lso uses reution in the ooling pity. Do not lose more thn three tues. 2. Fittings n rins tht hve een roken off the het exhnger n e retthe y rzing. - Het exhnger - Gsket - En p - Seling wsher 6747 Desription Nm l in. l ft Het exhnger en p srew If pplile, fsten the ir pump rket to the het exhnger. Tighten the srews seurely. 4. Fsten the ir mnifol to the het exhnger. Tighten the srews to speifition. Desription Nm l in. l ft Air mnifol srews 3 27 Instlltion 1. Lower the het exhnger onto the rket n simultneously tth the wter hoses. 2. Ensure tht ll hose ens re ligne n fully sete on the het exhnger fittings. Tighten ll hose lmps seurely. 90-8M AUGUST 2013 Pge 6C-15

16 3. Instll the lrge hose lmps roun the het exhnger rket n het exhnger. Position the ruer hoses unerneth the rket to prevent the rket from iretly ontting the hose lmps n reking them. - Hose lmp - Ruer hose Tighten the hose lmps to speifition. Desription Nm l in. l ft Hose lmps roun het exhnger n rket Connet the ir lines to the ir mnifol y inserting the line into the fitting until positive stop is enountere. 6. Ensure tht the ir lines re instlle properly.. Atth the ir pump to the fitting on the ir mnifol Green initors. Pull up on the ir pump lever (vertil) to lok the pump onto the fitting.. Pump ir into the system until oth green initors exten. If the green initors o not exten, the ir lines re not tthe properly. 7. Fill the lose ooling system with the speifie oolnt. Pge 6C M AUGUST 2013