Cooling System All Models Tle of Contents Setion 6A - All Models Flow Speifitions...6A-3 Sewter Inlet Speifitions...6A-4 Generl Informtion...6A-4 Sewter Pump Identifition...6A-4 Sewter Inlet Hose...6A-5 Sewter Pump Output Test...6A-6 Colleting Wter Pressure Dt...6A-7 Sterndrives With Closed Cooling Engines...6A-8 Brvo Models With Closed Cooling...6A-8 SeCore Models...6A-8 Instlling the Y Fitting...6A-10 Instlling the Sewter Supply Hose...6A-10 Through the Hull Sewter Pikup System...6A-11 Through Hull Sewter Pikup System...6A-11 Se Striner...6A-12 Sewter Pikup...6A-12 Seok...6A-13 Sewter Striner...6A-14 Sewter Striner Mounting Requirements...6A-14 Instlltion...6A-14 Clening the Sewter Striner, if Equipped...6A-15 Shft Log Sel...6A-15 Shft Log Sel Connetion Erly Models...6A-15 Shft Log Sel Connetion Lter Models Exept Sorpion Models...6A-16 Shft Log Sel Connetion Sorpion Models...6A-17 Hot Wter Heter Instlltion...6A-18 Requirements...6A-18 Sewter Cooled Models...6A-18 Closed Cooling Models...6A-20 Return Hose Connetion All Models...6A-22 Composite Sewter Pump...6A-22 Removl...6A-22 Disssemly...6A-22 Assemly...6A-23 Sewter Pump Bering Housing...6A-24 Disssemly...6A-24 Clening nd Inspetion...6A-25 Assemly...6A-26 Brss Sewter Pump...6A-28 Sewter Pump Exploded View...6A-28 Removl...6A-29 Disssemly...6A-29 Clening nd Inspetion...6A-30 Assemly...6A-30 Instlltion...6A-35 Wter Cirulting Pump...6A-36 Removl...6A-36 Clening nd Inspetion...6A-36 Instlltion...6A-36 Wter Distriution Housing...6A-37 Removl...6A-37 Clening nd Inspetion...6A-38 Instlltion...6A-38 6 A 90-864260400 AUGUST 2009 Pge 6A-1
Lurint, Selnt, Adhesives Tue Ref No. Desription Where Used Prt No. Shell Alvni No. 2 Grese 7 Lotite 271 Thredloker 9 Lotite 567 PST Pipe Selnt 19 Perfet Sel The vity etween sels The erings nd the vity etween the erings Outside dimeter of the two new rer sels The outside dimeter of the ering housing front oil sel Otin Lolly 92-809819 Hose fitting threds nd plsti plug threds 92-809822 Wter irulting pump gsket nd the threds of the tthing fsteners 92-34227Q02 34 Speil Lurint 101 Pump shft 92-802865Q02 66 Lotite 242 Thredloker Impeller housing over or sewter pump tutor housing srew 92-809821 68 Lotite 609 Front sel Otin Lolly 80 SAE Engine Oil 30W Shft nd the erings Outer dimeter of the erings Sewter pump shft Otin Lolly 95 2-4-C with Teflon Qud ring sel 92-802859A 1 116 RTV 587 Ultr Blue Silione Seler Seling surfes nd srew shft 92-809825 Speil Tools Computer Dignosti System (CDS) 4520 Order through SPX Monitors ll eletril systems for proper funtion, dignostis, nd lirtion purposes. For dditionl informtion, priing, or to order the Computer Dignosti System ontt: SPX Corportion 28635 Mound Rd. Wrren, MI 48092 or ll: USA 1 800 345 2233 Cnd 800 345 2233 Europe 49 6182 959 149 Austrli (03) 9544 6222 Universl Puller Plte 91 37241 Removes erings from gers nd the driveshft. 8505 Power Steering Pump Pulley Remover Kent Moore J 21239 Removes the pulley on the DHB power steering pumps nd wter pumps with smller shfts. 25952 Pge 6A-2 90-864260400 AUGUST 2009
Pulley Pusher Instller 91 93656A1 10047 Instlls the pulley onto the power steering pump. Air Line Cutter 91 883502 Cuts wter drin system ir lines without ollpsing them. 24887 Flow Speifitions Alph Sterndrive Models Cooling RPM Minimum flow L/min (gl/ min) Minimum kp (psi) 5.0L, 305 CID Sewter ooling 4000 57 L/min (15 gl/min ) 38 kp (5.5 psi) 5.7L, 350 CID Sewter ooling 4000 65 L/min (17 gl/min ) 42 kp (6 psi) Alph Sterndrive Models Cooling RPM 5.0L, 305 id 5.7L, 350 id Brvo Sterndrive Models 5.0L, 305 id Minimum flow L/min (gl/ min) per minute Minimum kp (psi) Closed ooling 4000 106 L/min (28 gl/min ) 138 kp (20 psi) Cooling Drive RPM Minimum flow L/min (gl/ min) per minute Minimum kp (psi) 57 L/min (15 gl/min ) 69 kp (10 psi) 5.7L, 350 id Sewter ooling Brvo 4000 65 L/min (17 gl/min ) 75 kp (11 psi) 6.2L, 377 id 65 L/min (17 gl/min ) 75 kp (11 psi) 5.0L, 305 id 5.7L, 350 id 6.2L, 377 id Closed ooling Brvo 4000 106 L/min (28 gl/min ) 138 kp (20 psi) Inord Models Cooling Sewter Pikup RPM 350 Mg MPI 350 Mg MPI Horizon MX 6.2 MPI MX 6.2 MPI Horizon Minimum flow L/min (gl/ min) per minute Minimum kp (psi) Closed ooling Through the Hull 4000 106 L/min (28 gl/min ) 138 kp (20 psi) Tow Sports Models 5.7L 350 Mg MPI Blk Sorpion MX 6.2 Blk Sorpion Cooling Sewter Pikup RPM Minimum flow L/min (gl/ min) per minute Minimum kp (psi) Sewter ooling Through the Hull 4000 65 L/min (17 gl/min ) 42 kp (6 psi) 90-864260400 AUGUST 2009 Pge 6A-3
Sewter Inlet Speifitions Sewter Inlet Speifitions Sewter inlet hose Sewter pikup Seok (ABYC requirement) Se striner (optionl) 32 mm (1 1/4 in.) I.D. (wire reinfored) Low restrition with 32 mm (1 1/4 in.) onnetions Generl Informtion Merury MerCruiser engines hve either sewter ooling system or losed ooling system. Sewter ooling systems re sometimes lled rw wter ooling or stndrd ooling, while losed ooling systems re sometimes lled fresh wter ooling. On engines with sewter ooling, the engine is ooled entirely y the sewter in whih the ot is eing operted. Closed ooling systems use omintion of fresh wter (ntifreeze nd wter) nd sewter for ooling. Both types of systems re designed to keep the engine operting temperture t pproximtely 71 degrees C (160 degrees F) for optimum performne, fuel eonomy nd durility. (Refer to ooling system flow digrms t end of setion.) To monitor the ooling system, temperture swith is inorported into the udio wrning system, whih lerts the opertor of n norml ondition if the temperture exeeds pproximtely 93 degrees C (200 degrees F). A temperture sender is lso employed to operte temperture guge t the dsh. On dul helm pplitions, this sender must e repled with dul sttion sender to otin the proper temperture reding t oth sttions. Refer to the Instrumenttion nd Controls setion for more informtion. The ooling system must reeive suffiient mount of sewter under ll operting onditions to operte properly. The design nd instlltion of the sewter supply system is the ot mnufturer's responsiility. Cooling system omponents must e onstruted, sized, nd instlled in ordne with the following guidelines. NOTICE Without suffiient ooling wter, the engine, the wter pump, nd other omponents will overhet nd suffer dmge. Provide suffiient supply of wter to the wter inlets during opertion. Sewter Pump Identifition The sewter inlet onnetion is the lower inlet on the omposite pump nd the upper inlet on the rss sewter punp. 30004 Composite sewter pump Pge 6A-4 90-864260400 AUGUST 2009
30005 Brss sewter pump without ir tutor 30006 Brss sewter pump with ir tutor Sewter Inlet Hose Use 32 mm (1 1/4 in.) I.D. wire reinfored hose tht is ple of supporting 10 in. Hg vuum, to prevent the sewter inlet hose from ollpsing from the sewter pump sution. The hose should e oil nd sewter resistnt. Use the shortest hose length possile with the lest numer of ends to minimize restrition. All onnetions must e seured with hose lmp. 90-864260400 AUGUST 2009 Pge 6A-5
Fsten hose s pproprite to mintin proper routing nd to prevent hfing or ontt with other moving prts. 7638 9361 Typil omposite sewter pikup pump - Sewter inlet hose onnetion Typil rss sewter pikup pump Sewter Pump Output Test If n overheting prolem exists, use this test to determine if suffiient mount of wter is eing supplied to ool the engine. IMPORTANT: The following informtion should e oserved efore proeeding with the test: The ot must e in the wter for this test. This test nnot e performed with flush test devie nd wter hose. Performed this test urtely or prolems my not e deteted. An error in setting the engine rpm, timing the test or mesuring the wter output will ffet the overll ury of the test nd my produe misleding results. To help ensure urte results, use shop thometer with n error of less thn 5 perent. Do not use the ot thometer s it my not hve the neessry preision. Use stop wth to time the durtion of the test to help ensure the ury is mintined within one seond. Use 9.5 L (10 US qt) or lrger pity ontiner to mesure the wter output. Due to the mnner in whih this test is performed, it my not e possile to detet mrginl ondition or high speed wter pump output prolem. 1. Models with the engine mounted sewter pump, remove the wter hose tht is etween the pump outlet nd the engine, nd reple with nother hose of the sme dimeter, ut pproximtely 1 m (3 ft) longer. The hose should e of dequte wll thikness to prevent it from kinking when performing the test. Clmp the hose t the pump outlet only. Do not lmp the hose t the engine ooler end. - Sewter inlet hose - Sewter outlet hose to ooler 30957 Pge 6A-6 90-864260400 AUGUST 2009
2. Models with sterndrive (Alph) mounted sewter pump, remove the wter inlet hose, whih is etween the giml housing wter tue nd the engine, nd reple with nother hose of the sme dimeter, ut pproximtely 1 m (3 ft) longer. The hose should e of dequte wll thikness to prevent it from kinking when performing the test. Clmp the hose t the giml housing wter tue only. Do not lmp the hose t the engine end. - Wter tue - Hose lmp - Wter hose 3. Ple 9.5 ll (10 US qt) or lrger ontiner ner the unlmped end of the hose. 4. With the ssistne of nother person, strt the engine nd djust the speed to extly 1000 RPM while holding the unlmped end of the hose on the onnetion on the engine. Remove the hose from the onnetion on the engine nd diret the wter flow into the ontiner for extly 15 seonds. At the end of 15 seonds, diret the wter flow overord, return the engine to idle nd stop the engine. Reonnet the hose to the engine. 5. Mesure the quntity of wter dishrged into the ontiner nd ompre with the speifitions given in the following hrt. 6. Repet the test four times to hek the repetility of the results. NOTE: Vlues listed re 70% of the nominl flow t 1000 RPM. Model Brvo sewter ooled engine Brvo losed ooled engine nd externl wter pik up All inord nd tow sport models Model Alph models Colleting Wter Pressure Dt 7802 Engine Mounted Sewter Pump Output For A 15 Seond Period Minimum Quntity L (US qt.) 7.1 L (7.5 US qt) 9.0 L (9.5 US qt) 9.0 L (9.5 US qt) Alph Sterndrive Sewter Pump Output For A 15 Seond Period Minimum Quntity L (US qt) 4.7 L (5.0 US qt) IMPORTANT: For models equipped with wter pressure trnsduer, ollet the wter pressure dt using Computer Dignosti System (CDS). Computer Dignosti System (CDS) Order through SPX IMPORTANT: On sewter ooled Alph sterndrive models, ollet the wter pressure dt etween the trnsom nd the sewter inlet on the power ssisted steering fluid ooler. IMPORTANT: On Alph nd Brvo sterndrive models equipped with losed ooling, the wter pressure dt is to e olleted within 152 mm (6 in.) of the sewter pump inlet. Speifitions Alph Sterndrive Models Cooling RPM Minimum flow L/min (gl/ min ) Minimum kp (psi) 4.3 L, 262 id Sewter ooled 4000 50 L/min (13 gl/min ) 35 kp (5 psi) 5.0 L, 305 id Sewter ooled 4000 57 L/min (15 gl/min ) 38 kp (5.5 psi) 90-864260400 AUGUST 2009 Pge 6A-7
Alph Sterndrive Models Cooling RPM Minimum flow L/min (gl/ min ) Minimum kp (psi) 5.7 L, 350 id Sewter ooled 4000 65 L/min (17 gl/min ) 42 kp (6 psi) Alph Sterndrive Models Cooling RPM 5.0 L, 305 id 5.7 L, 350 id Brvo Sterndrive Models Cooling RPM 5.0 L, 305 id Minimum flow L/min (gl/ min ) Minimum kp (psi) Closed ooled 4000 106 L/min (28 gl/min ) 138 kp (20 psi) Minimum flow L/min (gl/ min ) Minimum kp (psi) 57 L/min (15 gl/min ) 69 kp (10 psi) 5.7 L, 350 id Sewter ooled 4000 65 L/min (17 gl/min ) 75 kp (11 psi) 6.2 L, 377 id 65 L/min (17 gl/min ) 75 kp (11 psi) 5.0 L, 305 id 5.7 L, 350 id 6.2 L, 377 id Sterndrives With Closed Cooling Engines Brvo Models With Closed Cooling Closed ooled 4000 106 L/min (28 gl/min) 138 kp (20 psi) NOTE: Closed ooled Brvo models require through the hull or through the trnsom pikup in ddition to the sterndrive wter inlets in order to meet the minimum flow speifitions. When dditionl wter inlets re used, Y fitting is instlled to the engine sewter pump. Dul sewter pikup for Brvo losed ooled engines - Engine sewter pump - Hose from sewter pump inlet port to Y fitting - Y fitting port to Brvo drive d - Y fitting port to dditionl wter inlet d Models operted ove the fiftieth prllel of the northern hemisphere or elow the fiftieth prllel of the southern hemisphere do not require the dul sewter pikup with rvo sterndrive on losed ooling models. Remove the Y fitting t the sewter pump inlet. Instll sewter suppy hose tht meets MerCuiser speifitions. Cut the hose to fit from the trnsom inlet fitting to the sewter pump inlet. SeCore Models Some SeCore models do not require through the hull or through the trnsom sewter pikup to meet the minimum flow speifitions. See the hrt, Sewter Pikups for SeCore Sterndrive Engine Models. SeCore Brvo One nd Brvo Three Models The SeCore Brvo One nd Brvo Three engine pkges do not require through the hull or through the trnsom sewter pikup in ddition to the sterndrive wter pikups if: The sterndrive gerse hs dul wter pikups. 8485 The ot is ple of 64 km/h (40 MPH) with the ot fully loded nd operted within the speified operting rnge. Pge 6A-8 90-864260400 AUGUST 2009
NOTE: When not instlling the through the hull or through the trnsom sewter pikup, see Instlling the Sewter Supply Hose. SeCore Brvo Two Models The SeCore Brvo Two engine pkges must hve through the hull or through the trnsom sewter pikup in ddition to the sterndrive side wter pikups. Instll the Y fitting t the engine's sewter pump inlet. See Instlling the Y-Fitting. Sewter Pikups for SeCore Sterndrive Engine Models Sewter Pikups for SeCore Sterndrive Engine Models Bot speed with the ot fully loded nd operted within the speified operting rnge SeCore Brvo hs side wter pikup SeCore Brvo hs dul wter pikup Through the hull or through the trnsom sewter pikup 64 km/h (40 MPH) or greter Not required See Instlling the Sewter Supply Hose 30180 Less thn 64 km/h (40 MPH) Required See Instlling the Y-Fitting 30181 30180 64 km/h (40 MPH) or greter Required See Instlling the Y-Fitting 30181 Greter or Less thn 64 km/h (40 MPH) Models operted ove the fiftieth prllel of the northern hemisphere or elow the fiftieth prllel of the southern hemisphere. 30181 30180 Not required See Instlling the Sewter Supply Hose 90-864260400 AUGUST 2009 Pge 6A-9
Instlling the Y Fitting Engine models tht require through the hull or through the trnsom sewter pikup, require Y fitting t the engine sewter pump inlet port. The Y fitting direts the sewter from the sterndrive nd 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 - Hose 101.6 mm (4 in.) from sewter pump inlet to Y fitting port - Y fitting port to wter inlet t trnsom d - Y fitting port to through the hull or through the trnsom sewter pikup d NOTE: For models not ftory equipped with Y fitting, refer to Merury Prts Ctlog, Closed Cooling Systems (Brvo) to order the speified Y fitting, sewter supply ulk hose, nd hose lmps tht meets MerCruiser speifitions. 1. Cut 101.6 mm (4 in.) length piee of the supply hose nd instll it to the sewter pump inlet nd the Y fitting port. 2. Instll sewter supply hose to the Y fitting port nd the sterndrive's wter inlet t the trnsom. Cut off ny exess hose s needed. 3. Instll sewter supply hose to the Y fitting port nd the through the hull or through the trnsom sewter pikup. Cut off ny exess hose s needed. 4. Properly seure ll hoses to ll fittings to prevent wter leking into the ot. Instlling the Sewter Supply Hose 8485 For engine models 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 diretly to the sewter inlet fitting on the trnsom. Cut off ny exess hose s needed. 4. Properly seure the hose t oth ends to prevent wter leking into the ot. NOTE: For models not ftory equipped with sewter supply hose, refer to the Merury Prts Ctlog, Stndrd Cooling Systems (Brvo) to order the speified ulk hose, hose lmps, nd quik onnet fittings tht meet MerCruiser speifitions. NOTE: For models with quik onnetion fittings nd pull test informtion, refer to Setion 6, Sewter Inlet Fitting Connetion. Pge 6A-10 90-864260400 AUGUST 2009
Through the Hull Sewter Pikup System Through Hull Sewter Pikup System All Models IMPORTANT: Use 32 mm (1 1/4 in.) I.D. wire reinfored hose tht is ple of supporting 10 in. Hg vuum when sution is reted y the sewter pump impeller. f e Typil instlltion shown with through the hull sewter pikup - Sewter pikup nd seok - Hose lmp - Sewter hose to sewter striner d - Quiksilver sewter striner e - Sewter hose to engine f - Sewter pump hose onnetor (if equipped) g - Below sewter pump level IMPORTANT: Do not instll the sewter pikup diretly in line with the propeller, s the pikup my rete turulene nd llow ir to flow into the propeller slipstrem. This will use propeller ventiltion nd will dversely ffet ot performne. IMPORTANT: Mke grdul ends in the sewter hoses to void kinks. Hoses must not ome in ontt with steering system omponents, engine oupler, or drive shft. The sewter pikup must e lrge enough to permit suffiient sewter flow to engine sewter pikup pump for dequte engine ooling. The sewter pikup lso must supply positive hed while underwy. g d The sewter pikup should e loted s lose to the sewter pump inlet s possile nd in n re where n uninterrupted, solid strem of sewter will flow pst when the ot is underwy. 7924 90-864260400 AUGUST 2009 Pge 6A-11
Se Striner A se striner is reommended if the ot is operted in n re with high deris ontent. Use 32 mm (1 1/4 in.) I.D. wire reinfored hose on the inlet nd outlet side of the striner fittings. The striner must e sized to minimize restrition (See Speifitions) nd to provide resonle servie intervl. Lote the striner in n re tht will e esily essile for serviing. If the ot is not equipped with seok, the striner should e loted ove the sewter line to prevent sewter entry into ot when serviing. The striner must hve provision to llow drining in freezing temperture periods. 7533 Sewter Pikup Typil Se Striner Either through trnsom or through hull sewter pikup n e used. Selet pikup lotion to minimize the 32 mm (1 1/4 in.) I.D. wire reinfored sewter inlet hose length while providing n optimum lotion for sewter pikup. The lotion should e in n re tht will provide solid, ir free flow of sewter under ll operting onditions. Avoid res with distured sewter flow, suh s those ehind or in lose proximity to the propeller. Lotions tht re too fr forwrd or outord should lso e voided s these re prone to ertion prolems t high ot trim ngles nd in turns. Chek for ertion s outlined under Sewter Supply Test. IMPORTANT: Do not instll the sewter pikup diretly in line with the propeller, s pikup my rete turulene nd llow ir to flow into the propeller slip strem. This will use propeller ventiltion nd will dversely ffet ot performne. Openings in sewter pikup should e pproximtely 3 mm (1/8 in.) mximum to prevent lrger deris from entering nd logging the ooling system. IMPORTANT: Use sewter striner if the sewter pikup openings exeed 3 mm (1/8 in.). Provisions should e mde to minimize glvni orrosion, given the hull mteril eing used nd the omposition of the surrounding omponents. Some industry stndrds nd regultions lso require tht the pikup e onneted into the ot's onding system to minimize stry urrent orrosion. Refer to pplile stndrds nd regultions for more detils. Pge 6A-12 90-864260400 AUGUST 2009
IMPORTANT: Externl sewter pikup must hve n integrl seok. 7532 Typil seok g d e h f Typil trnsom pikup - Hose fitting - Nut (4) - Gsket d - O ring (4) e - Wsher (4) f - Srew (4) g - Plsti plug h - Pikup i - Sreen j - Srew (2) i j 7558 Tue Ref No. Desription Where Used Prt No. 9 116 Seok Lotite 567 PST Pipe Selnt RTV 587 Ultr Blue Silione Seler Hose fitting threds nd plsti plug threds 92-809822 Seling surfes nd srew shft 92-809825 The ABYC nd other industry stndrds nd regultions require the use of seok on ertin types of pplitions to stop the entry of sewter in the event of lek in the ooling system. Refer to pplile stndrds nd regultions for speifi requirements. The seok lso llows the sewter to e shut off when serviing the engine. 90-864260400 AUGUST 2009 Pge 6A-13
The seok must provide minimum restrition to sewter flow (see Speifitions). A ll vlve or gte vlve is reommended. The ll vlve is most ommon nd is typilly equipped with lever type hndle tht opertes in 90 degree r. This design gives ler indition of whether the vlve is open or shut. Industry stndrds nd requirements typilly require tht the seok e rigidly tthed to the hull t the sewter pikup. Seok lotion should e redily essile for quik, esy opertion. 7532 Sewter Striner Sewter Striner Mounting Requirements Typil seok Use properly sized striner to mintin n dequte supply of wter for ooling the engine. Mount the sewter striner in lotion tht will llow esy ess for serviing, nd mintenne. Mount the sewter striner in virtion free lotion. Do not mount the sewter striner on the engine. If not equipped with seok, mount the sewter striner ove the sewter line to prevent sewter entry into the ot when serviing. Use 32 mm ( 1/4 in.) I.D. wire hose. Do not llow hoses to ome in ontt with hot or moving prts on the engine. Instlltion Refer to the mnufturer's instrutions for detiled instlltion, opertion, nd mintenne. IMPORTANT: Instll Quiksilver sewter striner using the following guidelines. 1. Position the sewter striner in the pproprite lotion nd elow the level of the sewter pump. 2. Ensure the rrow tht indites the diretion of sewter flow points towrd the sewter pump. 3. Instll the sewter striner using flt wshers nd lg olts Typil sewter striner - Sewter striner - Arrow inditing diretion of wter flow - Mounting srew hole lotion (srews not shown) 25938 Pge 6A-14 90-864260400 AUGUST 2009
Clening the Sewter Striner, if Equipped NOTICE All Models An open sewter striner or seok during some servie or mintenne proedures n introdue wter into the ot, using dmge or sinking the ot. Alwys lose the wter supply from the sewter pump, wter inlet, or seok when performing servie or mintenne on the ooling system. 1. With the engine off, lose the seok, if equipped, or remove nd plug the sewter inlet hose. 2. Remove the srews, wshers, nd over. 3. Remove the striner, drin plug, nd seling wsher. 4. Clen ll the deris from the striner housing. Flush oth the striner nd housing with len wter. 5. Chek the over gsket nd reple when dmged or if it leks. 6. Reinstll the striner, drin plug, nd seling wsher.! CAUTION Sewter leking from the sewter striner ould use exess wter in the ilge, dmging the engine or using the ot to sink. Do not overtighten the over srews, or the over my wrp nd introdue sewter into the ilge. 7. Instll the sel nd over using the srews nd wshers. Do not overtighten the over srews. f - Srews nd wshers - Cover with glss - Striner d - Housing e - Drin plug nd seling wsher f - Sel d e 12863 8. Open the seok, if equipped, or remove the plug nd reonnet the sewter inlet hose. 9. Upon first strting the engine, hek for leks or ir in the system tht would indite n externl lek. Shft Log Sel Shft Log Sel Connetion Erly Models Models Covered Inord nd Tow Sports Models Seril Numer Or Yer 0M316999 nd elow NOTICE Inorretly instlling the wter supply hose to the shft log sel n use inresed exhust system orrosion or sumersion or freeze dmge due to siphoning. Position nd seurely fsten the wter supply hose with portion of the hose ove the engine exhust elows. Route the propeller shft log sel hose so tht portion of the hose extends ove the top of the engine exhust elows (to prevent siphoning tion when engine is not running). Fsten the hose seurely to keep it properly positioned. IMPORTANT: Aessing ooling wter from the wrong lotion n use dmge to the engine. 1. Using T fitting, splie into the port exhust mnifold wter hose. 2. Instll the T fitting. 90-864260400 AUGUST 2009 Pge 6A-15
3. Instll the shft log sel hose to the T fitting. 4. Fsten the T fitting with the hose lmps. Tighten seurely. 28124 - T fitting - Hose to shft log sel - Port exhust mnifold wter hose 5. Route the propeller shft log sel hose so tht portion of the hose extends ove the top of the engine exhust elows. 6. Fsten the hose seurely to keep it properly positioned. Shft Log Sel Connetion Lter Models Exept Sorpion Models Models Covered Inord And Tow Sports Models Seril Numer Or Yer 0M317000 1A089999 NOTICE Inorretly instlling the wter supply hose to the shft log sel n use inresed exhust system orrosion or sumersion or freeze dmge due to siphoning. Position nd seurely fsten the wter supply hose with portion of the hose ove the engine exhust elows. Route the propeller shft log sel hose so tht portion of the hose extends ove the top of the engine exhust elows (to prevent siphoning tion when engine is not running). Fsten the hose seurely to keep it properly positioned. Pge 6A-16 90-864260400 AUGUST 2009
A fitting is instlled t the ftory into the proper port on the port exhust elow. - Shft log sel fitting 7641 IMPORTANT: If not using shft log sel, this fitting must remin plugged. 1. Atth the shft log sel ooling wter hose to the reduer fitting. 2. Route the propeller shft log sel hose so tht portion of the hose extends ove the top of the engine exhust elows. 3. Fsten the hose seurely to keep it properly positioned. Shft Log Sel Connetion Sorpion Models Models Covered Blk Sorpion MX 6.2 Blk Sorpion Seril Numer Or Yer 0M391600 1A089999 0M391750 1A089999 NOTICE Inorretly instlling the wter supply hose to the shft log sel n use inresed exhust system orrosion or sumersion or freeze dmge due to siphoning. Position nd seurely fsten the wter supply hose with portion of the hose ove the engine exhust elows. Route the propeller shft log sel hose so tht portion of the hose extends ove the top of the engine exhust elows (to prevent siphoning tion when engine is not running). Fsten the hose seurely to keep it properly positioned. A rss plug is instlled t the ftory into the proper port on the port exhust elow. 11525 11526 In-line models - Brss plug V-Drive models IMPORTANT: If not using shft log sel, this fitting must remin plugged. 90-864260400 AUGUST 2009 Pge 6A-17
1. Remove the rss plug instlled t ftory. V-drive Models: Ensure the rss reduer fitting remins seure in the exhust elow sting. 2. Instll the shft log sel fitting from the prts g. 3. Atth the shft log sel ooling wter hose to the shft log sel fitting. 4. Route the propeller shft log sel hose so tht portion of the hose extends ove the top of the engine exhust elows. 5. Fsten the hose seurely to keep it properly positioned. Hot Wter Heter Instlltion Requirements When onneting in heter or hot wter heter: The supply hose (from the engine to the heter) nd return hose (from the heter to the engine) must not exeed 16 mm (5/8 in.) I.D. Mke the heter onnetions only t the lotions shown. Refer to the mnufturers' instrutions for the instlltion informtion. Do not reposition the engine temperture swith. NOTE: Some models my e equipped with dditionl fittings. NOTICE Bloking the oolnt flow t the heter n use redued engine performne or overheting. Chek for ontinuous oolnt flow from the engine to the wter irulting pump. NOTICE Prevent engine dmge from overheting. In models equipped with losed ooling, low oolnt levels my llow n ir poket to form when the hot wter heter or in heter is mounted higher thn the fill p on the het exhnger. Mount the heter lower thn the fill p of the het exhnger nd mintin the reommended oolnt level. Sewter Cooled Models Supply Hose Connetion for Erly Models Models Covered Crureted MCM models Crureted MIE models Seril Numer Or Yer 0M087348 0M599999 0L677227 0M316999 28192 Crureted intke mnifold shown - Intke mnifold plug Pge 6A-18 90-864260400 AUGUST 2009
28193 Supply hose lternte lotion - Thermostt housing supply lotion - Hose onnetor Supply Hose Connetion for Air or Mnul Drin Models Models Covered MPI Sterndrive models MPI Inord models Seril Numer Or Yer 0M600000 1A299999 0M310000 1A089999 - Supply lotion - Thermostt housing 28195 MPI intke mnifold shown - Intke mnifold supply lotion - Thermostt housing 28196 90-864260400 AUGUST 2009 Pge 6A-19
Supply Hose Connetion for Multiple Point Drin Models Models Covered MPI sterndrive models Crureted sterndrive models Crureted inord models Seril Numer Or Yer 0M600000 1A299999 0M317000 1A089999 28199 - Supply lotion - Thermostt housing 28200 Sorpion intke mnifold shown - Intke mnifold supply lotion - Thermostt housing Closed Cooling Models Supply Hose Connetion for Erly Models Models Covered Sterndrive Models Seril Numer Or Yer 0M599999 nd elow Pge 6A-20 90-864260400 AUGUST 2009
Models Covered Inord nd Tow Sports Models Seril Numer Or Yer 0M316999 nd elow 28202 - Supply lotion - Thermostt housing (top view) Supply Hose Connetion for Lter Models Models Covered Sterndrive Models Inord nd Tow Sports Models Seril Numer Or Yer 0M600000 1A299999 0M317000 1A089999 28203 - Supply lotion - Thermostt housing 90-864260400 AUGUST 2009 Pge 6A-21
Return Hose Connetion All Models - Return hose onnetion - Wter irulting pump IMPORTANT: A speil fitting 22 865526 my e used if the hex of the stndrd hose r fitting ontts the wter pump housing not llowing the fitting to turn efore the fitting is tight. 9258 25133 - Stndrd fitting - Speil fitting Composite Sewter Pump Removl 1. Drin the sewter setion of the ooling system. 2. Close the seok vlve, if equipped. 3. Remove oth of the hoses from the ft side of the sewter pump. 4. Remove the serpentine elt. 5. Remove the two olts tthing the sewter pump nd rket to the engine. Disssemly 1. Remove the five srews from the sewter pump ody. - Srews - Sewter pump ody 28214 Pge 6A-22 90-864260400 AUGUST 2009
2. Remove the sewter pump ody nd wer plte from the ering housing. - Sewter pump ody - Wer plte - Bering housing 28215 3. Remove the impeller from the sewterpump ody. Assemly IMPORTANT: The vnes of the impeller must e instlled s shown. 1. Lurite the sewter pump impeller with wter nd sop solution. Instll the impeller into the housing y rotting nd pushing it into ple. Push it down until it is flush with the housing. - Impeller 6723 2. Ple the qud ring into the pump ody groove. - Qud ring - Sewter pump 3. Ple the wer plte onto the ering housing. 4. Align the flt of impeller with the flt on the shft nd slide the ssemly down ginst the ering housing. NOTE: Assemly of the pump requires the mounting rket to e instlled while performing the following step. 6724 5. Instll two srews in the sewter pump ody holes s shown. Use these two srews to lign the sewter pump ody, then instll the remining srews. Tighten the srews to speifition. - Holes for lignment 28216 90-864260400 AUGUST 2009 Pge 6A-23
Desription Nm l in. l ft Sewter pump ody srew 41 32 Sewter Pump Bering Housing Disssemly 1. Remove the gsket, inner wer plte, nd qud ring sel. Disrd the gsket nd qud ring sel. - Qud ring sel 28219 2. Press the hu off of the shft with Universl Puller Plte nd n ror press. - Universl Puller Plte 28222 Universl Puller Plte 91 37241 3. Punture the front oil sel with tool nd pry the oil sel from the ering housing. - Front oil sel - Tool 28225 Pge 6A-24 90-864260400 AUGUST 2009
4. Remove the snp ring from the ering housing ore nd press the shft nd erings out of the pulley end of the housing. The erings hve slip fit in the housing; do not use exessive fore. - Snp ring 28227 5. If the erings require replement, remove the erings from shft with Universl Puller Plte nd n ror press. The erings must e repled if removed. - Wter pump shft - Bering Universl Puller Plte 91 37241 6. If the rer sels require replement, press the sels from the ering housing. Clening nd Inspetion! WARNING Spin drying erings with ompressed ir n use serious injury or deth. The erings n explode, even if spun t very slow speeds. Do not llow the erings to spin when drying with ompressed ir. 1. Clen the metl prts in solvent nd low them dry with ompressed ir. 2. Remove the gsket mteril nd seler from the seling surfes. 3. Inspet ll pump omponents for wer or rks. 4. Inspet the ering housing surfes, where the erings ontt the housing, for evidene tht the ering outer res hve rotted inside the housing. 5. Inspet the pump shft for grooves in the surfe where sels ontt the shft. Inspet the surfe where the erings ontt shft for evidene tht the inner res hve rotted on the shft. 6. Inspet the impeller for wer on the sides nd tips of the ldes nd for rks in the re where the ldes flex. Reple the impeller if the ldes hve tken set (remin in the urved position). 7. After lening, pply ot of light engine oil to the shft nd the erings to prevent rust. Tue Ref No. Desription Where Used Prt No. 80 SAE Engine Oil 30W Shft nd the erings Otin Lolly 8. Inspet the pump pulley. 6734 9. Inspet the serpentine drive elt for exessive wer. 90-864260400 AUGUST 2009 Pge 6A-25
Assemly 1. Apply thin ot of selnt to outside dimeter of the two new rer sels. Tue Ref No. Desription Where Used Prt No. 7 Lotite 271 Thredloker Outside dimeter of the two new rer sels 92-809819 2. Instll the rer sels into the ering housing with the sel edges fing the impeller end. 3. Press the first sel into the ering housing until it sets nd the seond sel (wter sel) in until flush with the ering housing. 4. Pk the vity etween the sels with lurint. Tue Ref No. Desription Where Used Prt No. Shell Alvni No. 2 Grese The vity etween sels Otin Lolly 5. Using n ror press nd suitle tool, press the ll erings onto the shft until they set. Press on the inner re of ering only. - Bering 6736 6. Pk the erings nd the vity etween the erings with lurint. Slide the erings nd shft into the ering housing ore nd instll the snp ring. - Bering - Shft - Bering housing 28232 - Snp ring 28227 Pge 6A-26 90-864260400 AUGUST 2009
Tue Ref No. Desription Where Used Prt No. Shell Alvni No. 2 Grese The erings nd the vity etween the erings Otin Lolly 7. Apply thin ot of selnt to the outside dimeter of the new ering housing front oil sel nd press the sel into the housing the with sel edge fing inwrd until it sets. - Front oil sel - Bering housing 28233 Tue Ref No. Desription Where Used Prt No. 7 Lotite 271 Thredloker The outside dimeter of the ering housing front oil sel 92-809819 IMPORTANT: Support the impeller end of the pump shft when instlling the pulley hu to prevent pling lod on the erings. 8. Apply lurint to the pump shft. Using n ror press nd pproprite tool, press the pulley hu onto the pump shft to the dimension speified. - 7 mm (.260 in. or 17/64 in.) 28234 Tue Ref No. Desription Where Used Prt No. 34 Speil Lurint 101 Pump shft 92-802865Q02 IMPORTANT: Pulley hu must e pressed onto pump shft to ext dimension on pumps with stmped steel mounting rket s this estlishes proper drive elt lignment. 9. Clmp the ering housing in soft jwed vise with the flnge end up. 10. Cot the qud ring sel with lurint nd instll into the groove in the housing. - Qud ring sel 28219 90-864260400 AUGUST 2009 Pge 6A-27
Tue Ref No. Desription Where Used Prt No. 95 2-4-C with Teflon Qud ring sel 92-802859A 1 11. Ple the wer plte over the ering housing. - Bering housing - Wer plte 28241 Brss Sewter Pump Sewter Pump Exploded View k j e d f h Sewter pump with out ir tutor - Sewter pump impeller housing over - O ring - Impeller d - Sewter pump impeller housing e - Rer oil sel f - Bering shft ssemly g - Tolerne ring h - Front sel i - Pulley j - Sewter pump rket k - Blue drin plug g i 24336 Pge 6A-28 90-864260400 AUGUST 2009
j d f e h g i 24331 Sewter pump with ir tutor - Sewter pump tutor housing - O ring - Impeller d - Sewter pump impeller housing e - Rer oil sel f - Bering shft ssemly g - Tolerne ring h - Front sel i - Pulley j - Sewter pump rket Removl 1. Drin the sewter setion of the ooling system. 2. Remove oth of the hoses from the ft side of the sewter pump. 3. For models equipped with n ir tuted drin vlve:. Disonnet the vent hose from the top of the drin vlve.. Disonnet the ir hoses from the drin vlve, y pushing in nd holding the plsti ring round the ir hose, nd pulling the ir hose out of the fitting. IMPORTANT: If elt is to e reused, it should e instlled in the sme diretion of rottion s efore. 4. Remove the serpentine drive elt. 5. Remove the sewter pump nd rket ssemly. Disssemly! CAUTION Removing the snp ring from the top of the ir tuted drin vlve n llow the omponents to ome prt forefully, resulting in injury or produt dmge. Do not try to repir the vlve or remove the snp ring. 1. Remove the sewter pump mounting rket. 2. Remove the sewter pump pulley using n pproprite puller. 90-864260400 AUGUST 2009 Pge 6A-29
Power Steering Pump Pulley Remover Kent Moore J 21239 3. Remove the sewter pump impeller housing over or the sewter pump tutor housing if equipped. 4. Remove the O ring. 5. Remove the impeller. 6. Remove the sel from the front of the sewter pump housing. 7. Remove the tolerne ring. 8. Press the ering shft ssemly out of the housing from the impeller side. 9. Remove the rer oil sel. Clening nd Inspetion! WARNING Spin drying erings with ompressed ir n use serious injury or deth. The erings n explode, even if spun t very slow speeds. Do not llow the erings to spin when drying with ompressed ir. 1. Clen the metl prts in solvent nd dry with ompressed ir. 2. Clen the gsket mteril nd selnt from the seling surfes. 3. Inspet the ering housing. Exmine the surfes (where the erings ontt the housing) for evidene of the ering outer res turning in the housing. 4. Inspet the sels in the ering housing for signs of dmge or leks. 5. Rotte the ering shft in the ering housing. Reple the ering shft ssemly if the erings feel rough or if either end of the shft woles. 6. Inspet the impeller housing nd impeller housing over surfes where the impeller rides. Reple the impeller housing if signifint grooves exist. NOTE: A revised housing over ssemly is ville s servie replement. The ssemly is omposite mteril with replele stinless steel wer plte. 7. Inspet the fe of the impeller housing over for grooves. The fe of the impeller housing over n e resurfed to remove grooves. Remove mximum of 1.0 mm (0.040 in.) of mteril. 8. Inspet the pump impeller nd reple if ny of the following onditions exist: wer on the ends nd tips of the ldes rks in the re where the ldes flex rks in the impeller hu lde set (ldes remin urved) 9. Inspet the pump pulley for ends or rks. 10. Inspet the serpentine elt for exessive wer. Assemly 1. Models with the seril numer 0M024999 nd elow, Instll the rer sel with the spring towrd the impeller vity. IMPORTANT: Models with the seril numer 0M025000 nd ove use one of two rer oil sel types. Identify the rer oil sel to e instlled nd follow tht speifi sel instrution for orret orinttion. 2. Models with the seril numer 0M025000 nd ove, nd using the rer oil sel (26 862037). Orient the front of the sel towrd the ering shft ssemly. Rer oil sel (26-862037) - Bk of sel (spring side) - Smooth outside dimeter - Front of sel 29827 Pge 6A-30 90-864260400 AUGUST 2009
Orienttion of the rer oil sel (26-862037) - Sewter pump impeller housing - Smooth outside dimeter of rer oil sel - Front of rer oil sel d - Bk of sel (spring side) e - Bering shft ssemly d e 3. Models with the seril numer 0M025000 nd ove, nd using the rer oil sel (26 8M2001645). Orient the k of the rer oil sel (spring side) towrd the ering shft ssemly. 30205 Rer oil sel (26-8M2001645) - Bk of sel (spring side) - Grooved outside dimeter - Front of sel 29828 Orienttion of the rer oil sel (26-8M2001645) - Sewter pump impeller housing - Grooved outside dimeter of rer oil sel - Bk of rer oil sel (spring side) d - Bering shft ssemly d 4. Lurite the ering shft nd the outer dimeter of the erings. 30206 Tue Ref No. Desription Where Used Prt No. 80 SAE Engine Oil 30W Outer dimeter of the erings Otin Lolly IMPORTANT: The ering shft ssemly is slip fit in the ering housing. Miniml fore is required to instll the ering shft ssemly into the housing. 90-864260400 AUGUST 2009 Pge 6A-31
5. Instll the ering shft ssemly into the impeller housing. The end of the shft with flt surfes should extend into the impeller vity. Clen ny ssemly lue or oil from the forwrd end of the impeller housing. 6. Insert the tolerne ring into the impeller housing. Bering shft ssemly 41977 Tolerne ring 7. Apply dhesive to the outer dimeter of front sel. Do not llow dhesive to ontt the sel portion or the ering shft ssemly. 41978 Tue Ref No. Desription Where Used Prt No. 68 Lotite 609 Front sel Otin Lolly 8. Instll the front sel onto the ering shft ssemly nd slide it down until it ontts the end of the impeller housing. Front sel 41979 Pge 6A-32 90-864260400 AUGUST 2009
9. Use suitle mnderel tht will press the front sel without ontting the ering shft. Press the front sel into ple. Wipe wy exess dhesive. - Hollow mndrel on press - Front sel - Front sel seted 10. Lurite the impeller with sopy wter. Align the flt surfes of the impeller hu nd ering shft nd instll the impeller into the impeller vity. 41980 Impeller instlled 11. Instll the O ring into the groove in the impeller housing rer fe. 41981 41982 O-ring instlled in grove 90-864260400 AUGUST 2009 Pge 6A-33
12. If you re instlling the omposite housing over, Instll the stinless steel wer plte if not lredy instlled. - Stinless steel wer plte - Composite housing over 42152 13. Align nd instll the impeller housing over or the sewter pump tutor housing if equipped onto the impeller housing ssemly. Sewter pump tutor housing is not shown - Impeller housing over - Sewter pump 41984 14. Apply dhesive to the threds of the impeller housing over or the sewter pump tutor housing srews. Tue Ref No. Desription Where Used Prt No. 66 Lotite 242 Thredloker Impeller housing over or sewter pump tutor housing srew 92-809821 15. Instll the four short impeller housing over or the sewter pump tutor housing srews nd tighten to speifition. Desription Nm l in. l ft Impeller housing over or the sewter pump tutor housing srew 10 88 16. Instll the sewter pump rket onto the sewter pump ssemly. Instll the two long srews through the rket nd into the sewter pump ssemly. tighten the srews to speifition. - Sewter pump rket srew (2) - Impeller housing over srew (4) - Sewter pump rket 41983 Pge 6A-34 90-864260400 AUGUST 2009
Desription Nm l in. l ft Sewter pump rket to sewter pump ssemly srew 10 88 17. Apply dhesive to the threds of the remining sewter pump rket srew tht tthes the sewter pump rket to the top of the sewter pump ssemly. Instll nd tighten the srew to speifition. 41985 Sewter pump rket long srew Tue Ref No. Desription Where Used Prt No. 66 Lotite 242 Thredloker Impeller housing over or sewter pump tutor housing srew 92-809821 Desription Nm l in. l ft Sewter pump rket to sewter pump ssemly srew 10 88 18. Lurite the sewter pump shft nd instll the sewter pump pulley onto the shft using n pproprite pulley instller. Ensure tht the end of the shft is even with the fe of pulley hu. Sewter pump pulley instlled 41999 Tue Ref No. Desription Where Used Prt No. 80 SAE Engine Oil 30W Sewter pump shft Otin Lolly Pulley Pusher Instller 91 93656A1 Power Steering Pump Pulley Remover Kent Moore J 21239 19. Instll the lue drin plugs in the sewter pump over or tutor housing if removed. Instlltion 1. Fsten the sewter pump nd rket to the engine. Tighten the olts to speifition. 90-864260400 AUGUST 2009 Pge 6A-35
Desription Nm l in. l ft Sewter pump rket to engine olt 40 30 2. Instll the sewter inlet nd outlet hoses. Tighten the hose lmps seurely. 3. For models equipped with n ir tuted drin vlve:. Instll the vent hose onto the top of the drin vlve. NOTE: The ir lines for the ir tuted drin vlve re two different sizes.. Instll the pproprite ir lines into the pproprite fittings on the ir tuted drin vlve y fully inserting the ir lines into the fittings. Pull on the ir lines to ensure tht they re properly instlled. IMPORTANT: If elt is to e reused, it should e instlled in the sme diretion of rottion s efore. NOTICE Without suffiient ooling wter, the engine, the wter pump, nd other omponents will overhet nd suffer dmge. Provide suffiient supply of wter to the wter inlets during opertion. 4. Instll the serpentine drive elt. 5. Supply ooling wter to the engine. 6. Strt the engine nd hek for leks. Wter Cirulting Pump Removl NOTE: The wter irulting pump pulley on wrm mnifold losed ooled models is new design nd nnot e repled with previous Merury MerCruiser wter irulting pump pulley. 1. Allow the engine to ool. 2. Drin the sewter or losed ooling setion of the engine. 3. Remove the hoses tthed to the wter irulting pump. 4. With the drive elt instlled to prevent rottion, loosen the wter irulting pump pulley olts. IMPORTANT: If elt is to e reused, it must e instlled in the sme diretion of rottion s efore. 5. Mrk the diretion of rottion nd remove the serpentine drive elt. 6. Remove the wter irulting pump olts nd pulley. 7. Remove the fsteners nd the wter irulting pump. - Wter irulting pump - Fsteners Clening nd Inspetion 1. Clen ll gsket mteril nd selnt from the seling surfes. 2. Chek the ering for exessive ply. 3. Chek the ering for norml noise when turning the shft. 4. Chek the pump ody for rks. 5. Chek the sel for signs of leking. Instlltion 28302 The mrine irulting wter pump ws revised in 2006 whih removed it's internl y pss. However, either versions of the wter pump re usle on the smll lok V8 GM engines. Pge 6A-36 90-864260400 AUGUST 2009
IMPORTANT: The erlier version gsket is usle on oth pumps. Do not use revised pump gsket on the erlier version pump. - Erlier version irulting wter pump - Internl y pss - Revised irulting wter pump 1. Cot oth sides of the new wter irulting pump gskets nd the threds of the tthing fsteners with selnt. Tue Ref No. Desription Where Used Prt No. 19 Perfet Sel 2. Instll the new wter irulting pump gskets to the ylinder lok 3. Instll the wter irulting pump. Tighten the olts to speifition. Wter irulting pump gsket nd the threds of the tthing fsteners 92-34227Q02 Desription Nm l in. l ft Wter irulting pump fsteners 47 35 4. Instll the wter irulting pump pulley to the wter irulting pump. Tighten the olts seurely. 5. Reonnet the hoses to the wter irulting pump. Tighten the hose lmps seurely. 6. Instll the serpentine drive elt nd djust the elt tension. 7. Fill the losed ooling system, if equipped. NOTICE Without suffiient ooling wter, the engine, the wter pump, nd other omponents will overhet nd suffer dmge. Provide suffiient supply of wter to the wter inlets during opertion. 8. Supply ooling wter to the engine. 9. Strt the engine nd hek for leks. Wter Distriution Housing 42028 Removl 1. Drin the sewter setion of the ooling system. 2. On Alph mnul single point drin, remove the drin rod from the wter distriution housing.. Remove the C lip from the drin rod. Retin the C lip. 90-864260400 AUGUST 2009 Pge 6A-37
. Turn the drin rod hndle ounterlokwise until the drin rod threds ler the lignment rket. Pull the drin rod stright up to ompletely remove. d - Drin rod with lue hndle - C lip - Drin rod threds d - Drin rod lignment rket e - Brket for the wter distriution housing f - Wter distriution housing ssemly e f 28330 3. On ir tuted single point drin, remove eh ir line from the wter distriution housing y pressing on the fitting relese lotion nd pulling the line out. 4. Disonnet the hoses from the wter distriution housing. 5. Remove the olt nd nut tthing the wter distriution housing nd rket to the engine. 6. Remove the rket from the the wter distriution housing. Clening nd Inspetion 1. Clen the wter distriution housing with wter nd dry with len loth or ompressed ir. 2. Inspet the housing for leks, rks, or orrosion dmge. Reple, if neessry. Instlltion 1. Align the wter distriution housing with the rket. 2. Instll nd tighten the srews in the order listed.. Top right hnd side srew.. Top left hnd side srew.. Bottom side srew. 3. Tighten the srews in the sme order. d e - Top right hnd side srew - Top left hnd side srew - Bottom side srew d - Brket for the wter distriution housing e - Wter distriution housing ssemly 29197 Pge 6A-38 90-864260400 AUGUST 2009
Desription Nm l in. l ft Wter distriution housing to rket srews 13 120 4. Instll the rket nd wter distriution housing to the engine. Do not tighten the olt nd nut t this time. 5. On mnul single point drin:. To otin orret lignment, leve the hoses disonneted from the wter distriution housing during instlltion.. Position the wter distriution housing ssemly to lign with drin rod.. Engge the drin rod into the wter distriution housing to omplete lignment. d. Ensure tht the rod is orretly ligned. The rod must srew in nd out of the wter distriution housing esily nd with little pressure. e. Instll C lip to drin rod. - Wter distriution housing - Drin rod - Drin rod hndle 30042 6. Tighten the olt nd nut tthing the wter distriution housing rket to the engine. Desription Nm l in. l ft Wter distriution housing rket olt nd nut 38 28 7. On ir tuted single point drin, instll the ir lines to the ir mnifold. IMPORTANT: Ensure tht the ir lines re routed to void shrp ends nd/or ontt with moving prts. NOTE: The ir line must remin ylindril. The ir line must not e distorted when ut. There is 1 mm (0.04 in.)mximum llowle ngle on the end of the ir lines 90-864260400 AUGUST 2009 Pge 6A-39
. Using the ir line utter, ut the ulk ir line to the pproprite length for instlltion. - Air line utter - Air line Air Line Cutter 91 883502. Connet the ir lines from the ir mnifold ssemly to the sewter pump onnetors nd the wter distriution housing onnetors y inserting the end of the ir line onto the onnetor pproximtely 6 mm (1/4 in.).. Connet the gry 3/16 in. OD ir lines into the lower onnetors on the ir mnifold, the wter distriution housing, nd the sewter pump. d. Connet the green 5/32 in. OD ir lines into the upper line onnetors on the ir mnifold, the wter distriution housing, nd the sewter pump. e. Connet the lk 5/16 in. OD vent tue onto the wter distriution housing ir tutor; seure with tie strps. 42000 d f g e 29210 - Lower ir mnifold ssemly ir line onnetor 3/16 in. - Upper ir mnifold ssemly ir line onnetor 5/32 in. - Lower sewter pump ir tutor ir line onnetor 3/16 in. d - Upper sewter pump ir tutor ir line onnetor 5/32 in. e - Lower wter distriution housing ir tutor ir line onnetor 3/16 in. f - Upper wter distriution housing ir tutor ir line onnetor 5/32 in. g - Vent tuing onnetion 5/16 in. 8. Ensure tht eh ir line is seurely onneted y pulling on the line. 9. Seure the ir lines with tie strps. 10. Connet the hoses to the wter distriution housing. Tighten the hose lmps seurely. Pge 6A-40 90-864260400 AUGUST 2009