SECTION 5.

25
COOLING SYSTEM

COOLING SYSTEM COMPONENTS WATER OUTLET

ELBOW CONNECTION
The cooling system consists of the following
components:
Jacket Water Circuit
· Jacket Water Header/Jacket Water

· Exhaust Manifold

· Jacket Water Pump

· Water Manifold

· Jacket Water Temperature Control Valve

· Remote Heat Transfer Device

Auxiliary Cooling Water Circuit EXHAUST

· Auxiliary Water Pump
· Intercooler
· Oil Cooler
· Auxiliary Water Temperature Control Valve
· Auxiliary Water Heat Transfer Device
JACKET WATER HEADER/JACKET WATER
The cooling water passageways in both the crankcase
and cylinder head comprise the jacket water system.
From the jacket water header, integrally cast within the
crankcase, cooling water circulates around the cylinder
sleeves. Three external sleeve seals ensure separation
of the cooling water and oil inside the cylinder block.
Passing up through seven water passage openings in
the deck of each cylinder head (see Figure 5.25-1), the
cooling water flows around the valve seats and exhaust
guides enroute to the water-cooled exhaust manifolds.
See Figure 5.25-2 for the cooling system arrangement
found on the engine.
PORT
CYLINDER
HEAD
Figure 5.25-1. Water Outlet Hole
EXHAUST MANIFOLD
From each cylinder head, water passes up through the
water outlet elbow connection to one segment of the
water-jacketed exhaust manifold. A portion of the
cooling water also exits the head through a hole
centered below the exhaust port (see Figure 5.25-1).
Each exhaust manifold assembly is comprised of six
individual water-cooled segments.
WATER MANIFOLD
The water manifold receives the cooling water flowing
out of each segment of the exhaust manifold and routes
it to a thermostatically controlled water outlet header.
JACKET WATER PUMP
A single centrifugal-type water pump, driven by two belts
from the crankshaft pulley, is mounted at the center of
the gear cover. Cooling water exiting the pump is piped
to the jacket water headers (see Figure 5.25-2).

FORM 6296 First Edition 5.25 -- 1

COOLING SYSTEM

WATER OUTLET

BYPASS
BYPASS

WATER
PUMP

WATER INLET WATER INLET

FROM HEAT FROM HEAT
EXCHANGER EXCHANGER

TO
INTERCOOLER

AUXILIARY
WATER PUMP

FROM HEAT
EXCHANGER

TO HEAT FROM INTERCOOLER

EXCHANGER
SHIPPED LOOSE

Figure 5.25-2. VHP Series Four 12 Cylinder Cooling System -- Sectional View

5.25 -- 2 FORM 6296 First Edition

 COOLING SYSTEM

7* 8*

5
4

6 9*

2
10*

11*

NOTE:
LEGEND All connections to unit must be flexible.
1. ENGINE JACKET COOLANT PUMP * Customer supplied component and piping.
2. AUXILIARY COOLANT PUMP Deaeration vent lines.
3. LUBE OIL COOLER (SHIPPED LOOSE) 1/4² tubing or 1/2² tubing with 1/4² orifice at the engine.
4. TOP ENGINE WATER MANIFOLD
5. ENGINE JACKET THERMOSTATS
6. ENGINE JACKET BYPASS
7. ENGINE JACKET EXPANSION TANK
8. AUXILIARY EXPANSION TANK
9. ENGINE JACKET COOLER
10. AUXILIARY COOLER
11. OPTIONAL COMPRESSOR COOLER
(REQUIRES EXTRA CAPACITY AUX. PUMP)

Figure 5.25-3. VHP Series Four GSI Engine Cooling System Schematic -- Standard And Elevated Jacket Water
Temperatures

CLUSTER THERMOSTAT HOUSING

CLUSTER
By regulating the circulation of coolant, multiple thermo- THERMOSTAT
static valves control the jacket water temperature HOUSING
normally at 180° F (83° C). A variety of other control
temperatures are available. The thermostatic valves are
enclosed in the cluster thermostat housing at the outlet
end (front) of the water manifold.
The thermostatic valves remain closed while the engine
is warming up, so cooling water is circulated through the
engine water jacket only. Water passes from the water
manifold to the thermostat housing and back to the
jacket water pump through the bypass tube(s) (see
Figure 5.25-4).

Figure 5.25-4. Cluster Thermostat Housing

FORM 6296 First Edition 5.25 -- 3

COOLING SYSTEM
The lead thermostat in the cluster thermostat housing
starts to open as the engine warms up to its normal
operating temperature. A portion of the coolant is
diverted to the remote heat transfer device, which
absorbs the heat and directs the coolant back to the
jacket water pump. The supply from the heat transfer
device mixes with that portion of the coolant that
continues to flow down the bypass tube(s) to provide a
blend that is within the normal range.
When the cooling water temperature rises 5° F (2.8° C)
above the Start to Open rating of the lead thermostat,
the remaining thermostatic valves begin to open.
Opening of the secondary thermostats allows an even
greater portion of the cooling water to be directed to the
heat transfer device. This operation results in rapid
warm up when the thermostatic valves are fully closed
and efficient cooling once the valves open.
REMOTE HEAT TRANSFER DEVICE
The remote heat transfer device may be a radiator,
cooling fan, cooling tower, heat exchanger or other
device.
AUXILIARY WATER PUMP
The auxiliary water pump, driven by two belts from the
crankshaft pulley, is mounted at the front of the oil pan.
The suction side of the auxiliary water pump is
connected to the outlet port of the auxiliary water
temperature control valve (see Figure 5.25-5). The
discharge of the pump is directed to the intercooler inlet
through external piping.
WASTEGATE
INTERCOOLER
OIL COOLER
Figure 5.25-5. Auxiliary Cooling Water Circuit
5.25 -- 4
INTERCOOLER
Each intercooler is a box-type tube and fin assembly
mounted at the rear of the engine. The flow of air
between the aluminum cooling fins runs perpendicular
to the vertical flow of cooling water in the copper tubes.
The configuration of the upper and lower bonnets create
a U-shaped path that enables the cooling water to pass
through the core assembly four times before exiting the
unit at the top (see Figure 5.25-6). Header plates
separate the air passing through the casing from the
cooling water in the upper and lower bonnets.
A supply tube connected to the intercooler cooling water
inlet, provides a continuous supply of cooling water to
the wastegate(s). The cooling water enters the lower
housing of the wastegate and passes through a cavity
that encircles the valve guide. Exiting the outlet port on
the opposite side of the lower housing, the water passes
to the intercooler cooling water outlet through a water
return tube (see Figure 5.25-5).
OIL COOLER
Exiting the outlet port of the intercooler, the coolant flows
to the remote or off engine mounted oil cooler.
The oil cooler is a tube and baffle type assembly. While
the coolant flows through a bundle of tubes in the oil
cooler, the lube oil circulates around them. Heat from the
oil passes through the tubes to the coolant which carries
it to a heat transfer device for dissipation. From the heat
transfer device, the coolant passes back to the auxiliary
water pump to repeat the circuit.
AUXILIARY WATER PUMP
TEMPERATURE
B CONTROL VALVE
C
FROM HEAT EXCHANGER
TO HEAT EXCHANGER
FORM 6296 First Edition

· Operational Description
· Makes Four Passes Through Intercooler
· Configuration Of Water Inlet/Outlet Plate
· Configuration Of Water Return Plate
· Location Of End Casts
· Configuration Of Tubing
· Air Sides
Figure 5.25-6. Intercooler Flow
FORM 6296 First Edition
COOLING SYSTEM
AUXILIARY WATER TEMPERATURE CONTROL
VALVE
One thermostatic valve controls the temperature of the
auxiliary cooling water. To maintain the correct tempera-
ture, the valve controls the flow of cooling water from the
heat transfer device. The thermostatic valve is enclosed
in a housing on the suction side of the auxiliary water
pump.
The thermostat housing has one outlet port stamped A
and two inlet ports stamped B (oil cooler) and C (heat
transfer device) (see Figure 5.25-7). The casting of the
thermostat housing prevents the flow of cooling water
through inlet port C when the thermostat is fully closed.
The flow from the oil cooler enters bypass port B and
exits outlet port A enroute to the auxiliary water pump.
OUTLET PORT A
(TO AUXILIARY WATER
PUMP)
THERMOSTATIC
VALVE
O-RING
BYPASS INLET
PORT B
(FROM OIL
COOLER)
LIP SEAL
THERMOSTAT
HOUSING
COOLING WATER INLET
PORT C (FROM HEAT
TRANSFER DEVICE)
Figure 5.25-7. Water Temperature Control Valve
The thermostatic valve begins to open as the engine
warms up to its normal operating temperature. The
casting of the thermostat housing is such that inlet port B
becomes restricted as outlet port C starts to open.
Therefore, a smaller portion of the coolant is received
from the oil cooler, while a greater portion of the cooling
water comes from the heat transfer device. Cool water
passing out the heat transfer device enters port C of the
thermostat housing and combines with hot water
passing through bypass port B. The cooling water
exiting outlet port A is a blend that falls within the normal
range.
AUXILIARY WATER REMOTE HEAT TRANSFER
DEVICE
The auxiliary or secondary heat transfer device may be
a radiator, cooling fan, cooling tower, heat exchanger or
some other device.
5.25 -- 5
COOLING SYSTEM

IMPORTANCE OF COOLING SYSTEM

MAINTENANCE

In order to ensure quality engine coolant, a coolant

analysis program is recommended. Failure to main-
tain coolant to engine specifications may result in
severe engine damage.

NOTE: The following Cooling System Guidelines and

Water Treatment Recommendations are from Service
Bulletin 4--2429G dated February 15, 2003. Any up-
dates to this information will be contained in follow on
Service Bulletins.
The cooling system is often overlooked in engine
maintenance programs. Ignoring an engine’s coolant
will lead to serious cooling system damage over time.
There are three types of damage that may occur:
corrosion, cavitation erosion, and mineral scale and
fouling deposits. All of these problems are prevent-
able with a quality water treatment program.
A competent water treatment specialist is essential in
creating an effective water treatment program. Norkool
Industrial Products Division of Union Carbide, Inc. (all
glycol based industrial coolants); Calgon Corporation;
and the Mogul Division of Dexter Corporation are
knowledgeable companies who can provide the coolant
analysis and services recommended in this service
bulletin.
CORROSION
Corrosion is a natural, electrochemical process by
which metal, reacting with oxygen that has entered the
system, breaks down and returns to its natural iron oxide
state.
Corrosion inhibitors, added to the engine coolant,
continuously coat and re--coat the metal surfaces of the
system with a film that insulates them from the
electrochemical processes that break down the metal.
Because the coating film is constantly being replaced,
the inhibitor concentrations need to be maintained.
Concentrations can only be determined through period-
ic testing.
CAVITATION EROSION
Cavitation is a mechanical process that erodes surfaces
in liquid. Fluctuating pressure causes the formation of
vapor bubbles that collapse under high pressure,
allowing pressure jets to impact surfaces. If this occurs
with great frequency over time, cavities will form (see
Figure 5.25-8).
Figure 5.25-8. Cavitation Eroded Steel
Adding cavitation inhibitors to the coolant will raise the
“flash point” or “vapor pressure” of the coolant, reducing
or eliminating formation of damaging vapor bubbles.
Coolant needs to be analyzed periodically to ensure that
inhibitor concentration is maintained to the most effec-
tive level.
MINERAL SCALE AND FOULING DEPOSITS
Mineral scale deposits, usually calcium and magne-
sium, are hard deposits that form on cooling system
surfaces. As the temperature of the coolant increases,
the ability of the coolant to hold certain dissolved
minerals in solution decreases, forcing the minerals out
of the solution and creating mineral scale, usually in
cylinder head and cylinder liner areas where heat
transfer is the greatest.
Fouling deposits are soft, suspended, gel--like impuri-
ties that collect in low flow areas within the cooling
system. These deposits can form when coolant is
contaminated or when inhibitors are improperly applied.
COOLING SYSTEM GUIDELINES FOR
WAUKESHA ENGINES
· The radiator or heat exchanger must be sized to
maintain normal jacket water temperature out of the
engine under all contract specified site conditions.
Normal jacket water outlet temperature is:
·· 180° F (83° C) for non-heat recovery applications
·· 220° F (105° C) for alternate fuel applications
·· 210 -- 265° F (99 -- 130° C) for heat recovery
applications
Consult the Engine Specification Sheet in the Tech Data
Manual for operating temperatures of specific engine
models.

5.25 -- 6 FORM 6296 First Edition


The engine power rating of intercooled engines is based
on the maximum water inlet temperature to the inter-
cooler (auxiliary) water pump. Consult the Power Rating
Chart or Tech Data Manual for power ratings at various
intercooler inlet water temperatures.
The radiator or heat exchanger must be sized for the site
conditions. Remember that special considerations must
be given to altitude, high or low ambient temperature,
and extremely dirty applications. Consult the Tech Data
Manual -- “Heat Balance” subsection of the specific
model for engine, intercooler, and oil cooler heat
rejection.
· If a unit mounted radiator with a pusher fan is used,
reduce the allowable ambient or increase the design
temperature by approximately 10° F (5.5° C). This is
necessary because of the increase in air temperature
as it flows across the engine. If the driven equipment,
such as a generator, radiates significant heat, then a
further temperature allowance must be made.
· Coolant flow and allowable system resistance are
based on the pump flow curves for the specific
configuration to which the engine is built. Consult the
Tech Data Manual -- “Cooling Systems” subsection
for the specific model.
· Heat rejection data are average values at standard
conditions and will vary for individual engines and
with operating and ambient conditions. An adequate
reserve for this variation and normal design fouling
factors should be used when sizing the cooling
system. Waukesha suggests 15% reserve.
· Use antifreeze protection for applications where the
engine or cooling system can be exposed to ambient
temperatures below 32° F (0° C). An adequate
mixture of ethylene glycol and water, or propylene
glycol and water is recommended to prevent freezing
during engine shutdown.
· If antifreeze or significant levels of other water
treatments are used, the cooling system heat rejec-
tion capacity must be increased. Glycol based
antifreeze solutions reduce the heat transfer capabili-
ty of the cooling system by approximately 3% for each
10% by volume addition of antifreeze. As an exam-
ple, if a 50/50 solution of ethylene glycol and water is
used instead of 100% water, the heat transfer
capability of the radiator must be increased by about
15%. If the capability of the radiator system is not
increased there will be an approximate 10° F (5.5° C)
decrease in the allowable ambient temperature.
FORM 6296 First Edition
COOLING SYSTEM
· For information on water treatment for engine cooling
systems refer to S7610-2 or its replacement.
· Initial add and make–up water must be treated before
use in a solid water system.
· The cooling system must be designed to properly
pressurize the system and remove entrained air from
the coolant. This can be accomplished by proper use
of vent lines, a static line, and an expansion tank (see
Figure 5.25-9).
EXPANSION TANK
VENT LINE
TRAPPED AIR
STATIC LINE
ENGINE
COMPONENT
COOLING COMPONENT 18
Figure 5.25-9. Cooling System Schematic
Vent lines should be 1/4 in. (0.65 cm) diameter on
systems with vent lines less than 10 ft. (3 m) long, or
1/2 in. (1.3 cm) diameter with a 1/4 in. (0.65 cm) orifice
on systems with vent lines more than 10 ft. (3 m) long.
These vent lines are piped from high points in the
cooling system to the expansion tank below the coolant
level but away from the static line connection. The
expansion tank is the highest component in the cooling
system. Trapped air can then flow to the expansion tank.
This system also bleeds air out of the system during
filling. It must bleed air with the thermostat fully opened
or fully bypassing.
The static line is sized much larger than the vent lines to
minimize flow velocity and pressure drop. The static line
is typically 1 in. (25 mm) diameter or larger for greater
than 400 gpm (1500 l/min) systems, and 3/4 in.
(20 mm) diameter or larger for less than 400 gpm
(1500 l/min) systems. This static line provides a static
head pressure to the inlet of the water pump equal to the
height of the expansion tank plus the pressure of the
expansion tank. Do not assume that a pressure cap will
pressurize the tank to the cap’s rating.
5.25 -- 7
COOLING SYSTEM

A pressure cap is required to prevent coolant evapora- Table 5.25-2. Waukesha Engine Coolant Filter System
tion losses and to prevent boiling in the system (see and Replaceable Parts
Table 5.25-1). SMALL LARGE
DESCRIPTION ASSEMBLY ASSEMBLY
Table 5.25-1. Pressure Cap Recommendations For Solid P/N P/N
Water Systems
Coolant Filter Assy. 489501 489625
RECOMMENDED
JACKET WATER SYSTEM PRESSURE Replacement Element 489508 489626
TEMPERATURE CAP SETTING Std. Temperature
200° F (93° C) 489528 489528
Up to 210° F (99° C) 7 psig (0.5 bar) Flow Indicator
210 -- 235° F (99 -- 113° C) 8 psig (0.6 bar) High Temperature
235 -- 265° F (113 -- 130° C) 25 psig (1.7 bar) 350° F (177° C) 489648 489648
Flow Indicator
NOTE: Reference Tech Data Manual for the solid water maximum
outlet temperature of each engine model. Seal Kit 489527 489527

The pressure cap must have a vacuum relief function to
prevent a vacuum from forming in the tank during load
reduction or cool-down operation. Only a single pres-
sure cap must be used in a cooling system and must be
at the highest point on the expansion tank.
· The expansion tank must be sized for 6% expansion
of the coolant. An additional 5% is recommended for
coolant makeup. With these volumes, an expansion
tank should be sized to contain 11% of the total
cooling system volume. Separate expansion tanks
must be used for separate auxiliary and jacket
cooling circuits. A sight glass is recommended for
monitoring expansion tank level.
· The expansion tank height and pressure must be
sufficient to provide pressure at the water pump inlet
to meet the requirements on S7424 (or its replace-
ment) for VHP engines. Do not assume that a
pressure cap will pressurize the tank to the cap’s
rating.
· Bypass water filtration can remove debris from the
cooling systems on any engine. Bypass water
filtration sized to remove 15 -- 25 micron particles
from 2% of the water flow is recommended. Wauke-
sha Engine offers a stainless steel coolant filter
available in two sizes: small filter P/N 489501 and
large filter P/N 489625. The small coolant filter is
recommended for engines that have a good coolant
program already in place. The large coolant filter
holds more contaminants requiring less cleaning and
is well--suited for new engine applications where
installation debris may be present or for older engines
that have mineral deposits in the cooling system.
Table 5.25-2 lists the filter system part numbers and
available replacement parts.
Care must also be taken when welding external cooling
system pipes together or when drilling and tapping a
hole anywhere in the water system. Ensure that the weld
slag and chips are totally cleaned from the cooling
system before the engine is operated. Debris in the
cooling system will cause erosion of water passages
and water pump seals.
· Jacket water and auxiliary water pump static inlet
pressure must not exceed pressures published in the
specifications section of the Tech Data Manual for the
specific engine model.
· For information on ebullient cooled systems refer to
the Waukesha Cogeneration Handbook, Form 7030
(or its replacement), and system manufacturers such
as:
Beaird Industries
Phone (318) 865--6351 or
Vaporphase
Phone (314) 821--7900
· Consider thermosiphoning prevention in cooling
system design. Thermal shock from thermosiphon-
ing is often a problem in engine shutdowns and
engines with coolers mounted above them. A shutoff
valve in the return leg from the cooler will prevent
thermosiphoning. See Application Notes, No.
WED 9/92, “Engine Thermal Shock At Shutdown
Due To Thermosiphoning.”
WATER TREATMENT FOR ENGINE
COOLING SYSTEMS
The primary purpose of any water treatment program is
to protect the surfaces of all water passages from
corrosion and any scaling or sludge deposits that will
impede the transfer of heat to or from the water. If the
system is exposed to low ambient temperatures,
antifreeze protection is needed. In addition, cavitation
erosion protection is required for engine cooling
systems.

5.25 -- 8 FORM 6296 First Edition


GENERAL COMMENTS
Cooling water quality is one of the most often overlooked
factors in an engine installation. Poor water quality and
lack of coolant maintenance contribute to scaling,
corrosion, and sediment buildup within the entire
cooling system. It leads to heat transfer problems that
can result in failed parts and downtime. This is
especially critical in low pressure steam systems with
ebullient cooled engines.
To get the most benefit from any water treatment
program, it is essential to apply the chemicals properly
and maintain close control over the process. Briefly,
inhibitors should be selected only after a thorough study
of the entire system and the specific water to be used. It
may be necessary to preclean or pretreat the system
before it is put into operation. Higher treatment levels
may be recommended during start--up to protect the
system quickly. Later, after protection is established,
treatment levels can be reduced to a maintenance
value. In all cases, it is essential to monitor the water
condition carefully and continuously.
Corrosion, scale, fouling, cavitation, and micro--biologi-
cal growth can be the major problems in all types of
cooling systems. Of these, corrosion is the most
important.
I. PRETREATMENT
Pretreatment is preparation of the water system to
ensure that the treatment program itself can work
effectively from start--up. New systems, or existing ones
being returned to service, can contain contaminants.
These include films of oil, grease, or other protective
coatings, biological contamination, rust spots, dirt,
casting sand, and welding slag. These materials are an
unavoidable result of the system’s construction, trans-
port, and storage. If these materials are not removed by
suitable pretreatment, the subsequent treatment pro-
gram may not be effective.
Common pretreatments are water flushing and acid
cleaning. Chelates can remove oil, scale and deposits
from a system; flush the system with water after using
chelates. Water flushing may reduce solid contami-
nants, but may not be effective on films. Untreated
flushing water will react with unprotected metal surfaces
to form corrosion.
Acid cleaning removes corrosion products and some
mineral scale but has little effect on organic material.
Improper cleaning may lead to severe metal attack.
Improper neutralization may leave metal surfaces in a
highly reactive state and vulnerable to rapid corrosion.
FORM 6296 First Edition
COOLING SYSTEM
II. CORROSION
The actual corrosion process is electrochemical. Re-
fined metals in the cooling system are returned to a more
basic metallic oxide state when they combine with
oxygen carried by the coolant flow. These chemical
reactions usually cause a low voltage electric current.
Where corrosion will occur in a water system and to what
degree it will progress depends on a number of factors:
quality of water, water pH, surface temperatures, the
type of metals in the system, mechanical conditions
(vibration, stress, relative motion of two adjacent parts,
etc.), trapped air, and both the type and amount of
inhibitor additives.
For corrosion inhibitors to be effective (and to neutralize
any blow--by gases), the jacket water pH of the standard
radiator cooled engine must be kept between 8.5 and
9.5.
Different system metals, such as iron, copper, alumi-
num, etc., corrode at different rates. An acidic coolant
with a pH of less than 7 will speed the corrosion of cast
iron, aluminum and steel, while a pH of 11 or higher will
accelerate the corrosion of aluminum and solder.
Many types of corrosion can exist in/with cooling
systems:
· Crevice
· Cavitation related
· Fretting selective leaching
· Galvanic
III. MINERAL SCALES AND FOULING
Compounds and minerals dissolved in water tend to
come out of solution when the water is heated. They
form either a scale on the metal surfaces or a fouling
precipitate (sludge) in the cooling system.
The primary effect of hard scale is to reduce heat
transfer efficiency. To allow for efficient heat absorption
by the cooling water, coolant passageways must be kept
clean and free of scale. Scale is a solid formed when the
impurity concentration in water exceeds its solubility
limit. Buildup of scale and minerals can completely plug
coolant passageways. Even if just the walls of cooling
passageways are coated, the ability of the engine to
transfer heat is greatly reduced. Only 0.012 of an inch of
scale (0.305 mm) may cut the transfer of heat by as
much as 40%. The composition of the scale will
determine the actual efficiency loss. This reduced heat
flow increases operating temperatures and can result in
parts cracking.
5.25 -- 9
COOLING SYSTEM
Sludge tends to accumulate in low spots and where
water velocity is low. Build--up can restrict or stop water
flow resulting, as with scaling, in parts cracking. Any new
water brought into the system by a coolant change or as
make--up will add new scale and sludge--forming
material to the system.
IV. CAVITATION EROSION
Cavitation erosion is a mechanical process of metal loss
caused by the collapse of vapor bubbles against a
spinning or vibrating metal surface. The force exerted by
the bursting vapor bubble is such that a very small
particle of metal can be removed. When this process
occurs with great frequency over a period of time, large
cavities or pits can form.
In advanced stages, cavitation erosion may cause
cooling water to seep into the lube oil, a condition that
compounds existing problems. Coolant mixed with
engine oil will cause catastrophic damage to main and
connecting rod bearings, quickly destroying the engine.
Inhibitor additives raise the “vapor pressure” or “flash
point,” which eliminates or at least reduces the formation
of damaging vapor bubbles. Water pH must be main-
tained within an acceptable range for the inhibitors to be
effective.
While water in motion erodes metal, greater system
pressure reduces the formation of vapor bubbles by
raising the temperature at which water boils or
vaporizes.
Harder metals, such as chrome, are much more
resistant to cavitation erosion than softer metals, like
cast iron.
V. MICROBIOLOGICAL GROWTH
The uncontrolled growth of micro organisms in a cooling
system can lead to deposit formations that contribute to
fouling. Microbial slimes are masses of microscopic
organisms and their waste products and are usually
gooey. This problem is usually associated with cooling
towers or other open cooling systems. Removal of
airborne debris is also of concern with a cooling tower or
other open cooling system. Coolant that is greater than
25% by volume glycol will prevent microbiological
growth.
COOLING WATER TREATMENT
RECOMMENDATIONS
A. SOLID HOT WATER COOLING
This is the common, closed loop radiator type cooling
system where steam is not allowed to form. These
systems generally operate between 170 -- 200° F
(77 -- 94° C) but maximum system temperatures up to
265° F (130° C) are possible.
5.25 -- 10
Being a closed system, very little make--up water is
required so proper treatment of the original cooling
water will ensure trouble--free service for longer periods
than ebullient systems where make--up water may be
constantly added.
This does not mean that closed systems should be
ignored; water samples should be drawn periodically,
daily in some cases, to ensure that additives are at the
correct levels.
The following points should be kept in mind for a closed,
solid water cooling system:
1. Sodium nitrite additive is recommended as a corro-
sion inhibitor to protect iron and steel components.
Waukesha recommends 800 -- 2500 ppm nitrites. In
addition to sodium nitrite, molybdate is added to prevent
bacterial growth.
A common corrosion inhibitor used by automotive
antifreeze suppliers is silicate. Silicates have the
disadvantage of building up an insulating layer on
components. Silicates more readily drop out of solution
and become “used up.” Industrial quality fluids combin-
ing corrosion inhibitors and glycol for freeze protection
are the most commonly used coolants for closed
systems. Silicates are not recommended for industrial
engines and therefore should be < 25 ppm.
2. A copper corrosion inhibitor is recommended. Tolyl-
triazole (TT2 for short) is a good protector of copper
components.
3. A synthetic polymer is suggested that assists in
preventing scale build--up. Polymers coagulate the
solids in the water causing them to drop out of
suspension. This action prevents calcium carbonate
from forming hard scale on hot engine surfaces.
4. A borax buffer should be used as required to raise the
pH of the coolant to between 8.5 and 9.2.
5. Softened or demineralized water should be used for
any cooling system fill and make--up. Hard chemicals
(calcium and magnesium) form a lime scale that
insulates hot engine parts from the cooling water.
Cooling water must meet the following specification:
Calcium (Ca) Less than 1 ppm
Magnesium (Mg) Less than 1 ppm
Total Hardness (CaCO3) Less than 1 ppm
Chloride Less than 25 ppm
Sulfate Less than 25 ppm
6. A water sampling program will verify that coolant
meets the requirements outlined here and determine
when it needs changing. If a cooling system analysis
program is not used, the cooling system should be
cleaned and flushed annually.
FORM 6296 First Edition

B. EBULLIENT SYSTEMS
Ebullient, or controlled boiling water, cooled engines
and equipment are extremely sensitive to water quality.
Since water is essentially boiled off during the ebullient
process, hard chemicals are left behind as scale
deposits. If the low pressure steam is used in an external
process, and not condensed for return to the engine,
make--up water is always being added. On the other
hand, closed steam loops that return condensate to be
used again are susceptible to higher corrosion rates due
to chemical changes in the water as it cycles through the
system.
The type of water treatment required depends upon the
design of the steam system and the quality of the water
used.
Ebullient cooling systems require the following
attention:
1. Hardness Removal
Ebullient systems (engines and heat recovery equip-
ment) cannot tolerate high levels of hard chemicals--
calcium and magnesium. It is recommended to maintain
0 ppm hardness by one or a combination of the following
methods:
1. Water softening, sodium zeolite type, similar to
common home water softeners, but sized for the
application. Sodium zeolite (salt brine) causes a reac-
tion that attracts hard chemicals that congregate on
resin beads within the softener.
These chemicals are then periodically flushed away.
Softeners can greatly reduce water hardness but not
totally eliminate it. Levels of 0.5 to 1 ppm hardness may
remain which should be further reduced by phosphate
treatment.
2. Phosphates can be used that cause a precipitative
reaction when in contact with calcium. This means that
calcium phosphate is formed that drops out of suspen-
sion as a soft sludge at the lowest points of the system.
Bottom blowdown ports are required to periodically rid
the system of accumulated sludge.
As phosphate will not react with magnesium salts,
silicates are added to precipitate the magnesium. Again,
blowdown is required. For silicates to work, pH of the
engine water must be 10.5 minimum.
3. Chelates and polymers, chemical additives that
prevent scale, do not precipitate the hard chemicals.
Instead, the hard chemicals are kept in suspension until
reaching the surface of the steam separator where
continuous surface blowdown will purge them from the
system.
FORM 6296 First Edition
COOLING SYSTEM
4. Deionization or demineralization is a process similar
to sodium zeolite softening. The end result, however, is
completely mineral free water. Although mineral--free,
demineralized water is corrosive and must be treated
accordingly.
2. Blowdown Of Ebullient Systems
There are two types of blowdown, surface and bottom.
Continuous surface blowdown in the heat recovery unit
will reduce the total dissolved solids (TDS) that increase
through addition of make--up water or condensate
return. TDS includes hardness ions, alkalines, silicates,
and iron. Total alkalinity, also called “M” alkalinity, is that
portion of TDS composed of carbonate, bicarbonate,
and hydroxide alkalinity.
A conductivity meter and probes mounted near the
surface level of the steam separator will monitor the TDS
level to indicate when a blowdown is required. The
probes measure electrical conductivity of the coolant
that increase as TDS increases. Too high a level of TDS
can cause foaming with carryover of liquid through the
steam system. This produces undesirable wet steam.
Bottom blowdowns are required, especially when pre-
cipitative chemicals such as phosphates and silicates
are added to reduce scaling. These chemicals produce
a soft sludge that must be removed at the lowest areas
of the engine and steam separator through blow ports.
Blowdown frequency should be twice per shift for
15 seconds or as recommended by a local water
treatment specialist.
3. Oxygen Scavengers
Water can contain dissolved oxygen and carbon diox-
ide. These gases can lead to corrosion of metal parts.
An oxygen scavenger eliminates oxygen and reduces
the likelihood of corrosion.
Sodium sulfite is a typical chemical oxygen scavenger.
This chemical reacts with oxygen to form sodium sulfate
that stays in suspension until surface blowdown elimi-
nates it from the system.
Other scavengers are available but they are not as safe
to handle as sodium sulfite.
4. pH
pH is a measure of alkalinity or acidity of water. As
mentioned, pH of the engine jacket water should be
maintained at 10.5 to 11.5 to allow certain hardness
removal chemicals to work.
5.25 -- 11
COOLING SYSTEM

In the steam separator, H2O and CO2 combine to form
carbonic acid, H2CO3. This acid is corrosive to down-
stream pipe work and equipment. The pH after the
steam separator will drop in conjunction with H2CO3
production.
pH should be kept at 7.5 to 8.5 in the steam loop to
prevent corrosion. Neutralizing amines may be added to
improve pH.
Steam condensate returning to the feed water reservoir
may be acidic and contain iron if corrosion has occurred.
This condensate must be monitored to determine
necessary treatment.
C. WATER QUALITY AND TESTING
Water treatment products vary in the chemicals used in
their make--up. All are proprietary to the water treatment
specialist who markets them and the specialist knows
how they will perform with a given quality of water in a
particular cooling system. Most products will do a good
job with a good quality distilled or deionized water but
may not perform well with a poor quality water, which
may be hard with chlorides and/or sulfates. Some
products may perform well with a poorer quality water
but may require an increased treatment level.
It is absolutely essential that a competent water
treatment specialist be consulted to prepare a good
water treatment program. Norkool Industrial Products
Division of Union Carbide, Inc., Calgon Corp., Mogul
Division of Dexter Corp., and other knowledgeable
companies are available. Review with the chosen
representative the details of the engine water system to
be treated.
The following should be covered at a minimum:
1. Metals in the system contacted by the coolant.
2. Operating temperatures.
3. Source and quality of water (if known).
4. Type of system: solid water or ebullient (steam).
5. Amount of make--up water required.
6. Age of installation.
7. Previous water treatments used and any history of
corrosion or scaling problems.
8. Engine model, speed and type of operation (stand--
by, loading, etc.).
The manufacturer recommendations should include the
following:
1. Any required cleaning of the system and how it
should be done.
2. Any pretreatment required if the quality of the water is
questionable.
3. Type of water treatment to be used and the level at
which it is to be maintained.
4. Control limits, if required, for pH, hardness, total
dissolved solids, alkalinity, chlorides, sulfates, nitrites,
silica, etc. that must be held in the treated water.
5. Frequency of tests for level of treatment and/or when
water samples should be taken and analyzed.
6. Corrective actions to be taken when control limits are
exceeded.
7. Amount and frequency of blowdown (ebullient
cooled systems).
Once the treatment program is in place, frequent testing
of the engine jacket water, make--up water, and any
condensate returned must be performed to ensure that
the required water quality is being maintained.
Table 5.25-3 lists recommended tests and acceptable
limits for ebullient cooling systems. Some of these tests
may be applicable to solid water systems. Consult your
water treatment specialist.

Table 5.25-3. Recommended Testing For Ebullient Cooling Systems

WATER CIRCUIT TEST TYPE ACCEPTABLE LIMITS CONTROL
Feed Water Total Hardness 0 ppm Water softening/phosphates
Total Hardness 0 ppm Water softening/phosphates
Make p Water
Make--up Wate
Chlorides Should equal untreated water Check softener rinse cycle
pH 10.5 -- 11.5 Adjust blowdown frequency
Conductivity 2500 -- 3000 MMHO Adjust blowdown frequency
Engine
g Jacket WAter O2 Scavenger 30 -- 50 ppm sulfites Adjust treatment level
Total alkalinity 200 -- 600 ppm Adjust blowdown frequency
Scale Inhibitor Varies Adjust treatment level
Condensate pH 7.5 -- 8.5 Adjust amine level

5.25 -- 12 FORM 6296 First Edition


GLOSSARY OF TERMS
ALKALINITY
A measurement of the acid--neutralizing capacity of a
water or coolant. It is usually expressed as “M“ alkalinity
(methyl orange indicator) or “P“ alkalinity (Phenolphtha-
lein indicator). These values are also used in boiler
water and cooling tower water as controls to predict the
tendency for a water to precipitate calcium and form
scale. Reserve “alkalinity“ is a term used by antifreeze
manufacturers to indicate the level of inhibitors in
solution. “Total“ alkalinity is another name for “M“
alkalinity.
BLOWDOWN
The process of removing total dissolved solids or
precipitated sludge from a cooling water system.
CAVITATION
A type of localized pitting occurring on cylinder liners
and other surfaces, usually perpendicular to the axis of
the crankshaft. The mechanical vibrations of the liner
cause dissolved gas and vapor bubbles to collapse, the
shock forces remove the protective films or coatings and
erode the surface. If the inhibitors of the water treatment
cannot keep up with this erosion, rapid localized
corrosion also occurs. These actions combine to form
deep pits on the liner surface. This type of damage is
also found on water pump impellers if the net positive
suction head (NPSH) requirement of the pump is not
maintained.
CHELATES
Chemical compounds used in cooling system cleaners
to remove oil contamination, scale and deposits from a
cooling system. System must be flushed with water
before filling with treated water.
CHLORIDE
A dissolved salt in water that forms ions that increase the
conductivity of water and interfere with the protective
films formed on the surfaces of metals. It increases the
corrosion tendency of water.
CREVICE CORROSION
A type of localized pitting occurring in or at the edges of
close fitting areas such as the liner flange to the
crankcase. The stagnant conditions of the coolant in the
fit area make it difficult to establish films or coatings for
corrosion protection.
DEAERATION
All water contains some dissolved gases. Increased
pressure of the gas and any splashing at the water
surface will increase the amount of dissolved gas in the
water. Deaeration removes these gases by steam
FORM 6296 First Edition
COOLING SYSTEM
scrubbing, heating or by the addition of chemicals.
Dissolved oxygen and carbon dioxide increase corro-
sion in water systems.
DEIONIZATION
Also known as demineralization, this is a process in
which all dissolved mineral salts and ions are removed
from water, resulting in almost chemically pure water.
This purity makes the water very corrosive, so it must be
treated with inhibitors before use in an engine water
system.
FRETTING CORROSION
Occurs when two highly loaded surfaces rub rapidly
together, causing mechanical removal of metal and the
protective films or coatings. The localized frictional heat
accelerates corrosion. This type of corrosion can occur
in fit areas of liner to crankcase.
GALVANIC CORROSION
When dissimilar metals are coupled in an electrolyte
such as an engine coolant, they tend to cause an
electronic current to flow through the metal. Metals high
on the galvanic series chart (anodic) tend to go into
solution leaving electrons behind to flow to the metals
low on this chart (cathodic). Corrosion tends to concen-
trate on the metals high on the galvanic series chart,
particularly if the relative area is small compared to the
cathodic parts. This type of corrosion may occur in
aluminum parts such as valves, fittings, heaters, etc.
when used in a water system and requires special
attention when selecting a water treatment.
HARDNESS
Calcium and magnesium salts in water cause hardness.
It is usually measured and reported as “total hardness
as CaCO3 in PPM.” If not removed from the water or
treated chemically, these salts will break down with heat
to form sludge, carbon dioxide and scale on the hot
surfaces in the engine. The carbon dioxide recombines
with the water to form carbonic acid and accelerates
corrosion. Temporary or carbonate hardness will “drop
out” (form scale or precipitate to form sludge) with
increased temperatures; permanent or non--carbonate
hardness will not.
INHIBITOR
A chemical part of a water treatment that reduces or
stops corrosion by interfering with the corrosion mecha-
nism. They function by forming a protective film on the
metallic surfaces of the cooling system. The inhibitors
are known as “anodic” or “cathodic” depending on what
part of the corrosion cell the films are formed on. Those
that form films on all metal surfaces are called “general
corrosion inhibitors.”
5.25 -- 13
COOLING SYSTEM
IONS
When any substance dissolves in water, it breaks down
into electrically charged atoms called “ions.” Some are
(+) charged (cations); others (--) charged (anions).
PH
A measurement of hydrogen ion concentration which
indicates the acidity or alkalinity of the water. The pH
scale is from 0 (highly acidic) to 14 (highly alkaline), with
a 7.0 reading neutral.
PPM
A ratio calculated on the basis of the whole being divided
into one million equal parts. The value may be calcu-
lated on a volume (ppmv) or weight (ppmw) basis. For
example, if 1 pound of amines is mixed with
9999 pounds of water, there is 100 ppmw of amines in
the mixture. Note that 10000 ppm equals 1%.
PRETREATMENT
Any preliminary cleaning or preparation of the water
system to ensure that the treatment program works
effectively right from the start.
RAINWATER
A natural deionized water. Rainwater contains large
amounts of dissolved oxygen (O2) and carbon dioxide
(CO2) that make it unsuitable for cooling systems
without treatment.
SELECTIVE LEACHING
A type of corrosion of alloyed metals (also called
de--alloying). In brass it is called dezincification and
involves the process of zinc dissolving into the water,
leaving a weak porous copper structure in place of the
original brass alloy. This type of corrosion is sometimes
found in heat exchangers and radiators if a poor quality
water and/or marginal water treatment is used.
SILICA
A dissolved mineral in water that combines with calcium
and magnesium to form a dense scale.
Table 5.25-4. Jacket Water Outlet Temperature Settings
DESCRIPTION
Jacket Water Outlet Temperature
180° F (82° C)
for continuous rating
Standard Cooling System
200° F (93° C)
and intermittent rating
5.25 -- 14
SOFTENING
A pretreatment given to water before it is treated with
inhibitors and used in an engine. Several different
softening processes are used to reduce the hardness
and scale forming tendency of water. In some pro-
cesses, the calcium and magnesium in the hardness
salts are replaced with sodium resulting in no reduction
in the total dissolved solids in the water. In other
processes the chemical reactions actually remove
these dissolved salts and result in a large reduction in
total solids. None of the softening processes will remove
chlorides, sulfates or silica from water if they are
present.
SOLDER BLOOM
A type of lead/tin corrosion found in solder type radiators
if poor quality water and/or marginal water treatment is
used. Corrosion is concentrated at the solder joint
because of galvanic action and the relatively small area
of lead/tin to copper in the radiator. The “bloom” or
corrosion deposit formed is relatively weak and rapidly
disintegrates the solder joint to cause leakage.
SOLIDS
“Suspended solids” are those that can be removed by
settling or filtration. “Dissolved solids” are impurities and
organic matter in solution. “Total solids” are the sum of
suspended and dissolved solids. Higher levels of total
solids increase the conductivity of water, tending to
increase corrosion.
SULFATE
A dissolved salt in water which forms ions that will
combine with calcium and magnesium to form sulfate
scale. These compounds can also combine with hydro-
gen to form acids which make water corrosive.
COOLING SYSTEM SPECIFICATIONS
Ensure that the temperature of the cooling water leaving
the engine (as indicated by the temperature gauge)
does not exceed the temperatures listed in
Table 5.25-4.
NORMAL ALARM SHUTDOWN
10° F (5.5° C) 20° F (11° C)
above normal/design above normal/design
temperature temperature
FORM 6296 First Edition
 COOLING SYSTEM

Engine overheating, as evidenced by high jacket water 3. Open air bleed petcock(s) on top of cluster thermo-
temperatures, may be caused by one or more of the stat housing.
following conditions:
4. Attach make-up line to ball valve and add treated
· inadequate sizing of the radiator cooling water to crankcase.
· defective thermostats NOTE: Always fill the engine from the bottom up to
minimize the formation of damaging air pockets. As the
· worn jacket water pump engine fills, air is pushed up and out.
· excessive jacket water pump suction 5. Close jacket water pump air bleed petcock (or needle
· loose drive belts valve) when water begins to flow out in a solid steady
stream.
· blown head gasket
6. Add coolant to engine until level causes it to escape
· faulty temperature gauge from petcock(s) on top of cluster thermostat housing
(see Table 5.25-5).
· low coolant level
Table 5.25-5. Jacket Water Capacity -- Engine Only
· overloaded engine ENGINE MODEL GALLONS (LITERS)

· air bound system L5774

L5794 107 (405)
( )
· insufficient air circulation L7044

· exhaust recirculation
7. Close cluster thermostat housing petcock(s) and
JACKET WATER CIRCUIT -- INITIAL FILL continue filling system until level of coolant reaches top
of surge tank or radiator.
NOTE: The following description is not applicable to
permanent vent systems.

1. Remove 3/4 in. NPT countersunk headless pipe Always install a pipe plug in the ball valve when the
plugs from drain hole just below level of jacket water hose connection is removed. If the lever of the ball
header (see Figure 5.25-10). valve is inadvertently bumped open, the absence of
NOTE: To facilitate draining and flushing of the engine a plug will cause the coolant to drain. During
jacket water, replace one of the 3/4 in. NPT countersunk operation, loss of any coolant may result in cata-
headless pipe plugs with a customer-supplied ball valve strophic engine damage. Escaping steam and/or
(see Figure 5.25-10). The ball valve must be threaded to hot water can cause severe burns. Disregarding this
accept both a hose connection and pipe plug. information could result in severe personal injury or
death.
WATER 8. Close ball valve and unthread hose connection.
HEADER
9. Apply pipe thread sealant to threads of pipe plug.
Install plug in ball valve.
PLUG
Air in the cooling system
speeds up the formation
of rust, increases corrosion and produces hot spots
within the engine. Disregarding this information
could result in product damage and/or personal
BALL injury.
VALVE
JACKET WATER
CRANKCASE DRAIN/FILL PORT 10. Bleed trapped air (see “Cooling Water System Air
Bleed” in this section).
Figure 5.25-10. Customer Supplied Ball Valve
11. Top off surge tank or radiator.
2. Open jacket water pump air bleed petcock in outlet
port to jacket water header.

FORM 6296 First Edition 5.25 -- 15

COOLING SYSTEM

AUXILIARY COOLING WATER CIRCUIT -- 1. Initial Bleed: Open each air bleed petcock prior to
INITIAL FILL engine startup. A hissing sound often accompanies the
escape of trapped air. Close petcock when hissing stops
NOTE: The following description is not applicable to and water begins to flow out in a solid steady stream.
permanent vent systems.

1. Open air bleed petcock(s) in intercooler cooling

water inlet/outlet bonnet(s).
Always wear protective clothing when bleeding the
2. Open air bleed petcocks in inlet side of wastegate cooling system on a heated engine. Slowly loosen
water return tubes. the air bleed petcock to relieve any excess pres-
sure. Escaping steam and/or hot water could result
3. From top of surge tank or radiator, add treated in severe personal injury or death.
cooling water to auxiliary cooling water circuit.
2. Check Bleed: Start engine and reopen each pet-
4. Continue filling circuit until level causes it to escape cock. Close petcock when hissing stops and water
from air bleed petcock(s) in intercooler cooling water begins to flow out in a solid steady stream.
inlet/outlet bonnet(s). Close petcock(s) when water
begins to flow out in a solid steady stream. 3. Final Bleed: Once temperature of jacket water
circuit has stabilized (as indicated by the panel mounted
5. Continue filling the auxiliary cooling water circuit until temperature gauge), reopen each petcock. Close
the level causes it to escape from the petcocks in the petcock when water begins to flow out in a solid steady
intercooler cooling water supply and the inlet side of the stream.
wastegate water return tubes. Close the petcocks when
water begins to flow out in a solid steady stream.
Air can be drawn into the
6. Continue filling the auxiliary cooling water circuit until engine through small
the level of the coolant reaches the top of the surge tank leaks in the jacket water system. The problem is
or radiator. compounded when the void created by the loss of
coolant is filled by more air. If aeration causes the
coolant to foam, the probability of engine damage
Air in the cooling
due to overheating is greatly increased. Disregard-
system speeds up the
ing this information could result in product damage
formation of rust, increases corrosion and pro-
and/or personal injury.
duces hot spots within the engine. Disregarding
this information could result in product damage
4. Carefully inspect jacket water system for coolant
and/or personal injury.
leaks while engine is running.
7. Bleed trapped air (see “Cooling Water System Air Table 5.25-6. Air Bleed Petcocks
Bleed” in this section). COOLING NUMBER
WATER OF LOCATION
8. Top off the surge tank or radiator. CIRCUIT PETCOCKS
Jacket water pump housing
COOLING WATER SYSTEM AIR BLEED 1 (front center); outlet port to left
Jacket bank jacket water header
Air bleed the jacket water and auxiliary cooling water Water
circuits at least once each day. Open and close the air Cluster thermostat housing
2 (above bypass outlet
bleed petcocks in the order that they are listed below, ports at front)
starting at the lowest petcock in the system and ending Intercooler water inlet/outlet
2
at the highest. Bleed one petcock at a time. The number bonnets (upper rear)
Auxiliary
of air bleed petcocks and their locations are as follows Wastegate water return tube
2 (rear right and left bank)
(see Table 5.25-6).

5.25 -- 16 FORM 6296 First Edition


JACKET WATER AND AUXILIARY WATER
CIRCUITS -- DRAIN AND FLUSH
Unless evidence of corrosion or sediment buildup
demonstrates the need for more frequent maintenance,
clean and flush both the jacket water and auxiliary water
circuits at least once each year.
Antifreeze and water treatment products require a clean
system in order to work effectively. If contaminants such
as dirt, rust, scale, lime, grease, oil and/or cleaning
agents are not completely flushed out, they can destroy
the corrosion inhibitors and scale suppressants in-
tended to keep freshly filled cooling systems clean.
NOTE: To facilitate draining and flushing of the engine
jacket water, replace one of the 3/4 in. NPT countersunk
headless pipe plugs (just below the level of the jacket
water header) with a customer-supplied ball valve. The
ball valve must be threaded to accept both a hose
connection and pipe plug. When finished, always install
a pipe plug to prevent inadvertent draining of the cooling
system.
Always install a pipe plug in the ball valve when the
hose connection is removed from the jacket water
header. If the lever of the ball valve is inadvertently
bumped open, the absence of a plug will cause the
coolant to drain. During operation, loss of any
coolant may result in catastrophic engine damage.
Escaping steam and/or hot water could result in
severe personal injury or death.
1. Start engine. Run engine for 10 minutes.
Always wear protective clothing when draining the
cooling systems on a hot engine. As air bleed
petcocks are opened, escaping steam and/or hot
water could result in severe personal injury or
death.
NOTE: Drain the coolant from the jacket water and
auxiliary water circuits immediately after shutting down
the engine. Draining the coolant immediately prevents
any sediment from re-settling.
2. Shut down engine. Open air bleed petcocks located
at highest point in jacket water and auxiliary water
circuit.
3. Verify that customer-supplied ball valve is closed.
Remove pipe plug and attach drain line.
FORM 6296 First Edition
COOLING SYSTEM
4. Open ball valve and drain coolant from jacket water.
5. Open all air bleed petcocks (see Table 5.25-6).
6. Open all water drain petcocks. Remove all drain
plugs (see Table 5.25-7).
Table 5.25-7. Water Drain Petcocks
COOLING NUMBER
WATER OF LOCATION
CIRCUIT PETCOCKS
2 Water manifold (front and rear)
Jacket Jacket water pump housing
Water 1 (see exit hole in side panel of
safety guard assembly)
2 Intercooler (rear, left and right)
Auxiliary
1 Auxiliary water pump (bottom)
Water return pipe (pipe end at
1 crankcase Vee, engine front)
7. Close all water drain petcocks. Install all drain plugs.
8. Add soft water to the crankcase (through ball valve).
NOTE: Always fill the engine from the bottom up to
minimize the formation of air pockets. As the engine fills,
air is pushed up and out (see Table 5.25-8).
Table 5.25-8. Jacket Water Capacity -- Engine Only
ENGINE MODEL GALLONS (LITERS)
L5774
L5794 107 (405)
( )
L7044
9. Close each air bleed petcock when water begins to
flow out in a solid steady stream.
10. Close thermostat housing petcock(s) and continue
filling jacket water system until level reaches top of
surge tank or radiator.
11. Add clean, soft water to surge tank or radiator of
auxiliary cooling water circuit.
12. Continue filling auxiliary cooling water circuit until
level reaches top of surge tank or radiator.
13. Perform “Initial Bleed” procedures. See “Cooling
Water System Air Bleed” in this section.
14. Perform “Check Bleed” procedures.
15. Perform “Final Bleed” procedures.
16. Stop engine. Drain crankcase and all cooling
system accessories. Drain auxiliary cooling system.
5.25 -- 17
COOLING SYSTEM

NOTE: Follow the manufacturer’s recommendations GREASE FITTINGS

for the proper concentration of cleaning solution and
length of cleaning time. Use a non--acidic, non--corro-
sive, biodegradable compound that prevents the loss of
metal in engine and avoids damage to internal gaskets
and seals.
17. Fill jacket water and auxiliary cooling water circuits
with a suitable cleaning solution.
IDLER PULLEY BEARING LUBRICATION
Grease the ball bearing in the jacket water pump idler
pulley bracket every 720 running hours.
1. Locate grease fitting mounted below drain located on
right bank side of upper safety guard assembly (see
Figure 5.25-11).

18. Perform “Initial Bleed” procedures. See “Cooling

Water System Air Bleed” in this section. DRAIN

Always wear protective clothing when draining the

cooling systems on a hot engine. As air bleed
petcocks are opened, escaping steam and/or hot
water could result in severe personal injury or
death.

19. Perform “Check Bleed” procedures.

20. Perform “Final Bleed” procedures.

GREASE FITTING
21. Top off surge tank or radiator for jacket water and
auxiliary water circuits. Figure 5.25-11. Idler Pulley Bearing

NOTE: Drain the coolant from the jacket water and

auxiliary water circuits immediately after shutting down
the engine. Draining the coolant immediately prevents
any sediment from re--settling.
22. Shut down engine and drain cooling systems.
23. Inspect internal surfaces. If the results are not
satisfactory, refill the engine with cleaning solution.
Repeat Steps 17 through 22 as necessary.
24. Fill jacket water and auxiliary cooling circuits with
clean, soft water. Drain immediately.
NOTE: Inspect the drain water for cleanliness. Fill and
flush the systems again, if necessary. The best results
are obtained when the drain water runs clear.
25. Fill jacket water and auxiliary cooling water
circuits with coolant.
26. Perform “Initial Bleed” procedures. See “Cooling
Water System Air Bleed” in this section.
27. Perform “Check Bleed” procedures.
28. Perform “Final Bleed” procedures.
Do not over grease the
idler pulley bearing. Over
greasing causes high bearing temperatures that
shorten bearing service life. Disregarding this
information could result in product damage and/or
personal injury.
2. Using a hand-held grease gun, apply one stroke of
Lithoplexâ Grease No. 2 (Multipurpose Lithium Com-
plex Formula Containing Molybdenum Disulfide) to
grease fitting.
AUXILIARY WATER PUMP BEARINGS
LUBRICATION
Grease the two ball bearings in the auxiliary water pump
every 720 running hours. The pump is mounted to a
bracket at the front left corner of the oil pan.
1. Locate two grease fittings on auxiliary water pump
support head (see Figure 5.25-12). Front ball bearing
grease fitting (pulley end) is reached through an access
hole in belt guard cover. Rear ball bearing grease fitting
is uncovered.

29. Carefully inspect water circuits for leaks.

5.25 -- 18 FORM 6296 First Edition


GREASE FITTING ACCESS
Figure 5.25-12. Auxiliary Water Pump Lubrication
Do not over grease the
water pump bearings.
Over greasing causes high bearing temperatures
that shorten bearing service life. Disregarding this
information could result in product damage and/or
personal injury.
2. Using a hand-held grease gun, apply two or three
strokes of Lithoplexâ Grease No. 2 (Multipurpose
Lithium Complex Formula Containing Molybdenum
Disulfide) to grease fittings.
GREASE RECOMMENDATIONS
A Lithium complex type grease is now recommended
over the Lithium soap based grease because of its
ability to resist water. Lithium complex type grease also
provides superior rust protection qualities (especially
steel surfaces), as well as its thermal and mechanical
stability at high operating temperatures. The lithium
complex grease has a continuous operating tempera-
ture of approximately 350° F (177° C), whereas the
lithium soap base grease has an upper operating
temperature limit of approximately 225° F (107° C).
Always install the safe-
ty guards after complet-
ing the service operation (see “Safety Guards
Installation” in this section). Never operate the
engine with the safety guards removed. Disregard-
ing this information could result in product damage
and/or personal injury.
FORM 6296 First Edition
COOLING SYSTEM
BELTS
JACKET WATER PUMP DRIVE BELTS
REPLACEMENT
1. See “Safety Guards Removal” in this section.
An accumulation of dirt
in the sheave grooves
impairs traction and accelerates belt wear. Disre-
garding this information could result in product
damage and/or personal injury.
2. Verify pulley sheaves are clean and completely free
of grease, oil, dirt and grit.
3. Inspect drive belts for fraying, cracks or wear. Belts
must not be glazed, split, peeled or greasy. Replace as
necessary.
Belts are matched and
tied in sets of two. Al-
ways replace the drive belts in pairs. Never replace
just one drive belt even if only one belt is worn.
Since the older belts are stretched during hours of
engine operation, the circumference of new belts is
slightly smaller. A difference in belt size will cause
the new belt to carry the full load, resulting in rapid
belt failure and possible damage to driven equip-
ment. Disregarding this information could result in
product damage and/or personal injury.
4. Inspect condition of new jacket water pump drive
belts (set of two matched belts for 10 in. crankshaft
pulley). Replace as necessary.
5. Remove auxiliary water pump drive belts. Back
upper thin hex lock nut on threaded rod away from
adjusting lever (see Figure 5.25-13). Pivot point of idler
lever follows adjusting lever in a counterclockwise
direction. Downward movement of idler pulley releases
drive belt tension. Slip drive belts off auxiliary water
pump and idler pulleys.
6. Loosen pivot bolt on which idler pulley bracket turns
(see Figure 5.25-14). Loosen slotted lock bolt to unlock
position of bracket. Belt tension is released as idler
pulley bracket rotates upward in a counterclockwise
direction.
5.25 -- 19
COOLING SYSTEM

cover. Slip belt into rear groove of jacket water pump

HEX HEAD
SCREW pulley.
IDLER LEVER
9. Place a new drive belt into second last groove of rear
crankshaft and jacket water pump pulleys.

THREADED ADJUSTING 10. Rotate idler pulley bracket clockwise to seat jacket
ROD LEVER water pump drive belts in two pulley grooves.

ELASTIC STOP 11. Refer to “Jacket Water Pump Drive Belt Tension
LOCK NUT Adjustment” in this section and adjust the belts.
LOCK
WASHER
JACKET WATER PUMP DRIVE BELT TENSION
ADJUSTMENT
SPACER
Check the tension and condition of the two jacket water
pump drive belts weekly. Replace the drive belts every
SPACER
8000 running hours or as necessary.
ELASTIC STOP
PIVOT ROD LOCK NUT 1. See “Safety Guards Removal” in this section.

THIN HEX LOCK NUT Be sure that the belts

are cool when the ten-
PLAIN WASHER
sion is checked or adjusted. The thermal expansion
STUD ANCHOR of warm belts will result in a false tension reading.
Disregarding this information could result in prod-
PLAIN WASHER
uct damage and/or personal injury.
Figure 5.25-13. Adjusting/Idler Lever Assembly
2. Using V-Belt Tension Tester (Tool P/N 474016),
check drive belt tension.
PIVOT BOLT
A. Align bottom of large O-ring on “Inches of Span”
scale at 19, which is measured belt span
between centerlines of crankshaft and jacket
water pump pulleys.

B. Align bottom of small O-ring on “Deflection Force”

scale with zero mark.

C. Place tension tester squarely on front drive belt at

IDLER PULLEY SLOTTED
BRACKET LOCK BOLT
Figure 5.25-14. Tighten Idler Pulley Bracket Bolts
7. Slip old drive belts off jacket water pump and idler
pulleys. Remove belts from rear crankshaft pulley and
discard.
8. Place a new drive belt in rear groove of rear
crankshaft pulley. Rear groove is one closest to gear
center of longest unsupported span (between
jacket water pump pulley and crankshaft pulley).
Apply inward force on plunger perpendicular to
belt span until bottom of large O-ring is even with
top of rear drive belt (see Figure 5.25-15).
D. Remove tension tester and read force applied
from bottom of small O-ring on deflection force
scale. Tension of used belts must be between
11.9 -- 17.5 lb. (53 -- 77 N).
E. Check rear belt tension in same manner.
NOTE: If the tension tester is not available, moderate
hand pressure should deflect the long part of the belt
approximately 0.25 -- 0.50 in. (6 -- 13 mm).

5.25 -- 20 FORM 6296 First Edition

 COOLING SYSTEM

FRONT DRIVE BELT

REAR DRIVE BELT

SMALL O-RING
LARGE O-RING

DEFLECTION
SPAN SCALE FORCE SCALE

Figure 5.25-15. Jacket Water Pump Drive Belt Tension Tester

3. If belt tension adjustment is necessary, loosen pivot Belts that are too loose
bolt on which idler pulley bracket turns (see result in belt slippage.
Figure 5.25-16). Loosen slotted bolt to unlock position Slippage causes burn spots, overheating, rapid
of bracket. Belt tension is released as idler pulley wear and breakage. The vibration created by loose
bracket rotates upward in a counterclockwise direction. belts may also be sufficient to cause unnecessary
wear of the pulley grooves. Disregarding this
information could result in product damage and/or
PIVOT personal injury.
BOLT
JACKET WATER 4. To reset belt tension, insert a pry bar between upper
PUMP PULLEY
edge of idler pulley bracket and untapped boss on left
DRIVE BELT bank side of water pump housing (see Figure 5.25-17).
(FRONT)
To tighten drive belts, use pad above untapped boss for
leverage and push up on pry bar to move idler pulley
bracket downward (CW).
SLOTTED
LOCK BOLT
LEVERAGE DRIVE
IDLER PULLEY BRACKET PAD BELT
IDLER PULLEY

Figure 5.25-16. Jacket Water Pump Drive Belt

Tensioning

Belts that are too tight

result in excessive
stretching and overheating. Too much tension may
also damage drive components, such as sheaves PRY BAR
and shafts, and lead to premature failure of the idler
pulley and/or water pump bearings. Disregarding IDLER PULLEY
this information could result in product damage BRACKET
and/or personal injury.
Figure 5.25-17. Jacket Water Pump Drive Belt Tension

FORM 6296 First Edition 5.25 -- 21

COOLING SYSTEM

5. Holding pry bar in position, use tension tester to Figure 5.25-18). Pivot point of idler lever follows adjust-
apply inward pressure to center of longest unsupported ing lever in a counterclockwise direction. Downward
span on front drive belt (between jacket water pump movement of idler pulley releases drive belt tension.
pulley and crankshaft pulley).

6. Tension of used belts must be between 11.9 -- 17.5 lb. IDLER LEVER HEX HEAD
SCREW
(53 -- 77 N).

NOTE: If the tension tester is not available, moderate

hand pressure should deflect the long part of the belt
THREADED ADJUSTING
approximately 0.25 -- 0.5 in. (6 --13 mm). ROD LEVER

7. Tighten slotted lock bolt on idler pulley bracket when ELASTIC STOP
proper belt tension is obtained (see Figure 5.25-16). LOCK NUT
LOCK
Tighten pivot bolt. WASHER

8. Inspect belts for proper seating. V-belts should ride

on sides of pulley sheaves, not on bottom of groove. SPACER

9. Verify tension of front drive belt is between SPACER

11.9 -- 17.5 lb. (53 -- 77 N). Verify tension of rear drive
belt. PIVOT ROD
ELASTIC STOP
LOCK NUT
10. See “Auxiliary Water Pump Drive Belt Tension
Adjustment” in this section. THIN HEX LOCK NUT

Always install the safe-
ty guards after checking
or adjusting the jacket/auxiliary water pump drive
belt tension. Never operate the engine with the
safety guards removed. Disregarding this informa-
tion could result in product damage and/or personal
injury.
11. See “Safety Guards Installation” in this section.
PLAIN WASHER
STUD ANCHOR
PLAIN WASHER
Figure 5.25-18. Adjusting/Idler Lever Assembly
4. Remove drive belts from auxiliary water pump and
idler pulleys (see Figure 5.25-19). Remove belts from
rear crankshaft pulley and discard.

AUXILIARY WATER PUMP DRIVE BELT AUXILIARY WATER

REPLACEMENT PUMP DRIVE BELTS

An accumulation of dirt
in the sheave grooves
impairs traction and accelerates belt wear. Disre-
garding this information could result in product
damage and/or personal injury.

1. Verify pulley sheaves are clean and completely free

of grease, oil, dirt and grit.

2. Inspect drive belts for fraying, cracks or wear. Belts

must not be glazed, split, peeled or greasy. Replace as
necessary.
Figure 5.25-19. Auxiliary Water Pump Belts
3. If replacement is necessary, back upper thin hex lock
nut on threaded rod away from adjusting lever (see

5.25 -- 22 FORM 6296 First Edition


Belts are matched and
tied in sets of two. Al-
ways replace the drive belts in pairs. Never replace
just one drive belt even if only one belt is worn.
Since the older belts are stretched during hours of
engine operation, the circumference of new belts is
slightly smaller. A difference in belt size will cause
the new belt to carry the full load, resulting in rapid
belt failure and possible damage to driven equip-
ment. Disregarding this information could result in
product damage and/or personal injury.
5. Inspect condition of new auxiliary water pump drive
belts. Replace as necessary.
6. Place new drive belt in smaller groove of rear
crankshaft pulley (directly in front of first jacket water
pump drive belt) (see Figure 5.25-20). Slip belt into rear
grooves of both auxiliary water pump and idler lever
pulleys.
JACKET WATER
PUMP BELTS
AUXILIARY WATER
PUMP BELTS
Figure 5.25-20. Jacket/Auxiliary Water Pump Belts
7. Using grooves directly in front of first auxiliary water
pump drive belt, slide a second drive belt around rear
crankshaft, auxiliary water pump and idler lever pulleys.
8. To tighten drive belts, thread upper thin hex lock nut
toward adjusting lever. Pivot point of idler lever follows
adjusting lever in a clockwise direction. Upward move-
ment of idler pulley increases drive belt tension.
9. Refer to “Auxiliary Water Pump Drive Belt Tension
Adjustment” to adjust belts.
FORM 6296 First Edition
COOLING SYSTEM
AUXILIARY WATER PUMP DRIVE BELT TENSION
ADJUSTMENT
1. See “Safety Guards Removal” in this section.
Be sure that the belts are
cool when the tension is
checked or adjusted. The thermal expansion of
warm belts will result in a false tension reading.
Disregarding this information could result in prod-
uct damage and/or personal injury.
2. Using V-Belt Tension Tester (Tool P/N 474016),
check drive belt tension.
A. Align bottom of large O-ring on “Inches of Span”
scale at 19, which is measured belt span
between centerlines of crankshaft and jacket
water pump pulleys.
B. Align bottom of small O-ring on “Deflection Force”
scale with zero mark.
C. Place tension tester squarely on front drive belt at
center of longest unsupported span (between
jacket water pump pulley and crankshaft pulley).
Apply inward force on plunger perpendicular to
belt span until bottom of large O-ring is even with
top of rear drive belt (see Figure 5.25-21).
D. Remove tension tester and read force applied
from bottom of small O-ring on deflection force
scale. Tension of used belts must be between
11.9 -- 17.5 lb. (53 -- 77 N).
E. Check rear belt tension in same manner.
NOTE: If the tension tester is not available, moderate
hand pressure should deflect the long part of the belt
approximately 0.25 -- 0.50 in. (6 -- 13 mm).
Belts that are too tight
result in excessive
stretching and overheating. Too much tension may
also damage drive components, such as sheaves
and shafts, and lead to premature failure of the idler
pulley and/or water pump bearings. Disregarding
this information could result in product damage
and/or personal injury.
NOTE: Since the circumference of new belts is some-
what smaller, reuse of the setting established for the
discarded drive belts will result in belts that are too tight.
3. To loosen drive belts, back upper thin hex lock nut on
threaded rod away from adjusting lever. Pivot point of
idler lever follows adjusting lever in a counterclockwise
direction. Downward movement of idler pulley releases
drive belt tension.
5.25 -- 23
COOLING SYSTEM

FRONT DRIVE BELT

REAR DRIVE BELT SMALL O-RING

LARGE O-RING

DEFLECTION
SPAN SCALE FORCE SCALE

Figure 5.25-21. Jacket Water Pump Drive Belt Tension Tester

4. When correct tension is obtained, thread 3/8 in. Always install the safe-
elastic stop lock on upper end of threaded rod toward ty guards after checking
adjusting lever. Be sure lock nuts (thin hex and elastic or replacing the auxiliary water pump drive belts
stop) on each side of adjusting lever are properly (see “Safety Guards Installation” in this section).
tightened. Never operate the engine with the safety guards
removed. Disregarding this information could re-
5. Inspect belts for proper seating. V-belts should ride sult in product damage and/or personal injury.
on sides of pulley sheaves, not on bottom of groove.
JACKET WATER PUMP SEAL
6. Because of initial stretching, recheck belt tension INSPECTION
after 10 minutes run time. Check belt tension again after
first 30 minutes run time and then every 250 hours Even with proper cooling system maintenance, all jacket
thereafter. water pumps require periodic overhaul.
1. Inspect “weep hole” in casting directly below water
Belts that are too loose pump pulley (see Figure 5.25-22). Weep hole drains
result in belt slippage. any coolant that leaks past ceramic water pump seal.
Slippage causes burn spots, overheating, rapid
wear and breakage. The vibration created by loose
belts may also be sufficient to cause unnecessary
wear of the pulley grooves. Disregarding this
information could result in product damage and/or
personal injury.
7. To tighten drive belts, back elastic stop lock nut on
upper end of threaded rod away from adjusting lever.
Use a 3/8 in. deepwell socket for best results.

8. Thread upper thin hex lock nut toward adjusting

lever. Pivot point of idler lever follows adjusting lever in a
clockwise direction. Upward movement of idler pulley
increases drive belt tension.

9. When correct tension is obtained, thread elastic stop

lock nut on upper end of threaded rod toward adjusting
lever. Be sure lock nuts (thin hex and elastic stop) on
each side of adjusting lever are properly tightened. “WEEP HOLE”

Figure 5.25-22. Jacket Water Pump “Weep Hole” --

Water Pump Shown Removed

5.25 -- 24 FORM 6296 First Edition

 COOLING SYSTEM

The presence of coolant
at the weep hole indi-
cates that the jacket water pump must be rebuilt.
A defective water pump seal results in coolant
loss and contamination of the inner ball bearing
grease. Disregarding this information could re-
sult in product damage and/or personal injury.
2. Overhaul jacket water pump if any leakage at weep
hole is observed (see “Jacket Water Pump” in this
section).
CRANKCASE WATER INLET ELBOWS
3. Remove two capscrews, lock washers, gasket and
lower crankcase water inlet elbow from crankcase.
CRANKCASE WATER INLET ELBOWS REMOVAL --
RIGHT BANK
1. Remove two nuts, lock washers, capscrews, and
washers from right crankcase water inlet flange on water
pump.
2. Remove two capscrews, lock washers, washers,
right bank crankcase water inlet elbow, crankcase water
inlet flange, and gasket from crankcase.

CRANKCASE WATER INLET ELBOWS REMOVAL 3. Remove two crankcase water inlet flanges and
-- LEFT BANK O-rings from the ends of crankcase water inlet elbow.

1. Remove two nuts, lock washers, capscrews, and CRANKCASE WATER INLET ELBOWS
washers from left crankcase water inlet flange on water INSTALLATION -- LEFT BANK
pump (see Figure 5.25-23).
1. Look at part numbers stamped on crankcase water
2. Remove two nuts, lock washers, washers and inlet elbows to separate left bank (letter “T” suffix) from
capscrews and remove upper crankcase water inlet right (letter “U”).
elbow from lower elbow. Remove two O-rings and
2. Inspect ends of left bank water inlet elbow. Note one
crankcase water inlet flanges from each end of upper
end is slightly skewed.
elbow. Discard O-rings.

WASHER
O--RING
LOCK GASKET
WASHER

FLANGE
CAPSCREW NUT

FLANGE LOCK
ELBOW WASHER WASHER

CAPSCREW

NUT

LOCK
WASHER ELBOW
WASHER CAPSCREW
FLANGE LOCK
O--RING WASHER
CAPSCREW PLUG

NUT

LOCK GASKET
WASHER
WASHER
O--RING
CAPSCREW
ELBOW

Figure 5.25-23. Water Pump

FORM 6296 First Edition 5.25 -- 25

COOLING SYSTEM
3. Position a crankcase water inlet flange (diamond
shaped) on each end of water inlet elbow. Be sure inside
counterbore of both flanges faces outward toward ends
of elbow (see Figure 5.25-24).
COUNTERBORE
Figure 5.25-24. Crankcase Water Inlet Flange
4. Place a new O-ring on each end of elbow.
5. Inspect ports of water inlet adapter. Note one side
has a beveled counterbore, while other is flat.
6. With 1/4 in. NPT allen head pipe plug facing front-
ward, align flange holes on skewed end of elbow with
holes in beveled end of inlet adapter. Finger tighten
fasteners (two capscrews, 1/2 in. x 2-1/4 in. with flat
washers, lock washers and hex nuts).
7. Align holes in crankcase water inlet flange on other
end of elbow with those in nearest water pump outlet
port and finger tighten fasteners (two capscrews
1/2 in. x 2-1/4 in. with flat washers, lock washers and
hex nuts).
8. Install fasteners in flat side of crankcase water inlet
adapter (2 capscrews 1/2 in. x 2-1/4 in. with lock
washers).
9. Position a new gasket on ends of capscrews. Finger
tighten adapter to left bank crankcase water inlet
header.
10. Alternately wrench tighten six crankcase water inlet
flange and crankcase water inlet adapter capscrews.
NOTE: The left bank water pump inlet elbow has an
indentation in the back to accommodate the left bank
crankcase water inlet elbow (see Figure 5.25-25).
5.25 -- 26
INDENTATION (IN REAR)
Figure 5.25-25. Water Pump Inlet Elbow -- Left Bank
CRANKCASE WATER INLET ELBOWS
INSTALLATION -- RIGHT BANK
1. Position O-ring flange (diamond shaped) on each
end of right bank crankcase water inlet elbow. Be sure
inside counterbore of both flanges faces outward toward
ends of elbow (see Figure 5.25-24).
2. Place a new O-ring on each end of elbow.
3. With 1/4 in. NPT allen head pipe plug in elbow facing
upward, align holes in crankcase water inlet flange with
those in nearest water pump outlet port. Finger tighten
fasteners (two capscrews 1/2 in. x 2-1/4 in. with flat
washers, lock washers and hex nuts).
4. Install fasteners in crankcase water inlet flange on
other end of water inlet elbow (two capscrews 1/2 in. x
2-1/4 in. with washers and lock washers). Slide crank-
case water inlet flange (no counterbore, both sides flat)
down capscrews until it contacts crankcase water inlet
flange. Position a new gasket on ends of crankcase
water inlet flange capscrews. Finger tighten assembly to
right bank crankcase water header.
5. Alternately wrench tighten four crankcase water inlet
flange capscrews.
WATER PUMP INLET ELBOWS AND
WATER HEADER
WATER PUMP INLET ELBOWS AND WATER
HEADER REMOVAL
The water header weighs approximately 56 lb.
(25 kg). Use a suitable lifting device and exercise
caution during removal or installation to avoid
severe personal injury or death.
FORM 6296 First Edition
 COOLING SYSTEM

1. Attach suitable lifting device to water header (see

Figure 5.25-26).

SEAL/RETAINER

WATER INLET
ELBOWS

Figure 5.25-28. Water Pump Inlet Elbows

OUTLET CLAMP WATER WATER PUMP INLET ELBOWS AND WATER

PIPE BOLT HEADER HEADER INSTALLATION

Figure 5.25-26. Water Header Assembly -- Front Left
2. Remove four nuts and disconnect two halves of seal
retainer connecting water pump elbows to water header
assembly.
1. Verify pipe ends of water pump inlet elbows and
water header outlet pipes are clean and free of dirt and
oil. Verify surfaces where rubber seals contact pipe are
gouges, grooves, burrs, nicks or dents. Surface
imperfections will adversely affect sealing performance.

3. Using a suitable lifting device, remove water header
from water pump inlet elbows.
4. Remove coupling sleeve and two seals from water
pump inlet elbows (see Figure 5.25-27). Discard seals.
2. Position seal retainer onto water pump inlet elbows,
concave side faces toward pipe end (see
Figure 5.25-27 and Figure 5.25-29).
CLAMP BOLT

RUBBER
COUPLING SLEEVE SEAL
SEAL
RETAINER

COUPLING
SLEEVE

SEAL Figure 5.25-29. Dresser Coupling

RETAINER SEAL

3. Using a small paintbrush, lubricate seals, pipe ends

Figure 5.25-27. Water Header Assembly Couplings
and sleeve flares with Parker Super O-Lubeä.
5. Remove four capscrews, lock washers water pump 4. With tapered end facing opposite retainer, position a
inlet flange, and flange gasket from each water pump seal on water pump inlet elbow (see Figure 5.25-27).
inlet elbow and remove from water pump (see
Figure 5.25-28).

FORM 6296 First Edition 5.25 -- 27

COOLING SYSTEM
5. Insert unflanged end of water pump inlet elbows into
sleeves on water header outlet pipes. Left bank elbow
has an indentation in back to accommodate crankcase
water inlet elbow (see Figure 5.25-25). Start three
clamp bolts in each coupling.
The water header weighs approximately 56 lb.
(25 kg). Use a suitable lifting device and exercise
caution during removal or installation to avoid
severe personal injury or death.
6. Attach suitable lifting device to water header and
raise water header into position (see Figure 5.25-26).
NOTE: Install the oil cooler supports before installing
the water inlet header (see Figure 5.25-30). See
Section 5.30 Lubrication System for more information.
WATER INLET HEADER
OIL COOLER
SUPPORT BRACKET
Figure 5.25-30. Water Header Installation
7. Position fasteners through square-shaped flange of
water pump inlet elbow (4 capscrews 1/2 in. x 1-1/2 in.
with lock washers) (see Figure 5.25-28). Position new
gasket on capscrews. Thread capscrews into water
pump inlet flange. Tighten in an alternating pattern.
Repeat procedure on other bank.
8. Alternately tighten three clamp bolts on water pump
inlet elbow couplings (see Figure 5.25-27 and
Figure 5.25-29). Tighten clamp bolts to 35 ft-lb
(47 N×m).
5.25 -- 28
LOWER/UPPER BYPASS TUBES AND
WATER BYPASS ELBOWS
LOWER/UPPER BYPASS TUBES AND WATER
BYPASS ELBOWS REMOVAL
1. Remove four capscrews and lock washers and
gasket from upper bypass tube and cluster thermostat
housing (see Figure 5.25-34).
2. Loosen three nuts and remove upper bypass tube
from lower bypass tube (see Figure 5.25-31).
UPPER BYPASS TUBE
DRESSER
COUPLING
LOWER BYPASS TUBE
Figure 5.25-31. Bypass Tubes -- Front Left
3. Remove three nuts and disassemble both sides of
the Dresser coupling (see Figure 5.25-29).
4. Remove two ferryhead capscrews, lock washers,
lower bypass tube and gasket from water bypass elbow
(see Figure 5.25-34).
5. Remove four ferryhead capscrews, lock washers,
gasket and water bypass elbow from water pump (see
Figure 5.25-34).
6. If required, remove square head pipe plug from water
bypass elbow.
7. Perform Steps 1 through 6 for opposite side of
engine.
LOWER/UPPER BYPASS TUBES AND WATER
BYPASS ELBOWS INSTALLATION
1. If removed, apply pipe sealant to threads, and install
square head pipe plug on water bypass elbow.
2. Install water bypass elbow on water pump with
gasket, four ferryhead capscrews, and lock washers
(see Figure 5.25-34).
3. Fasten lower bypass tube to water bypass elbow with
gasket, two ferryhead capscrews and lock washers.
FORM 6296 First Edition
 COOLING SYSTEM

4. Install Dresser couplings between lower and upper 6. Insert upper bypass tube into coupling sleeve (see
bypass tube as follows: Figure 5.25-33).

A. Verify pipe ends are clean and free of dirt and oil.
Verify surfaces where rubber seals contact pipe UPPER BYPASS TUBE
are free of gouges, grooves, burrs, nicks or
dents. Surface imperfections will adversely affect
sealing performance.

B. Measure back on each pipe end one-half of

sleeve length plus 2 in. (50.8 mm) and place a
chalk mark.

C. Slide seal retainer onto lower bypass tube. DRESSER

Concave side faces upward toward pipe end. COUPLING

D. Using a small paintbrush, lubricate seals, pipe LOWER BYPASS TUBE

ends and sleeve flares with Parker Super
O-Lubeä.
Figure 5.25-33. Bypass Tubes -- Front Left
E. With tapered end facing opposite retainer, install
seal onto lower bypass tube. Pipe end must 7. Fasten flange of upper bypass tube to cluster
extend past end of seal a minimum of 1 in. thermostat housing bypass outlet port with two caps-
(25.4 mm). Slide on sleeve until it contacts crews and lock washers.
rubber seal.
8. Alternately tighten three clamp bolts to evenly draw
5. Install second seal retainer and seal on unflanged up seal retainers.
end of upper bypass tube (see Figure 5.25-32).
9. Tighten clamp bolts to 35 ft-lb (47 N×m).

RUBBER
10. Position upper water bypass tube over outlet port
SEAL on cluster thermostat housing.

11. Install upper water bypass tube to cluster thermo-

stat housing with gasket, four capscrews, and lock
washers.

12. Perform Steps 1 through 11 for opposite side of

engine.

SEAL
RETAINER

Figure 5.25-32. Dresser Coupling

FORM 6296 First Edition 5.25 -- 29

COOLING SYSTEM

THERMOSTAT
HOUSING

GASKET

COUPLING

FERRYHEAD
CAPSCREW
UPPER
BYPASS TUBE

LOCK
WASHER

LOWER
BYPASS TUBE

ELBOW
GASKET
GASKET
LOCK WASHER

FERRYHEAD
CAPSCREW
PLUG

Figure 5.25-34. Water Bypass Tube

WATER MANIFOLD
SUPPORT
BRACKET
WATER MANIFOLD REMOVAL
1. Drain coolant from water manifold and cluster
thermostat housing.

2. Remove cluster thermostat housing.

3. Remove breather venturi assembly.

4. Remove thermocouple conduit assembly.

5. Remove four capscrews, lock washer and gasket

from each water outlet elbow (see Figure 5.25-35).
WATER OUTLET
6. Remove two capscrews and lock washers from four ELBOW
water manifold support brackets.
Figure 5.25-35. Exhaust Manifold Flanges -- Rear Left

8. Using suitable lifting device, remove water manifold

The water manifold weighs approximately 102 lb.
(46 kg). Use a suitable lifting device and exercise
caution during removal or installation to avoid
severe personal injury or death.
7. Attach suitable lifting device to water manifold.
from exhaust manifolds.
9. Position water manifold on wooden blocks (to avoid
damage to drain cocks and to keep casting from rocking
on pipe plugs).

5.25 -- 30 FORM 6296 First Edition

 COOLING SYSTEM

10. Loosen twelve flexmaster couplings from water WATER MANIFOLD INSTALLATION
manifold (see Figure 5.25-36).
1. Apply pipe thread sealant to threads of two drain
cocks and reducer bushings. Install drain cocks and
FLANGE FLEXMASTER reducing bushings at bottom of water manifold (front and
COUPLING
rear).

Deposits left on gasket

surfaces will cause
leaks. Verify that the gasket and gasket mating
surfaces are clean and completely free of grease
CAPSCREW
ASSEMBLY and oil. Disregarding this information could result
in product damage and/or personal injury.

BRACKET
2. Install cover plate on manifold with two capscrews,
lock washers and gasket.
WATER OUTLET
ELBOW 3. Disassemble both sides of twelve Flexmaster cou-
plings (see Figure 5.25-38).
Figure 5.25-36. Water Manifold Bracket

11. Remove capscrew assembly and remove support

brackets from exhaust manifold flanges (see
Figure 5.25-36 and Figure 5.25-37). CLAMP SEAL
BOLT RETAINER
CAPSCREW

BELLEVILLE
WELDED WASHER
FLANGE COUPLING
SLEEVE

RUBBER
SEAL

CLAMP

BELLEVILLE
SUPPORT WASHER Figure 5.25-38. Flexmaster Coupling
BRACKET

FLEX LOC NUT
Figure 5.25-37. Front Water Manifold Bracket Mount
12. Remove two capscrews, lock washers, cover plate
and gasket from water manifold (see Figure 5.25-39).
4. With concave side facing outward toward pipe end,
position a seal retainer on water inlet pipes.
5. Position seals in hollowed portion of each retainer.
Slide on coupling sleeves.

13. If required, remove two drain cocks and reducing 6. Wrap open clamps around seal retainers and flared
bushings from bottom of water manifold. end of each sleeve, finger tighten clamp bolt hex nuts.

14. If required, note location and remove seven square

head pipe plugs from water manifold.

FORM 6296 First Edition 5.25 -- 31

COOLING SYSTEM

LOCK WASHER
PLUG

CAPSCREW

COVER
PLATE
WATER
GASKET MANIFOLD

REDUCING
BUSHING

DRAIN COCK

PLUG

PLUG

PLUG

REDUCING
BUSHING

DRAIN COCK

Figure 5.25-39. Water Manifold

7. Verify pipes of each water outlet elbow and water

inlet pipes (see Figure 5.25-40 and Figure 5.25-41) are
clean and completely free of dirt and oil. Check surfaces
where coupling seal contacts elbow outlet pipe and
water inlet pipes to verify no gouges, burrs, nicks or
dents. Surface imperfections will adversely affect seal-
ing performance.
8. With concave side facing toward pipe ends, slide
seal retainers on water outlet elbows.
9. Position seals in hollowed portion of each retainer.
10. Slide pipe of each water outlet elbow into free end of
Flexmaster coupling sleeves.
11. Wrap an open clamp around each seal retainer and
flared end of sleeve. Leave clamp bolt hex nuts loose
THERMOSTAT WATER INLET
until water manifold is positioned on engine. HOUSING PIPE

Figure 5.25-40. Water Manifold -- Front

5.25 -- 32 FORM 6296 First Edition

 COOLING SYSTEM

ELBOW OUTLET CAPSCREW

PIPE ASSEMBLY

WELDED
FLANGE

SUPPORT
BRACKET

Figure 5.25-43. Front Water Manifold Bracket

CAPSCREW
Figure 5.25-41. Water Outlet Elbow
BELLEVILLE
WELDED WASHER
12. Position four capscrews and lock washers on each FLANGE
water outlet elbow (see Figure 5.25-42).

WATER MANIFOLD FLEXMASTER

COUPLING

BELLEVILLE
SUPPORT WASHER
BRACKET

FLEX LOC NUT

Figure 5.25-44. Front Water Manifold Bracket Mount

FLANGE FLEXMASTER
COUPLING

WATER OUTLET WATER

ELBOW OUTLET
ELBOW

Figure 5.25-42. Water Manifold Connections

13. Secure welded flange onto support bracket located

at front of water manifold with capscrew, two belleville
washers and flex loc nut. Belleville washers are placed
on top of welded flange and bottom support bracket (see
Figure 5.25-43 and Figure 5.25-44).

14. Install right and left bank support brackets to side BRACKET
flanges welded at rear of water manifold (see
Figure 5.25-45) with capscrew, two washers, lock Figure 5.25-45. Water Manifold Bracket -- Rear Left
washer and hex nut. Be sure to install second flat
washer between welded flange and support bracket.

FORM 6296 First Edition 5.25 -- 33

COOLING SYSTEM
The water manifold weighs approximately 102 lb.
(46 kg). Use a suitable lifting device and exercise
caution during removal or installation to avoid
severe personal injury or death.
15. Attach suitable lifting device to water manifold.
16. Position gaskets on water outlet openings on
exhaust manifolds.
17. Position water manifold on exhaust manifolds.
Loosely install support brackets to exhaust manifolds
with two capscrews and lock washers per support
bracket.
18. Tighten four capscrews and lock washers on each
of twelve water outlet elbows.
19. Tighten clamp bolts and nuts on twelve flexmaster
couplings.
20. Tighten support brackets to exhaust manifolds with
two capscrews and lock washers per support bracket.
CLUSTER THERMOSTAT HOUSING AND
THERMOSTATIC VALVES
CLUSTER THERMOSTAT HOUSING AND
THERMOSTATIC VALVES REMOVAL
NOTE: Drain the jacket water system until the level of
the coolant drops below the cluster thermostat housing.
1. Remove the ferrule nut to detach the air venting tube
from the bottom of the cluster thermostat housing (male
connector tube fitting) (see Figure 5.25-46).
WATER OUTLET CLUSTER
CONNECTION THERMOSTAT UPPER BYPASS
HOUSING TUBE (LB)
UPPER BYPASS
TUBE (RB)
AIR VENT
TUBE
WATER MANIFOLD
(FRONT)
Figure 5.25-46. 12 Cylinder Cluster Thermostat
Housing
2. Remove the two brass air bleed petcocks at the top of
the cluster thermostat housing.
5.25 -- 34
3. Remove the cooling water outlet flange adapter from
the cluster thermostat housing (4 capscrews, 1/2 in. x
1-1/2 in., with lock washers).
4. Remove the upper bypass tube flanges from the
cluster thermostat housing bypass outlet ports (4 caps-
crews per flange, 1/2 in. x 1-1/4 in., with lock washers).
The cluster thermostat housing weighs approxi-
mately 70 lb. (32 kg). To avoid serious personal
injury, lift only with a properly rated lifting device
and rigging.
5. Remove the cluster thermostat housing from the
front end of the water manifold (10 capscrews, 3/8 in. x
1-1/8 in., with lock washers).
6. Set the thermostat housing on a suitable workbench
with the expansion elements of the thermostatic valves
facing upward.
7. Pull out the six thermostatic valves. Take note of the
nominal temperature ratings of the lead and following
thermostats. The lead thermostat is located in the right
front port of the cluster thermostat housing.The temper-
ature rating is stamped at the bottom of the expansion
element (bulb). The part number is stamped on the valve
sleeve.
8. Remove lip seals. Use a rolling head pry bar for best
results.
CLUSTER THERMOSTAT HOUSING AND
THERMOSTATIC VALVES CLEANING AND
INSPECTION
Use of caustic solutions should be restricted to a
well ventilated area. Contact with skin, clothing and
eyes could result in severe personal injury or death.
Compressed air can pierce the skin and cause
severe personal injury or death. Never use your
hand to check for leaks or to determine air flow
rates. Wear safety glasses to shield your eyes from
flying dirt and debris.
1. Submerse thermostat housing in caustic hot tank to
remove all paint, dirt, grease and oil. Follow up with a
thorough hot rinse. Dry parts with moisture free com-
pressed air.
FORM 6296 First Edition
 COOLING SYSTEM

2. Verify valves are in fully closed position. If any valve D. Remove valve and observe its closing action.
is frozen open or if there is any obvious distortion, Valve should seal evenly and tightly (see
discard it. If valve appears in good condition, test as Figure 5.25-48).
follows:

A. Suspend thermostatic valve in a container of

water. Do not let thermostat rest against sides or
bottom.

Do not boil the thermo-

static valve. Excessive
temperatures will force the valve to exceed its
normal operating travel and may result in perma-
nent product damage and/or personal injury.

FULLY CLOSED FULLY OPEN

B. Gradually heat water while stirring with a quality
glass laboratory thermometer (see Figure 5.25-48. Thermostat Open And Closed
Figure 5.25-47). Observe action of valve.
E. If thermostatic valve is defective, replace it.

3. Take note of temperature ratings and part numbers

stamped on old thermostatic valves. Temperature rating
is stamped at bottom of expansion element (bulb) (see
Figure 5.25-49 and Figure 5.25-50). Waukesha part
number is stamped on valve sleeve.

WEIR
NOTCH
DETAIL

VENDOR
IDENTIFICATION
Figure 5.25-47. Thermostat Testing

C. Valve should begin to open at “Start To Open”

temperature rating listed in Table 5.25-9 and be P/N
completely open at “Full Open” temperature,
± 5° F (± 2.8° C).
Figure 5.25-49. Thermostats -- P/N 208627 Series

Table 5.25-9. Jacket Water Thermostats -- P/N 211887 Series

P/N TYPE QTY. NOMINAL TEMP. START TO OPEN FULL OPEN

°F (°C) °F (°C) °F (°C)
211887A Lead 1 165 (74) 161 -- 168 (72 -- 76) 184 (84)
211887B Follow 5 170 (77) 166 -- 173 (74 -- 78) 189 (87)

FORM 6296 First Edition 5.25 -- 35

COOLING SYSTEM
TOP VIEW
COLOR CODE
RUBBER
WAUKESHA SEAT
PART NUMBER
SIDE VIEW
VENDOR IDENTIFICATION
AND NOMINAL
TEMPERATURE RATING
Figure 5.25-50. Thermostats -- P/N 208660 Series
The colored dot centered at the top of the thermostatic
valve is also used to readily identify its temperature
rating. With the exception of the lead thermostat, all
valves should have the same color code.
NOTE: If the old thermostatic valves are not available,
check the engine specification pack to be sure that the
new valves are correct.
P/N 208627 series thermostats use a weir notched seal
design for a gradual transition of coolant flow. This
thermostat series does not require a “lead thermostat”
because of the weir notch seal design. All thermostats
will be of the same part number. The P/N 208627C
thermostat is used in landfill gas and high temperature
applications.
4. Place a new O-ring in thermostat housing outlet port
flange. Lubricate O-ring with clean glycol.
AUXILIARY WATER TEMPERATURE CONTROL
VALVE INSTALLATION
The thermostat housing assembly weighs approxi-
mately 50 lb. (23 kg). Use a suitable lifting device
and exercise caution during removal or installation
to avoid severe personal injury or death.
1. Install lifting strap to support thermostat housing
assembly. Move assembly to location of oil pan pipe
support bracket.
5.25 -- 36
2. Fasten cooling water outlet port flange (stamped A)
to thermostat housing with 4 capscrews and washers.
Tighten capscrews evenly and securely.
3. Install U-bolt securing inlet port pipe nipple to oil pan
support bracket with washers, lock washers and hex
nuts.
4. Remove lifting device.
5. Fasten cooling water inlet flange connection (from
heat transfer device) to inlet port C of thermostat
housing.
6. Fasten cooling water inlet flange connection (from
the oil cooler) to bypass inlet port B of thermostat
housing.
7. Refill auxiliary cooling water system and bleed
trapped air.
CLUSTER THERMOSTAT
HOUSING/THERMOSTATIC VALVES
INSTALLATION
Remove any deposits
on gasket surfaces. De-
posits left on gasket surfaces may cause leaks.
Exercise care to keep
the gasket debris out of
the cluster thermostat housing. Gasket debris left in
the thermostat housing may cause damage to
equipment.
1. Scrape old gasket material from bottom of cluster
thermostat housing, if necessary. Scrape bypass tube
and cooling water outlet flanges of cluster thermostat
housing.
2. Scrape gasket mating surfaces at top of the water
manifold, two upper bypass tubes flanges and cooling
water outlet flange, if necessary.
3. Verify all gaskets and gasket mating surfaces are
clean and completely free of grease and oil.
4. With open side facing inward, press fit new lip seals
(P/N 153610) into cluster thermostat housing (see
Figure 5.25-51).
THIS SIDE INTO
THERMOSTAT HOUSING
Figure 5.25-51. Thermostat Seal
FORM 6296 First Edition
 COOLING SYSTEM

5. For best results, use a pipe or tube of equal diameter.

Verify each seal is square in bore and completely seated
around its circumference) (see Figure 5.25-52). The cluster thermostat housing weighs approxi-
mately 70 lb. (32 kg). To avoid serious personal
RIGHT BANK BYPASS
OUTLET PORT injury, lift only with a properly rated lifting device
SEAL LIP and rigging.
TO THE LEAD
INSIDE THERMOSTAT
WATER 12. With water outlet flange facing front of engine,
OUTLET PORT install cluster thermostat housing at front of water
manifold (10 capscrews, 3/8 in. x 1-1/8 in., with lock
washers). Tighten capscrews in an alternating pattern.

13. Apply 3M Scotch Gripä 847 Rubber And Gasket

Adhesive to two bypass outlet port flanges of cluster
thermostat housing. Position new gaskets
(P/N 208943) on contact cement.

14. Fasten upper bypass tubes to cluster thermostat

housing bypass outlet ports (4 capscrews per flange,
1/2 in. x 1-1/4 in., with lock washers).
THERMOSTATIC
VALVES 15. Slide fasteners through holes in cluster thermostat
housing water outlet flange adapter (4 capscrews,
1/2 in. x 1-1/2 in., with lock washers). Hang a new
gasket (P/N 208949B) on the capscrews.
LEFT BANK BYPASS
OUTLET PORT
16. Position flange adapter over outlet port. Tighten
Figure 5.25-52. Thermostat Housing (Bottom View) capscrews.

6. Using a small paintbrush, lubricate lip seals with
clean ethylene glycol (antifreeze).
7. Take note of temperature ratings and part numbers
stamped on old thermostatic valves.
8. With bulb of expansion element facing outward,
place lead thermostat in right front port of cluster
thermostat housing (see Figure 5.25-52). Lead thermo-
stat has a nominal temperature rating lower than others,
normally 5° F (2.8° C).
9. Install thermostatic valves in five remaining ports.
17. Apply Perma Lokâ Heavy Duty Pipe Sealant with
Teflon to threads of two air bleed petcocks. Install
petcocks in holes above bypass outlet ports on each
side of cluster thermostat housing.
18. Finger tighten ferrule nut to attach water header air
venting tube to bottom of cluster thermostat housing
(male connector tube fitting).
19. Scribe or ink ferrule nut and wrench tighten 1-1/4
turns. After several remakes, it may be necessary to
advance ferrule nut 1/3 of a hex flat to obtain a leak-tight
seal.

10. Apply 3M Scotch Gripä 847 Rubber And Gasket 20. Refill jacket water system and bleed trapped air.
Adhesive to top of thermostat housing at front of water
manifold.

11. Place new gasket (P/N 208939) on contact cement.

Allow gasket adhesive to cure. See manufacturer’s
recommendations.

FORM 6296 First Edition 5.25 -- 37

COOLING SYSTEM
IDLER PULLEY BRACKET DISASSEMBLY
1. Remove grease fitting from idler pulley bracket.
2. Loosen two nylok socket head set screws in idler
pulley (see Figure 5.25-53).
SET SCREWS
Figure 5.25-53. Idler Pulley
3. Remove pulley from shaft (see Figure 5.25-54).
Figure 5.25-54. Idler Pulley Shaft Removal
Always wear proper eye protection when removing
tack welds. Failure to wear eye protection could
result in severe personal injury or death.
5.25 -- 38
4. Break three tack welds securing cover to back of idler
pulley bracket (see Figure 5.25-55).
Figure 5.25-55. Cover Removal
Always wear proper eye protection when removing
retaining (snap) rings. Verify the correct retaining
ring pliers is used and the pliers is in good
condition. If the retaining ring slips off the pliers
when being installed or removed, it can be propelled
with enough force to cause a serious eye injury.
Disregarding this information could cause serious
personal injury.
5. Remove large retaining ring from bore at back of idler
pulley bracket.
6. Remove ball bearing/shaft assembly from idler
pulley bracket (see Figure 5.25-56).
Figure 5.25-56. Remove Ball Bearing/Shaft Assembly
FORM 6296 First Edition

7. Remove grease seal from bore of bracket (see
Figure 5.25-57). Discard seal.
Figure 5.25-57. Grease Seal Removal
8. Remove small retaining ring from idler pulley shaft.
9. Center ball bearing support under ram of arbor
press. Center ball bearing on bearing support. Center
driver on idler pulley shaft.
10. Lower ram until it makes contact with driver.
11. Lower ram until idler pulley shaft drops out of ball
bearing (see Figure 5.25-58). Release ram pressure.
Discard ball bearing.
SHAFT
PRESSURE
OUT
BALL
BEARING
Figure 5.25-58. Idler Pulley Assembly
FORM 6296 First Edition
COOLING SYSTEM
IDLER PULLEY BRACKET CLEANING AND
INSPECTION
Cleaning solvents may be toxic or flammable. Keep
away from heat or flame. Read the manufacturer’s
warnings on the container. Always use approved
cleaning solvents in a well ventilated area. Avoid
contact with skin. Disregarding this information
could result in severe personal injury or death.
Compressed air can pierce the skin and could result
in severe personal injury or death. Never use your
hand to check for leaks or to determine air flow
rates. Wear safety glasses to shield your eyes from
flying dirt and debris.
1. Thoroughly clean internal parts of assembly with
solvent to remove all grease and dirt. Hot tank idler
pulley and bracket. Blow dry parts with moisture free
compressed air.
2. Inspect two retaining rings for damage or distortion.
Replace rings if necessary.
3. Inspect pulley sheave groove sidewalls for exces-
sive wear. Replace pulley if groove walls are dished out
or if sheaves are chipped or bent.
4. Inspect idler pulley shaft for damage and wear. Shaft
must be straight and free of nicks and burrs. Inspect ball
bearing seating surface for scoring, scuffing and exces-
sive wear. Replace shaft if necessary.
IDLER PULLEY BRACKET ASSEMBLY
1. Center ball bearing support under ram of arbor
press.
To avoid damage to the
ball bearing, be sure that
the inner race is properly supported. Disregarding
this information could result in product damage
and/or personal injury.
2. Center a new ball bearing on bearing support.
3. Position idler pulley shaft upright in ball bearing ID so
retaining ring groove is at bottom (see Figure 5.25-59).
5.25 -- 39
COOLING SYSTEM

SHAFT Always wear safety glasses when removing retain-

SHOULDER ing (snap) rings. Verify the correct retaining ring
pliers is used and the pliers is in good condition. If
the retaining ring slips off the pliers when being
installed or removed, it can be propelled with
enough force to cause a serious eye injury. Disre-
garding this information could cause serious per-
sonal injury.

9. Install small retaining ring in groove on idler pulley

shaft. Rotate ring to verify it is fully seated.

RETAINING RING 10. Pack Lithoplexâ Grease No. 2 (Multipurpose Lithi-

GROOVE
Figure 5.25-59. Idler Pulley Shaft
4. Center driver over idler pulley shaft. Verify shaft is not
cocked in bearing ID.
5. Lower ram until it makes contact with driver.
To avoid damage, use
only enough ram force to
seat the ball bearing. Disregarding this information
could result in product damage and/or personal
injury.
6. Press idler pulley shaft into ball bearing until shoulder
makes solid contact with inner race (see
Figure 5.25-60).
um Complex Formula Containing Molybdenum Disul-
fide) between inner and outer races of ball bearing.
11. With pulley side facing press table, center bore of
idler pulley bracket under ram.
12. With retaining ring at top, position ball bearing/shaft
assembly upright in bracket bore. Center bearing driver
over outer race of ball bearing.
13. Verify ball bearing/shaft assembly is aligned in
bracket bore. Lower ram until it makes contact with
bearing driver.
14. Press ball bearing/shaft assembly into bore. Exert
uniform pressure against outer race of bearing until it
makes solid contact with inside counterbore.
15. Install large retaining ring in bracket bore. Rotate
the ring to verify that it is fully seated in the groove.

16. Lightly lubricate a new grease seal ID with a lithium

complex type grease.
BALL
BEARING
17. With pulley side facing upward on press table,
center bore of idler pulley bracket under ram.

18. With lipped side facing inward towards ball bearing,

position grease seal over bracket bore.

19. Center driver over grease seal. Lower ram until it

makes contact with driver.

20. Press grease seal into bracket bore until closed

side of carrier is flush with top of casting.
RETAINING RING
GROOVE 21. Press pulley on idler pulley shaft until it makes solid
Figure 5.25-60. Idler Pulley Ball Bearing/Shaft contact with shaft shoulder.
Assembly
22. Install two new nylok socket head set screws in idler
pulley. Tighten set screws to secure pulley to idler pulley
7. Release ram and remove driver.
shaft.
8. Verify ball bearing rotates freely on idler pulley shaft
without any drag.

5.25 -- 40 FORM 6296 First Edition


23. Position rear cover in back of idler pulley bracket.
Rotate cover so that 1/8 in. vent hole is within 1/2 in. of
centerline between idler pulley shaft and pivot bolt hole
(see Figure 5.25-61).
PIVOT BOLT IDLER PULLEY
HOLE BRACKET
CENTERLINE
REAR COVER
VENT HOLE
IDLER PULLEY
SHAFT
GREASE PULLEY
FITTING
Figure 5.25-61. Idler Pulley Bracket Vent Hole Location
Ball bearing grease
pressure may dislocate
the rear cover if it is not properly secured to the idler
pulley bracket. Disregarding this information could
result in product damage and/or personal injury.
Always wear protective eye shields when welding,
cutting or watching a welding operation. Protective
clothing and face shields must be worn. Never weld
or cut near combustible materials. Disregarding
this information could result in severe personal
injury or death.
24. Using a mild steel rod, place three tack welds (of
equal distance) where edge of cover contacts back of
bracket.
25. Lightly tap on welds to check for cracks. Use crocus
cloth to remove any weld spatter.
26. Install grease fitting in idler pulley bracket.
27. Using Lithoplexâ Grease No. 2 (Multipurpose Lithi-
um Complex Formula Containing Molybdenum Disul-
fide), slowly fill bearing cavity until grease extrudes from
vent hole in rear cover.
FORM 6296 First Edition
COOLING SYSTEM
IDLER PULLEY BRACKET INSTALLATION
1. Install pivot bolt and lock washer through hole in idler
pulley bracket. Position idler pulley bracket assembly
against face of water pump and install pivot bolt in
threaded boss above right bank water pump outlet port
(see Figure 5.25-62).
JACKET IDLER PULLEY
WATER PUMP BRACKET
PIVOT
BOLT
SLOTTED
LOCK BOLT
Figure 5.25-62. Idler Pulley Bracket
2. Install lock bolt, lock washer and washer through slot
in idler pulley bracket. Install bolt in threaded boss below
right bank water pump outlet port (see Figure 5.25-62).
3. Position V-belts on idler pulley.
4. Refer to “Jacket Water Pump Drive Belt Tension
Adjustment” in this section and adjust water pump drive
belts.
JACKET WATER PUMP
JACKET WATER PUMP REMOVAL
1. Refer to “Crankcase Water Inlet Elbows Removal,”
“Water Pump Inlet Elbows And Water Header Removal,”
and “Lower/Upper Bypass Tubes And Water Bypass
Elbows Removal” in this section and remove these
components.
2. Remove capscrew, lock washer, washer, bracket
and spacer from upper gear cover flange (see
Figure 5.25-63).
3. Remove nut, capscrew, lock washer and bracket
from water drain pipe.
4. Remove pipe plugs from left and right bank water
bypass elbows.
5.25 -- 41
COOLING SYSTEM

6. Remove ten nuts and lock washers from water pump

UPPER GEAR PIPE and carefully remove pump using a suitable lifting
COVER FLANGE BRACKET
device.

7. Remove water pump cover gasket and water pump

cover from gear cover.

8. Remove water pump cover to gear cover gasket from

gear cover (see Figure 5.25-65).

WATER PUMP
COVER
SPACER

WATER DRAIN
PETCOCK

Figure 5.25-63. Water Drain Petcock -- Front Right

The water pump weighs approximately 105 lb.
(48 kg). Use a suitable lifting device and exercise
caution during removal or installation to avoid
severe personal injury or death.
5. Install an eye bolt, 5/16 in. threads, in threaded hole
at base of upper center boss (see Figure 5.25-64).
Attach a suitable lifting device to eye bolt.
WATER PUMP
COVER GASKET
Figure 5.25-65. Water Pump Cover And Cover Gasket
9. Remove drain cock, pipe coupling, two pipe nipples
and elbow from bottom of water pump.
JACKET WATER PUMP DISASSEMBLY

THREADED HOLE
(FOR EYE BOLT)
The water pump weighs approximately 105 lb.
(48 kg). Use a suitable lifting device and exercise
caution during removal or installation to avoid
severe personal injury or death.

1. Remove water drain petcock from pipe nipple

assembly. Remove air bleed petcock from water pump
housing.

2. Loosen nut on pulley end of water pump shaft (see

Figure 5.25-79). If necessary, thread two hardened
capscrews into impeller puller holes (3/8 in.--16 threads)
and use a bar to keep shaft from turning.

CENTER BOSS
3. Loosen thin nut on impeller side. Use pulley puller
(UPPER) holes (3/8 in.--16 threads) to hold shaft if necessary.

4. Remove thin nut and flat washer on both pulley and

Figure 5.25-64. Lifting The Jacket Water Pump
impeller ends of shaft.

5. Turn pump over, impeller side up.

6. Remove impeller from shaft. Two threaded holes in

impeller (3/8 in.--16 threads) may be used with a T-type
gear puller and air impact wrench.

5.25 -- 42 FORM 6296 First Edition


Always wear safety glasses when removing
springs. If the spring slips when being installed or
removed, it can be propelled with enough force to
cause a serious eye injury. Disregarding this infor-
mation could result in severe personal injury.
7. Remove spring from shaft. Remove brass retainer/
carbon seal assembly. Use a small puller tool if
necessary. Discard seal assembly.
8. Remove ceramic seal and rubber seat from counter-
bore. Discard seal and seat. Turn water pump over,
pulley side up.
9. Remove pulley from water pump shaft. Two threaded
holes in pulley (3/8 in.--16 threads) may be used with a
T-type gear puller and air impact wrench, if necessary.
10. Remove outer grease seal from water pump
housing. Discard seal.
Always wear safety glasses when removing retain-
ing (snap) rings. Verify the correct retaining ring
pliers is used and the pliers is in good condition. If
the retaining ring slips off the pliers when being
installed or removed, it can be propelled with
enough force to cause a serious eye injury. Disre-
garding this information could cause serious per-
sonal injury.
11. Remove retaining ring from groove in water pump
housing.
12. Place pump in an arbor press, impeller side up.
Press on impeller side of shaft to remove bearing and
shaft assembly.
13. Remove inner grease seal from water pump
housing. Discard seal.
JACKET WATER PUMP CLEANING AND
INSPECTION
1. Inspect pulley sheave groove sidewalls for exces-
sive wear. Replace pulley if groove walls are dished out
or if sheaves are bent, chipped or pitted.
Always wear insulated gloves when handling
heated parts. Use of bare hands will result in burns.
Disregarding this information could result in severe
personal injury or death.
FORM 6296 First Edition
COOLING SYSTEM
2. Remove pulley hub wear sleeve. Briefly heat sleeve
around its circumference using a propane torch. Expan-
sion of sleeve will cause it to slip off pulley hub.
3. Inspect water pump housing for cracks or corrosion.
Look for signs of cavitation where impeller vanes pass
volute just inside water pump housing. Replace housing
if necessary.
Compressed air can pierce the skin and cause
severe personal injury or death. Never use your
hand to check for leaks or to determine air flow
rates. Wear safety glasses to shield your eyes from
flying dirt and debris.
4. Hot tank water pump housing and pulley to remove
old gasket material, grease and dirt. Blow dry parts with
moisture free compressed air.
JACKET WATER PUMP ASSEMBLY
Assemble the jacket water pump using the appropriate
rebuild kit.
NOTE: Installation of the new jacket water pump
assembly requires use of the new water pump cover
plate (P/N 200161B). The previous cover plate
(P/N 200161) cannot be used with the current water
pumps (double row ball bearings).
1. Position larger diameter ball bearing down pulley
end of water pump shaft (see Figure 5.25-66).
PULLEY END IMPELLER END
Figure 5.25-66. Jacket Water Pump Shaft
2. Place bearing sleeve base (see Figure 5.25-67 --
Tool #1) on deck of arbor press. With larger diameter ball
bearing positioned over pulley end of water pump shaft,
insert pulley end of shaft into sleeve base until inner race
of larger diameter ball bearing contacts top of sleeve.
5.25 -- 43
COOLING SYSTEM

BALL
BEARING
DRIVER

1 2 3

PRESS ON
INNER RACE
5 OF BEARING

4 6

8
9
10
7

1. BEARING SLEEVE BASE

2. BEARING DRIVER BEARING
3. GREASE PACKING FIXTURE SLEEVE
4. INNER GREASE SEAL DRIVER BASE TOOL
5. SEAL PROTECTOR SLEEVE PRESS ON
6. BEARING SHAFT DRIVER INNER RACE
7. OUTER GREASE SEAL DRIVER OF BEARING
8. PULLEY WEAR SLEEVE DRIVER
9. CERAMIC SEAL DRIVER
10. BRASS RETAINER/CARBON SEAL DRIVER

Figure 5.25-67. Service ToolKit P/N 474013 Figure 5.25-68. Press Bearings Onto Shaft

3. Position smaller diameter ball bearing over impeller 8. Remove ball bearing shaft assembly from bearing
end of shaft. Slide bearing driver (see Figure 5.25-67 -- sleeve base tool. Verify bearings are completely seated
Tool #2) over shaft until it contacts inner race of smaller against shaft shoulders. Verify bearings rotate freely
diameter ball bearing (see Figure 5.25-68). without drag.

4. Center bearing sleeve base tool under ram. Verify 9. Position a new O-ring down pulley end of water pump
water pump shaft is completely vertical and ball shaft until it makes contact with inner race of larger
bearings are positioned correctly on shaft. diameter ball bearing.

5. Lower ram until it makes contact with bearing driver.
Use only enough ram
force to install the bear-
ings, 150 lb. (667 N) minimum, 1500 lb. (6672 N)
maximum. To avoid use of excessive force, fit the
ram with the proper size load cell. Damage to the ball
bearings will result in premature water pump failure.
Disregarding this information could result in prod-
uct damage and/or personal injury.
6. Lower ram until both ball bearings are seated solidly
against shoulders on water pump shaft.
7. Release ram and remove bearing driver.
NOTE: The impellor and pulley are held in place by the
clamp load resulting from torquing the shaft nuts on
each end.
10. If using previous P/N 200456B shaft, position a new
Woodruff key in slot on pulley end of water pump shaft.
Using a brass hammer or punch, tap key to properly seat
it in keyway. Verify key is level.
11. Clamp arm of grease packing fixture (see
Figure 5.25-67 -- Tool #3) in a vise with open end of cup
facing upward.
12. Insert impeller end of bearing shaft assembly into
packing fixture (see Figure 5.25-69).

5.25 -- 44 FORM 6296 First Edition


OUTSIDE
ROW
FILL SPACE
WITH GREASE GREASE
FITTING
OUTSIDE
ROW
Figure 5.25-69. Pack Water Pump Bearings
Do not operate the valve of the pneumatic greaser
unless connected to the grease fitting on the
packing fixture. The pneumatic greaser produces a
high velocity discharge that can cause severe
personal injury. Disregarding this information could
result in severe personal injury or death.
NOTE: A pneumatic greaser is recommended to en-
sure a fully packed cavity and to protect against grease
contamination. To fill the cavity with a hand-held grease
gun, as many as 130 strokes may be necessary. If a
pneumatic grease gun is not available, hand pack the
cavity before placing the bearing shaft assembly in the
packing fixture. Use the grease gun to complete the
task.
13. Using grease fitting on side of packing fixture, apply
a pressurized lithium complex type grease (see “Grease
Recommendations” in this section). Hold top of water
pump shaft to keep assembly stationary and fill cavity
between two bearings until grease extrudes from
outside row of upper ball bearing (pulley side). Verify
grease also extrudes through outer row of lower ball
bearing (impeller side).
14. Remove grease supply line from packing fixture
grease fitting.
FORM 6296 First Edition
COOLING SYSTEM
15. Lift out bearing shaft assembly to verify grease fills
entire space between ball bearings (from shaft to
bearing OD).
16. Remove any excess grease from impeller and
pulley ends of shaft (external to grease cavity). Remove
excess grease extruding from outside row of each ball
bearing. Wipe excess grease from outside diameter of
each ball bearing.
17. Insert bearing assembly back into packer until it is
ready to be installed in water pump housing. Lay a clean
shop cloth over top of packing fixture to keep out dust
and dirt.
18. Place water pump casting on press table with pulley
side up.
19. Thoroughly wipe water pump housing seal bore
with a clean cloth. Use compressed air to blow out all
dust and debris.
20. Thoroughly wipe new inner grease seal with a clean
cloth. Verify seal lip spring is in place. Carefully check
seal for defects. Replace if damaged.
21. Fit inner grease seal (2-1/16 in. diameter) onto seal
driver (see Figure 5.25-67 -- Tool #4) with open (lipped)
side of carrier (see Figure 5.25-70) facing collar of tool.
Lower inner grease seal into pulley bearing bore (see
Figure 5.25-71).
CARRIER
INNER
GREASE SEAL
SEAL LIP
GARTER SPRING
(BENEATH LIP)
OUTER GREASE SEAL
Figure 5.25-70. Open (Lipped) Side Of Carriers
5.25 -- 45
COOLING SYSTEM

INNER GREASE Figure 5.25-72). Position of shaft is critical for a straight

SEAL DRIVER press. Guide end of shaft so as not to damage or disturb
inner grease seal or lip garter spring.

BEARING SHAFT
DRIVER
INNER
GREASE SEAL
WOODRUFF
KEY

SHAFT AND
O-RING BEARING
ASSEMBLY

COUNTERBORE

COUNTERBORE

Figure 5.25-71. Install Inner Grease Seal

22. Center inner grease seal driver under ram.

23. Lower ram until it makes contact with driver.

Minimal ram force is re-

quired to install the inner
grease seal. The object of the ram is to ensure a
straight press. To avoid product damage and/or PLASTIC SEAL PROTECTOR SLEEVE
personal injury, use only enough ram force to
Figure 5.25-72. Install Shaft And Bearing Assembly
complete the task.
29. Position bearing shaft driver (see Figure 5.25-67 --
24. Lower ram until shoulder of driver makes solid
Tool #6) over top of water pump shaft (pulley side)
contact with inside counterbore.
aligning notch on inside diameter of tool with installed
25. Release ram and remove inner grease seal driver. Woodruff key.

30. Lower ram until it makes contact with bearing shaft

The shoulders and
threads on the water
pump shaft can damage the sealing surface of the
inner grease seal if the protector sleeve is not used.
Disregarding this information could result in prod-
uct damage and/or personal injury.
26. Slide black plastic seal protector sleeve (see
Figure 5.25-67 -- Tool #5) over threads on impeller end
of shaft until it seats against shaft shoulder.
27. Lightly lubricate seal protector sleeve with a lithium
complex type grease. Lightly lubricate exposed portion
of water pump shaft (from protective sleeve to ball
bearing).
28. Carefully insert impeller end of bearing shaft
assembly into water pump housing (see
driver.
To avoid damage to the
smaller diameter ball
bearing (impeller side), use only enough ram force
to complete the task. Do not exceed 250 lb. (1112 N).
Damage to the ball bearing will result in premature
water pump failure. Disregarding this information
could result in product damage and/or personal
injury.
31. Lower ram until outer race of larger diameter ball
bearing (pulley side) makes solid contact with inside
counterbore.

5.25 -- 46 FORM 6296 First Edition


NOTE: The outer race of the smaller diameter ball
bearing (impeller side) is not supported during the
assembly procedure. To prevent damage to the ball
bearing, do not exceed a force of 250 lb. (1112 N). If a
greater force is required to press the bearing/shaft
assembly into the water pump housing, then the bearing
bore and/or the OD of the smaller diameter ball bearing
is not within specification. Since an accurate measure-
ment determines whether the parts are properly fitted
and also prevents damage to the inner race of the
smaller diameter ball bearing, fit the ram of the press
with the proper size load cell.
32. Release ram and remove bearing shaft driver.
33. Remove plastic seal protector sleeve from impeller
end of water pump shaft.
Always wear safety glasses when removing retain-
ing rings. Verify the correct retaining ring pliers is
used and it is in good condition. If the retaining ring
slips off the pliers when being installed or removed,
it can be propelled with enough force to cause a
serious eye injury. Disregarding this information
could result in severe personal injury.
34. With beveled edge on OD facing upward, install
retaining ring in groove on pulley side of water pump
housing (see Figure 5.25-73). Verify ring is fully seated
in groove.
OUTER GREASE
SEAL DRIVER
WOODRUFF
KEY
O-RING
OUTER
GREASE
SEAL
RETAINING
RING
Figure 5.25-73. Install Retaining Ring/Outer Grease
Seal
FORM 6296 First Edition
COOLING SYSTEM
35. Thoroughly wipe new outer grease seal with a clean
cloth. Verify seal lip spring is in place. Carefully check
seal for defects. Replace if damaged.
36. Slide outer grease seal (3-1/4 in. diameter) onto
seal driver tool (see Figure 5.25-67 -- Tool #7) with open
(lipped) side of carrier (see Figure 5.25-70) facing
opposite collar on tool. Lower outer grease seal into
water pump housing.
37. Center outer grease seal driver under ram.
38. Lower ram until it makes contact with driver.
Minimal ram force is
required to install the
outer grease seal. The object of the ram is to ensure
a straight press. To avoid product damage and/or
personal injury, use only enough ram force to
complete the task.
39. Lower ram until shoulder of driver makes solid
contact with the edge of the casting (see
Figure 5.25-73).
40. Release ram and remove outer grease seal driver
from water pump housing.
41. Lightly lubricate ID of installed outer grease seal
with a lithium complex type grease. Also apply some
grease around the face of the seal. Wipe off any excess.
42. With concave side up, place water pump pulley on
press table. Thoroughly wipe pulley hub OD with a clean
cloth. Use compressed air to blow out all dust and
debris.
43. With lipped side down (see Figure 5.25-74), posi-
tion a new stainless steel wear sleeve over pulley hub.
Be sure sleeve is square on the hub.
LIP
Figure 5.25-74. Pulley Hub Wear Sleeve
44. Center pulley under ram of arbor press. Center
sleeve driver (see Figure 5.25-67 -- Tool #8) over pulley
hub, so bottom of shroud makes complete contact with
lip of wear sleeve. Verify driver is completely vertical and
wear sleeve is not cocked on hub.
5.25 -- 47
COOLING SYSTEM

45. Lower ram until it makes contact with sleeve driver.
Minimal ram force is re-
quired to seat the wear
sleeve. The object of the ram is to ensure a straight
press. To avoid product damage and/or personal
injury, use only enough ram force to complete the
task.
49. Align keyway in pulley hub with Woodruff key in
water pump shaft. Inserting hub into outer grease seal,
hand push pulley onto shaft. Do not run pulley in using
thin nut.
50. Lubricate threads on pulley end of water pump shaft
with clean engine oil (SAE 30).
51. Install flat washer and finger tighten thin nut.

46. Lower ram until lip of wear sleeve makes solid 52. Turn water pump over to access impeller side of
contact with machined surface at bottom of pulley hub shaft.
OD (see Figure 5.25-75).
53. Obtain a new water pump seal.
WEAR SLEEVE BOTTOMS 54. Remove spring from brass seal retainer (carbon
ON PULLEY HUB
seal half of water pump seal).

55. Carefully check carbon ring (primary seal) for

cracks, nicks or other defects. Replace water pump seal
assembly if damaged.

56. Remove ceramic ring (mating seal) from its rubber

seat (see Figure 5.25-76). Carefully check ceramic
material for cracks or nicks. Inspect rubber seat for tears
or cuts. Replace water pump seal assembly if damaged.

Oily deposits left on the

sealing faces will cause
traces of carbon to adhere to the ceramic seat,
resulting in premature failure of the water pump
seal. Disregarding this information could result in
product damage and/or personal injury.

57. Verify sealing faces of carbon and ceramic seals

Figure 5.25-75. Install Pulley Hub Wear Sleeve
47. Release ram and remove sleeve driver.
48. Lubricate wear sleeve with a lithium complex type
grease. Wipe off any excess.
are free of oily, greasy or waxy deposits. Use a clean
solvent to clean sealing surfaces, if necessary. Wipe
surfaces clean and dry with absorbent paper or a soft
cloth.
58. With flat highly polished surface facing outward,
squarely seat ceramic seal ring in rubber seat. Rear face
of seal can be easily identified by a groove that runs
perpendicular to seal ID.

CERAMIC SEAL SEAL RETAINER

RUBBER SEAT CARBON SEAL SPRING

Figure 5.25-76. Water Pump Seal Assembly

5.25 -- 48 FORM 6296 First Edition


59. Using a 50/50 mix of clean ethylene glycol and
water, lubricate outside diameter of rubber seat. Slide
ring over shaft with ceramic material facing outside.
Move ring down shaft until it contacts casting bore. Use
seal driver (see Figure 5.25-67 -- Tool #9) to hand press
ceramic seal ring against counterbore in water pump
housing (see Figure 5.25-77).
CERAMIC
SEAL DRIVER
RUBBER CERAMIC SEAL
SEAT
Figure 5.25-77. Install Ceramic Seal
60. Using a 50/50 mix of clean ethylene glycol and
water, lubricate rubber insert and carbon seal ID within
seal retainer. Using same solution, lightly lubricate
lipped side of carbon seal.
61. With lipped side of carbon seal facing inward, slide
brass seal retainer assembly over water pump shaft.
62. Use seal driver (see Figure 5.25-67 -- Tool #10) to
hand press brass retainer/carbon seal assembly flat
against ceramic seal (see Figure 5.25-78).
NOTE: The impellor and pulley are held in place by the
clamp load resulting from torquing the shaft nuts on
each end.
CARBON SEAL
DRIVER CARBON HALF
OF SEAL
Figure 5.25-78. Install Carbon Seal
FORM 6296 First Edition
COOLING SYSTEM
63. If using previous P/N 200456B shaft, position a new
Woodruff key in slot on impeller end of water pump shaft.
Using a brass hammer or punch, tap key to properly seat
it in keyway. Verify key is level.
Always wear safety glasses when removing
springs. If spring slips when being installed or
removed, it can be propelled with enough force to
cause a serious eye injury. Disregarding this infor-
mation could result in severe personal injury.
64. Position spring down water pump shaft until it
contacts spring seat around edge of brass seal retainer.
65. With blades facing inward, position a new impeller
on shaft. Do not run impeller in using thin nut.
NOTE: Although the clearance fit of the impeller should
make it relatively easy to install, there may be some
difficulty in aligning the notch in the hub with the key on
the shaft. Use a grease pencil to mark the center of the
keyway on the end of the shaft if necessary.
66. Lubricate threads on impeller end of shaft with
clean engine oil (SAE 30). Install flat washer and finger
tighten thin nut.
67. Tighten pulley and impeller thin nuts to draw water
pump assembly together (see Figure 5.25-79).
68. Use reaction torque technique to tighten both
impeller and pulley thin nuts simultaneously.
A. Attach a 1-1/2 in. socket to a breaker bar.
B. Lock socket in a vise with opening facing upward.
To prevent socket from turning, verify handle of
breaker bar is in contact with base of vise.
C. Holding pump so impeller is parallel to table top,
fit pulley nut in socket. Some assistance will be
required to hold pump.
D. Tighten impeller nut to 195 -- 200 ft-lb (265 --
270 N×m).
69. Using a feeler gauge, check impeller vane to water
pump housing clearance at three equally spaced
locations (see Figure 5.25-80). Verify clearance is
between 0.015 -- 0.045 in. (0.38 -- 1.15 mm).
5.25 -- 49
COOLING SYSTEM

BODY

INNER
GREASE SEAL

RETAINING
RING
OUTER
SPRING
GREASE SEAL

WOODRUFF
WOODRUFF
KEY
KEY

WASHER
THIN NUT

THIN NUT
WASHER

O-RING

WATER PUMP
SEAL ASSEMBLY

PULLEY
IMPELLER
SHAFT AND BEARING
ASSEMBLY

Figure 5.25-79. VHP Series Four Water Pump Assembly

70. Apply pipe thread sealant to threads of two brass

MEASURE AT THREE PLACES SPRING petcocks. Install drain cock, pipe coupling, two pipe
nipples, and elbow on bottom of water pump water drain
petcock into pipe nipple assembly (see Figure 5.25-81).

71. Pressure test water pump at 15 psig (103 kPa) air

pressure.

72. Check for leakage at “weep hole” below drive belt

pulley. Presence of water indicates water pump seal is
defective and jacket water pump must be rebuilt.

73. Inspect water pump housing for leaks. Discard

casting if any cracks are found.

Figure 5.25-80. Check Impeller Clearances

5.25 -- 50 FORM 6296 First Edition

 COOLING SYSTEM

4. Moving counterclockwise around perimeter of gear

AIR BLEED PETCOCK
cover flange, install studs in holes 2 through 5 (see
OUTLET Figure 5.25-82 and Figure 5.25-83). Skipping hole
number 6, install studs in holes 7 through 11. Skip hole
number 12.

INLET INLET
WATER PUMP
COVER

OUTLET

WEEP HOLE
BENEATH PULLEY

WATER DRAIN PETCOCK

Figure 5.25-81. Jacket Water Pump

JACKET WATER PUMP INSTALLATION WATER PUMP

COVER GASKET
1. Check ten water pump mounting studs for nicks,
cracks, burrs, galled or stretched threads and other Figure 5.25-83. Water Pump Cover And Cover Gasket
obvious damage. Replace as necessary.

2. Each water pump stud has both fine and coarse Deposits left on gasket
threads. Using a small paintbrush, apply Bostik Never surfaces will cause
Seezâ Anti-Seize and Lubricating Compound to all leaks. Disregarding this information could result in
threads on the coarse side. product damage and/or personal injury.

Do not install water
pump studs with a pipe
wrench or similar device. Use collet style stud driver
to install studs. Disregarding this information could
result in product damage and/or personal injury.
3. Install ten studs around perimeter of gear cover
water pump mounting flange. Drive coarsely threaded
side of first stud into flange in 11 o’clock position (see
Figure 5.25-82). Thread stud until last coarse thread is
turned into casting.
GEAR COVER
11 O¢CLOCK
POSITION
5. Verify gaskets and gasket mating surfaces are clean
and completely free of grease and oil.
If the water pump cover
gasket is installed incor-
rectly, rotation of the impeller will shear off the ears,
a condition that may adversely affect sealing
effectiveness. Disregarding this information could
result in product damage and/or personal injury.
6. Position a new gear cover gasket onto ten studs
around perimeter of gear cover water pump mounting
flange (see Figure 5.25-84).
STRAIGHT EDGE OF
EARS ANGULAR

SKIP
INCORRECT CORRECT

WATER PUMP
MOUNTING FLANGE STRAIGHT EDGE
OF EARS VERTICAL
Figure 5.25-82. Water Pump Mounting Flange Figure 5.25-84. Install Water Pump Cover Gasket

FORM 6296 First Edition 5.25 -- 51

COOLING SYSTEM
7. Position water pump cover plate with center hump
(and Waukesha part number) facing inside towards
block (see Figure 5.25-85).
WATER PUMP
COVER
WATER PUMP
COVER GASKET
Figure 5.25-85. Water Pump Cover And Cover Gasket
If the water pump cover
gasket is installed incor-
rectly, rotation of the impeller will shear off the ears,
a condition that may adversely affect sealing
effectiveness. Disregarding this information could
result in product damage and/or personal injury.
8. Position water pump cover gasket on water pump
cover. Be sure lettering on gasket faces cover plate and
straight edge of each ear is vertical, not angular (see
Figure 5.25-85).
NOTE: Install the oil cooler or surge tank support
brackets before installing the water pump (see
Figure 5.25-86). Access is required to tighten the
bracket fasteners to the correct torque.
BRACKET
Figure 5.25-86. Oil Cooler Support Bracket
9. Apply pipe thread sealant to threads and install pipe
plugs on left and right bank water bypass elbows.
5.25 -- 52
The water pump weighs approximately 105 lb.
(48 kg). Use a suitable lifting device and exercise
caution during removal or installation to avoid
severe personal injury or death.
10. Install a 5/16 in. eye bolt in threaded hole at base of
upper center boss (see Figure 5.25-87). Attach suitable
lifting chain or sling and carefully raise pump using an
overhead hoist.
THREADED HOLE
(FOR EYE BOLT)
CENTER BOSS (UPPER)
Figure 5.25-87. Jacket Water Pump
11. Install water pump on mounting studs and remove
lifting device. Tighten fasteners (ten 3/8 in. hex nuts with
lock washers) in an alternating pattern to 35 ft-lb
(47 N×m).
12. Install pipe bracket to 8-1/2 in. long pipe nipple on
water drain petcock assembly. Secure assembly to
open bolt hole in upper gear cover flange (one capscrew
1/2 in. x 4-1/2 in. with lock washer, flat washer and 3 in.
spacer) (see Figure 5.25-88).
UPPER GEAR
COVER FLANGE
BRACKET
SPACER
Figure 5.25-88. Water Drain Petcock -- Front Right
FORM 6296 First Edition
 COOLING SYSTEM

13. Refer to “Crankcase Water Inlet Elbows Installa-

tion,” “Water Pump Inlet Elbows And Water Header LEFT HAND BELT
GUARD PANEL
Installation,” and “Lower/Upper Bypass Tubes And
Water Bypass Elbows Installation” in this section and
install these components.

SAFETY GUARDS
SAFETY GUARDS REMOVAL
1. Remove eight capscrews and front pulley guard from
two front belt guard panels (see Figure 5.25-89).

WATER PUMP
BELT GUARDS
SUPPORT
BRACKET

UPPER AND
LOWER FRONT
BELT GUARDS

Figure 5.25-90. Left Hand Belt Guard Panel

GREASE RIGHT HAND BELT

FITTING GUARD PANEL

PULLEY GUARD

Figure 5.25-89. Front Pulley Guard

2. Remove 13 capscrews and upper and lower halves

of 2 front belt guard panels.

3. Remove 12 capscrews and 2 water pump belt guard

panels.

4. Remove capscrew, lock washer and support bracket

from center boss of water pump.

5. Remove two capscrews from left hand belt guard

panel (see Figure 5.25-90).
RIGHT HAND
BRACKET BELT COVER
6. Remove capscrew, spacer, and left hand belt guard
panel from front engine cover.
Figure 5.25-91. Right Hand Belt Guard Panel
7. Remove two capscrews and grease fitting from right
hand belt guard panel (see Figure 5.25-91). 8. Remove capscrew, spacer, and right hand belt guard
panel from front engine cover.

9. Remove two screws and right hand belt cover from

support bracket on oil pan.

10. Remove capscrew, washer, lock washer and brack-

et from oil pan.

FORM 6296 First Edition 5.25 -- 53

COOLING SYSTEM
11. Remove three capscrews and outer halve of
auxiliary water pump belt guard panel (with grill) from
inner half of auxiliary water pump belt guard panel (see
Figure 5.25-92).
AUXILIARY
WATER PUMP
BELT PANELS
Figure 5.25-92. Auxiliary Water Pump Belt Guards
12. Remove two capscrews from slots on inner auxilia-
ry water pump belt guard panel (see Figure 5.25-93).
INNER AUXILIARY
WATER PUMP BELT
GUARD PANEL
Figure 5.25-93. Inner Auxiliary Water Pump Belt Guard
13. Remove capscrew, washer, lock washer, spacer
and inner auxiliary water pump belt guard panel.
SAFETY GUARDS INSTALLATION
1. Install inner auxiliary water pump belt guard panel
with capscrew, washer, lock washer, and spacer (see
Figure 5.25-93).
2. Install two capscrews in slots on inner auxiliary water
pump belt guard panel.
5.25 -- 54
3. Secure outer halve of auxiliary water pump belt
guard panel (with grill) to inner half of auxiliary water
pump belt guard panel and bracket with three caps-
crews (see Figure 5.25-92).
4. Install capscrew, spacer, and left hand belt guard
panel on front engine cover (see Figure 5.25-90).
5. Install two capscrews on left hand belt guard panel.
6. Install right hand belt guard panel on front engine
cover with capscrew and spacer.
7. Install right hand belt cover on support bracket and oil
pan with two capscrews (see Figure 5.25-91).
8. Install right hand belt guard panel on front engine
cover with capscrew and spacer.
9. Install two capscrews and grease fitting on right hand
belt guard panel.
10. Install support bracket on center boss of water
pump with capscrew and lock washer (see
Figure 5.25-89).
11. Install two water pump belt guard panels with
12 capscrews.
12. Install front pulley guard onto two front belt guard
panels with eight capscrews.
AUXILIARY WATER TEMPERATURE
CONTROL VALVE
AUXILIARY WATER TEMPERATURE CONTROL
VALVE REMOVAL
Remove and test the thermostat in the auxiliary cooling
water circuit annually. Inspect the thermostat sooner if
an increase or decrease in water temperature cannot be
traced to a malfunctioning water pump, loose belts,
excessive engine load or other cooling system related
problems.The cooling water temperature at the inter-
cooler cooling water inlet is either 85° F or 130° F (29° C
or 54° C), depending upon application.
NOTE: Drain the auxiliary cooling water circuit.
1. Remove flange connection from cooling water inlet
port C (from heat transfer device) (see Figure 5.25-94).
FORM 6296 First Edition
 COOLING SYSTEM

Do not boil the thermo-

TO BYPASS INLET PORT static valve. Excessive
B (FROM OIL COOLER)
temperatures will force the valve to exceed its
normal operating travel and may result in perma-
nent damage. Disregarding this information could
U-BOLT
result in product damage and/or personal injury.

B. Gradually heat water while stirring with a quality

glass laboratory thermometer. Observe action of
valve.

C. Valve should begin to open at “Start To Open”

INLET PORT C
temperature rating listed (see Table 5.25-10) and
(FROM HEAT be completely open at “Full Open” temperature,
OUTLET PORT A TRANSFER DEVICE) ± 5° F (± 2.8° C).

Figure 5.25-94. Temperature Control Valve D. Remove valve and observe its closing action.
Valve should seal evenly and tightly (see
2. Remove flange connection from bypass inlet port B Figure 5.25-95).
(from the oil cooler).

3. Remove cooling water outlet port flange (stamped A) OUTLET PORT A

(TO AUXILIARY WATER PUMP)
from thermostat housing (4 capscrews with flat
washers).

THERMOSTATIC
VALVE
The thermostat housing assembly weighs approxi-
mately 50 lb. (23 kg). Use a suitable lifting device
and exercise caution during removal or installation O-RING
to avoid severe personal injury or death.
BYPASS INLET
4. Install lifting strap to support thermostat housing PORT B
assembly. Assembly consists of thermostat housing and (FROM OIL
COOLER)
cooling water inlet pipe fittings and flanges.

5. Remove U-bolt securing cooling water inlet pipe

nipple to oil pan support bracket (5/16 in. flat washers,
lock washers and hex nuts).

6. Move thermostat housing assembly to a suitable

workbench.

AUXILIARY WATER TEMPERATURE CONTROL LIP SEAL

THERMOSTATIC VALVE INSPECTION AND TEST
1. Pull out thermostatic valve. Remove and discard
rubber O-ring seal. THERMOSTAT
HOUSING
2. Verify valve is in fully closed position. If valve is
frozen open or if there is obvious distortion, discard it. If COOLING WATER INLET PORT C
valve appears in good condition, test as follows: (FROM HEAT TRANSFER DEVICE)

Figure 5.25-95. Auxiliary Cooling Water Temperature

A. Suspend thermostatic valve in container of water. Control Valve -- All Models
Do not let thermostat rest against sides or
bottom. E. If thermostatic valve is defective, discard it.

FORM 6296 First Edition 5.25 -- 55

COOLING SYSTEM

Table 5.25-10. Auxiliary Cooling Water Thermostat -- All Models

P/N NUMBER NOMINAL TEMPERATURE START TO OPEN FULL OPEN

° F (° C) ° F (° C) ° F (° C)
208063H 1 120 (49) 111 (44) 130 (54)

AUXILIARY WATER TEMPERATURE CONTROL
VALVE ASSEMBLY
1. Pull lip seal out of thermostat housing. Use a rolling
head pry bar for best results.
2. Refer to Section 5.35 Exhaust System and remove
turbocharger air inlet elbows, exhaust tube and support
brackets.
3. Refer to Section 5.15 Air Induction System “Air
Tubing Removal” and remove intercooler air outlet
tubes.

Use of caustic solutions should be restricted to a
well ventilated area. Avoid contact with skin, cloth-
ing and eyes. Disregarding this information could
result in severe personal injury or death.
Turbocharger Oil Supply/Drain Tube Connections
Removal
1. Loosen union tube fitting ferrule nuts to separate
upper and lower turbocharger oil supply tubes (both
banks) (see Figure 5.25-96).

UNION TUBE UPPER TURBO

Compressed air can pierce the skin and cause FITTING OIL SUPPLY TUBE
severe personal injury or death. Never use your
hand to check for leaks or to determine air flow INTERCOOLER
BONNET
rates. Wear safety glasses to shield your eyes from
flying dirt and debris.

2. Submerse thermostat housing and pipe flange

connections in caustic hot tank to remove all paint, dirt,
grease and oil. Follow up with a thorough hot rinse. Dry
parts with moisture free compressed air.

3. Press fit a new lip seal of same diameter (see

Figure 5.25-95). Make sure seal is completely seated
around its circumference.
4. Using a small paintbrush, lubricate lip seal with clean
glycol.
5. Take note of temperature rating and part number
stamped on old thermostatic valve. Part number and
nominal temperature rating are stamped on metal
spring frame.
NOTE: If the old valve is not available, check the engine
specification pack to be sure that the new valve is
correct.
6. Install new thermostatic valve with expansion ele-
ment facing outward.
INTERCOOLER
INTERCOOLER REMOVAL
NOTE: Drain the auxiliary cooling water circuit.
1. Refer to Section 5.20 Turbochargers “Turbochar-
ger(s) Removal” and remove turbochargers, turbochar-
ger air outlet elbows and compressor discharge tubes.
LOWER TURBO TUBE
OIL SUPPLY TUBE CLIP/SPACER
Figure 5.25-96. Turbocharger Oil Supply Tube -- Rear
Left
2. Detach oil supply tubes from intercooler air inlet/
outlet bonnets (four capscrews, 3/8 in. x 2-1/2 in., with
lock washers, washers and 1 in. spacers) (see
Figure 5.25-97).
3. Remove upper oil supply tubes from top flange of
center housing (two allen head capscrews, 3/8 in. x
1 in., with lock washers) (see Figure 5.25-98).
4. Remove tube clip securing left oil supply tube to front
slot in rail support bracket.
5. Remove union tube fitting ferrule nuts to separate
upper and lower oil drain tubes (both banks).
6. Remove oil drain tubes from bottom flange of
turbocharger center housing (two allen head capscrews
3/8 in. x 1 in. with lock washers).

5.25 -- 56 FORM 6296 First Edition

 COOLING SYSTEM

COMPRESSOR DISCHARGE TUBE WASTEGATE COMPRESSOR TURBO OIL SUPPLY TUBE

FROM TURBO AIR OUTLET ELBOW DISCHARGE TUBE (3/8² X 2 1/2² CAPSCREWS)
(3/8² X 1-3/8² CAPSCREWS) (3/8² X 1-1/4² CAPSCREWS) BOTH SIDES
BOTH SIDES

NOTE: * Regular bonnet capscrews are 3/8² x 1-1/4²

Figure 5.25-97. Intercooler Bonnet Attachments -- Right Bank Side

INTERCOOLER WATER TUBE MODIFICATIONS

UPPER OIL
TUBE Instead of replacing the intercooler water tubes, you can
modify the existing tubes by drilling holes and welding
1/4 in. NPT pipe couplings in the correct locations.
Complete the following steps to modify the intercooler
water tubes. This procedure allows P/N A211700L to be
converted to P/N A214100L, and P/N A211761E to be
converted to P/N A214100M. See Table 5.25-11 for
parts required for conversion.
1. Remove tubing. See “Wastegate Tube Connections
Removal” in this section.

2. Locate and drill 0.91 in. (23 mm) holes in the tubes
according to the dimensions shown in Figure 5.25-99
and Figure 5.25-100.

LOWER OIL
TUBE SECTIONS

Figure 5.25-98. Turbocharger

FORM 6296 First Edition 5.25 -- 57

COOLING SYSTEM

Table 5.25-11. Parts Required For Retrofit

1/4² NPT COUPLING 2.75²
P/N 209242M 69.8mm P/N DESCRIPTION QTY.
214067P Right Bank Inlet Tube 1
214067M Left Bank Inlet Tube 1
214067V Right Bank Outlet Tube 1
1.47² 214067R Left Bank Outlet Tube 1
.12 37.3mm
26750 1/4² NPT Pipe Plug 2
A214100L Pump To Intercooler Tube, Rear 1
Intercooler Water Outlet Tube,
A214100M Rear 1

Wastegate Tube Connections Removal

NOTE: New wastegate water inlet and outlet tubes are
Figure 5.25-99. P/N A211700L To P/N A214100L
Modification
are available (see Figure 5.25-102). See “Intercooler
Water Tube Modifications” in this section. All engines
shipped after March 25, 2002, have the reconfigured
wastegate tubing installed.

1. Remove tube retaining clips joining right bank

wastegate water supply tube to left bank water return
tube. Clips are positioned between cooling water
inlet/outlet piping of two core assemblies (see
.12
Figure 5.25-101).
5.375²
1/4² NPT COUPLING 136.5mm WASTEGATE WATER
TUBE CLIPS
P/N 209242A RETURN TUBE (LB)

Figure 5.25-100. P/N A211761E To P/N A214100M

Modification

Comply with the welder manufacturer’s recommen-

dations for procedures concerning proper use of
the welder. Improper welder use can result in severe
personal injury or death.
WASTEGATE WATER
SUPPLY TUBE (RB)
Disconnect all engine
harnesses and electroni- Figure 5.25-101. Intercooler Connections -- Top
cally controlled devices before welding on or near
an engine. Failure to disconnect the harnesses and 2. Remove ferrule nuts (11/16 in. hex) to remove water
electronically controlled devices could result in supply tubes between wastegates (male elbow tube
severe engine damage. fitting -- right bank; male connector tube fitting -- left
bank) and male branch tee tube fitting in supply pipe tee.
3. Weld 1/4 in. NPT couplings (P/N 209242A) as Supply pipe tee is on left bank side of rear intercooler
shown in Figure 5.25-99 and Figure 5.25-100 with core assembly (see Figure 5.25-102 and
water tight welds. Figure 5.25-103).

5.25 -- 58 FORM 6296 First Edition

 COOLING SYSTEM

INTERCOOLER
WATER OUTLET
WATER INLET TUBE
TUBE RB
DRAIN COCK
TEE CONNECTOR WASTEGATE

PUMP TO
INTERCOOLER
TUBE
TEE
NIPPLE

TEE

WATER INLET
TEE TUBE RB
WATER OUTLET
TUBE LB

CONNECTOR

ELBOW
DRAIN COCK
NIPPLE WATER INLET
TUBE LB

WASTEGATE
ELBOW

Figure 5.25-102. Retrofitted Wastegate Water Inlet And Outlet Tubes

WASTEGATE WATER Compressor Discharge Tube Removal

SUPPLY TUBE (RB)
WASTEGATE WATER
1. Remove ferrule nuts (9/16 in. hex) to detach com-
RETURN TUBE (LB) pressor discharge pressure sensing tubes from “Air”
port at side of each wastegate (male elbow tube fitting)
COMPRESSOR (see Figure 5.25-103 and Figure 5.25-104) and air
DISCHARGE TUBE
outlet ports on intercooler (see Figure 5.25-105).
WATER RETURN
PIPE TEE
WASTEGATE COMPRESSOR
DISCHARGE TUBE
COMPRESSOR
DISCHARGE
TUBE

INTERCOOLER WATER SUPPLY

PIPE TEE AIR
INLET/OUTLET
Figure 5.25-103. Intercooler/Wastegate Tube BONNET
TUBE CLIP AND
SUPPORT BRACE

Figure 5.25-104. Intercooler Connections

FORM 6296 First Edition 5.25 -- 59

COOLING SYSTEM

LEFT COMPRESSOR 45° Y-BRANCH

DISCHARGE TUBE FITTING
RIGHT
BRACE AND COMPRESSOR
TUBE CLIP DISCHARGE
TUBE

LEFT
OUTLET
ELBOW

WASTEGATE
MALE CONNECTOR COMPRESSOR
TUBE FITTING DISCHARGE TUBE

Figure 5.25-105. Intercooler Connections

2. To free right bank compressor discharge tube, Figure 5.25-107. Y-Branch

remove tube clip from support bracket on upper rear
right side of intercooler. Intercooler Removal
3. If applicable, remove ferrule nuts (1-1/8 in. hex) to 1. Loosen Flexmaster elbow coupling clamp bolts (see
detach compressor discharge tube (3/4 in. tube OD) Figure 5.25-108) on rear end of intercooler cooling
from right side elbow (see Figure 5.25-106 and water return and supply pipes.
Figure 5.25-107).
FLEXMASTER COUPLING
COMPRESSOR
DISCHARGE TUBE

Figure 5.25-108. Flexmaster Elbow Coupling

2. Remove bottom 3/4 in. hex nuts and washers on four

AIR OUTLET intercooler mounting studs (see Figure 5.25-109).
ELBOW

Figure 5.25-106. Compressor Discharge Tube STUD BOSS

4. Remove ferrule nuts (1-1/8 in. hex) to remove

compressor discharge tube (3/4 in. tube OD) from left
side elbow (see Figure 5.25-107).

STUD

Figure 5.25-109. Intercooler Mounting -- Rear Left

5.25 -- 60 FORM 6296 First Edition

 COOLING SYSTEM

WASTEGATE COMPRESSOR
DISCHARGE TUBE
The intercooler assembly weighs approximately
423 lb. (192 kg). Use a suitable lifting device and
exercise caution during removal or installation to
avoid severe personal injury or death.
TUBE CLIP AND
SUPPORT BRACE
3. Wrap lifting strap around intercooler assembly so
strap is positioned in recess below rail support bracket
flanges (both sides) (see Figure 5.25-110).

AIR INLET/OUTLET
BONNET

Figure 5.25-111. Intercooler Connections

2. Remove ferrule nut (11/16 in. hex) to detach com-

pressor discharge pressure sensing tube (3/8 in. tube
OD) from flange above air outlet port of each intercooler
bonnet (both sides) (see Figure 5.25-112).
SUPPORT LIFTING STRAP

Figure 5.25-110. Intercooler Removal

4. Raise intercooler until mounting studs are free of

slots on mounting brackets. Remove four 3/4 in. wash-
ers from mounting bracket platforms.

Do not move the upper

3/4 in. hex nuts on the
intercooler mounting studs. The position of these
nuts holds the correct height of the intercooler in
relation to the top of the exhaust manifold. Disre-
garding this information could result in product WASTEGATE
damage and/or personal injury. MALE CONNECTOR COMPRESSOR
TUBE FITTING DISCHARGE TUBE
5. Install 3/4 in. hex nuts removed from bottom of
intercooler mounting studs. Run each nut up stud until it Figure 5.25-112. Intercooler Connections
makes solid contact with upper nut.
3. Using 5/8 in. hex on connector body, remove male
Intercooler Connection Removal
connector tube fitting from air outlet port flange (both
1. Remove tube clips to free right and left bank sides).
compressor discharge pressure sensing tubes from
intercooler mounted tube support braces (see 4. Remove support rails from air inlet/outlet bonnet
Figure 5.25-111) (one capscrew per clip 3/8 in. x 1/2 in. flanges (see Figure 5.25-113) (four capscrews per rail
with lock washer, washer and hex nut). Remove two 1/2 in. x 1 in. with lock washers).
capscrews, lock washers and tube support braces from
intercooler.

FORM 6296 First Edition 5.25 -- 61

COOLING SYSTEM

2. Repeat Step 1 on second water box. Use a different

EXHAUST ELBOW color paint, so disassembled water bonnets can be
SUPPORT BRACKET
easily associated with correct core during assembly.

SUPPORT RAIL 3. Remove end nuts on each side of two 45° elbow
Dresser couplings to disconnect cooling water inlet/out-
let piping between core assemblies (see
Figure 5.25-115 and Figure 5.25-116). Remove and
discard armored gaskets.

Figure 5.25-113. Support Rails

5. Remove right bank compressor discharge tube

support bracket (and tube clip) from intercooler (two
capscrews 3/8 in. x 1-3/8 in. with lock washers) (see
Figure 5.25-114).

OUTLET PIPE INLET PIPE

TUBE SUPPORT
BRACKET
Figure 5.25-115. Intercooler Connections

COUPLING ELBOW
SEAL
RETAINER

AIR INLET/OUTLET RUBBER

BONNET SEAL

Figure 5.25-114. Intercooler Connections
INTERCOOLER DISASSEMBLY
Each intercooler consists of two air inlet/outlet bonnets
and two water box core assemblies. Each core assem-
bly consists of a water inlet/outlet bonnet (top), water
return bonnet (bottom), a tube and fin assembly, two end
castings and associated gaskets.
1. Make a painted mark on edge of each water
inlet/outlet bonnet (top), water return bonnet (bottom)
and corresponding header plate (see Figure 5.25-117).
Water leakage will occur if bonnets are inadvertently
reversed in assembly.
END NUT
Figure 5.25-116. 45° Elbow Dresser Coupling
Do not bump, bend or
otherwise damage the
corrugated aluminum fins of the core assemblies.
Damaged fins obstruct the flow of air through the
intercooler core and reduce cooling efficiency.
Disregarding this information could result in prod-
uct damage and/or personal injury.
4. Remove air inlet/outlet bonnets and gaskets from air
sides of intercooler core assemblies (36 capscrews per
bonnet 3/8 in. x 7/8 in. with lock washers).

5.25 -- 62 FORM 6296 First Edition

 COOLING SYSTEM

INLET/ OUTLET
BONNET GASKET

WATER INLET/OUTLET
BONNET

WATER HEADER PLATE

(UPPER)

END CASTING

END CASTING GASKET

(NOT AVAILABLE)
PAINTED MARK

END CASTING GASKET

(NOT AVAILABLE)
END CASTING
WATER HEADER PLATE
(LOWER)

RETURN BONNET
GASKET WATER RETURN
BONNET

PAINTED MARK

Figure 5.25-117. Intercooler

5. Remove brass drain petcock/pipe nipple assemblies

from water return bonnets (two petcocks per bonnet).
FRONT
6. Separate two box-type core assemblies.

7. Remove brass air bleed petcock/pipe nipple assem-

bly from water inlet/outlet bonnets (one petcock per
bonnet).
8. If required, remove piping from top of both intercool-
ers (see Figure 5.25-118).

REAR

Figure 5.25-118. Intercooler Piping

FORM 6296 First Edition 5.25 -- 63

COOLING SYSTEM
INTERCOOLER CLEANING AND INSPECTION
When handling or clean-
ing the intercooler core
assemblies, exercise caution to avoid bending the
aluminum cooling fins. Fins should be straightened
by using the proper size fin straightening tool.
Damaged fins obstruct the flow of air through the
intercooler and reduce cooling efficiency. Disre-
garding this information could result in product
damage and/or personal injury.
Do not submerge the
intercooler core or outlet
bonnets in the caustic hot tank. While the treatment
may effectively remove lime and mineral scale
deposits from within the copper tubes, it may also
dissolve and warp the aluminum cooling fins and
damage the end casting gaskets. Disregarding this
information could result in product damage and/or
personal injury.
Caustic solutions can
cause severe burns.
Wear approved eye protection and safety equip-
ment to avoid severe personal injury. Disregarding
this information could result in product damage
and/or personal injury.
1. Clean intercooler by circulating a caustic solution
such as Oaklite 32â through core. Rinse and neutralize
with Oaklite 162â.
2. Fins should be straightened by using proper size fin
straightening tool.
INTERCOOLER ASSEMBLY
1. Position core assemblies side by side approximately
1/4 in. apart so nameplates and port holes of water
inlet/outlet bonnets are on outside (see
Figure 5.25-117).
2. Install air inlet/outlet bonnets and gaskets on air
sides of intercooler core assemblies (36 capscrews per
bonnet 3/8 in. x 7/8 in. with lock washers).
3. Alternately tighten water inlet/outlet bonnet caps-
crews. Tighten capscrews to 17 ft-lb (23 N×m).
4. Apply pipe thread sealant to threads of two brass air
bleed petcock/pipe nipple assemblies. Install petcock/
pipe nipple assemblies in water inlet/outlet bonnets (one
air bleed petcock per bonnet).
5.25 -- 64
5. Apply pipe thread sealant to threads of drain
petcock/pipe nipple assemblies. Install petcock/pipe
nipple assemblies in water return bonnet (two drain
petcocks per bonnet) of rear core assembly. Rear core
assembly can be identified by water supply and return
pipe tees in water inlet/outlet bonnet. Leave free end of
petcock/pipe nipple assemblies pointing sideways to-
ward air sides.
6. Apply pipe thread sealant to threads of two brass
drain petcocks. Install petcocks in water return bonnet of
front core assembly.
7. If removed, apply pipe thread sealant to threads of
fittings and install intercooler piping.
8. Verify ends of cooling water outlet pipes (between
two core assemblies at top of intercooler) are clean and
completely free of dirt and oil. Check surfaces where
rubber seals contact pipe ends to ensure there are no
gouges, grooves, burrs, nicks or dents. Surface
imperfections will adversely affect sealing performance.
9. Obtain new gaskets for 45° elbow Dresser coupling.
10. With concave side facing pipe ends, slide coupling
end nuts onto two ends of cooling water outlet pipes (see
Figure 5.25-119).
COUPLING ELBOW
SEAL
RETAINER
RUBBER
END NUT SEAL
Figure 5.25-119. 45° Elbow Dresser Coupling
11. Fit tapered end of rubber seals into hollowed side of
seal retainers. Install seals in ends of coupling, so that
rubber face seats against beveled counterbore.
12. Position coupling between cooling water outlet
pipes. Alternately tighten end nuts.
13. Repeat Steps 7 through 12 to install 45° elbow
Dresser coupling between cooling water inlet pipes.
FORM 6296 First Edition

Intercooler Connection Installation
1. Fasten support rail to flanges above air inlet and
outlet bonnets (see Figure 5.25-120) on each side of
intercooler assembly (four capscrews per rail 1/2 in. x
1 in. with lock washers).
SUPPORT RAIL BRACKET
Figure 5.25-120. Support Rails
2. Install exhaust elbow support brackets to support
rails (see Figure 5.25-120) with two capscrews per
bracket, lock washers, washers and hex nuts.
3. Install right bank compressor discharge tube support
bracket to intercooler with two capscrews and lock
washers) (see Figure 5.25-121).
TUBE SUPPORT
BRACKET
Figure 5.25-121. Intercooler Connections
4. Install tube clip to bracket.
5. Apply pipe thread sealant to large end of two male
connector tube fittings (3/8 in. tube OD). Using 5/8 in.
hex on connector body, install fittings in flange above air
outlet port of each intercooler bonnet (both sides) (see
Figure 5.25-122).
FORM 6296 First Edition
COOLING SYSTEM
WASTEGATE
MALE CONNECTOR COMPRESSOR
TUBE FITTING DISCHARGE TUBE
Figure 5.25-122. Intercooler Connections
6. Install to male connector tube fittings (both sides).
7. Secure tube clip to right and left wastegate compres-
sor discharge pressure sensing tubes. Fasten clips to
tube support braces (see Figure 5.25-123) (one caps-
crew per clip 3/8 in. x 1/2 in. with lock washer, washer
and hex nut).
WASTEGATE COMPRESSOR
DISCHARGE TUBE
TUBE CLIP AND
SUPPORT BRACE
Figure 5.25-123. Compressor Discharge Pressure
Sensing Tubes Support Braces
8. Apply pipe thread sealant to threads of two reducing
bushings (1/4 in. to 2 in. NPT). Install bushings in two
pipe tees threaded into water inlet/outlet bonnet (top) of
rear intercooler core assembly.
9. Apply pipe thread sealant to threads of two male
branch tee tube fittings. Install fittings in each reducing
bushing, two ferrule nuts are lined up in a horizontal
position (see Figure 5.25-124 and Figure 5.25-125).
5.25 -- 65
COOLING SYSTEM

WASTEGATE WATER
10. Install right wastegate water supply tube to male
COMPRESSOR
SUPPLY TUBE (RB) DISCHARGE TUBE branch in supply pipe tee (see Figure 5.25-124). Supply
pipe tee is on left side of rear intercooler core assembly.
WASTEGATE WATER 11. Install left bank wastegate water return tube to male
RETURN TUBE (LB)
branch in return pipe tee (see Figure 5.25-124). Return
pipe tee is on right side of rear intercooler core
WATER RETURN assembly.
PIPE TEE
12. Join two tube retaining clips to fasten right bank
wastegate water supply tube to left bank water return
tube. Position clips between 45° elbow Dresser cou-
COMPRESSOR plings connecting cooling water inlet/outlet piping of two
DISCHARGE
TUBE intercooler core assemblies (see Figure 5.25-124).

13. Install water inlet and outlet elbows and gaskets on

intercooler pipe tee and cross (see Figure 5.25-126).

NOTE: Delay installation of the left bank water supply

and right bank water return tubes until after mounting of
WATER SUPPLY the turbocharger assembly.
INTERCOOLER PIPE CROSS

Figure 5.25-124. Intercooler/Wastegate Tube

Connections

LEFT BANK

WASTEGATE

TO OIL COOLER

FROM AUXILIARY
WATER PUMP

INTERCOOLER

RIGHT BANK
WASTEGATE
COMPRESSOR DISCHARGE PRESSURE SENSING TUBES
WATER SUPPLY TUBES
WATER RETURN TUBES

Figure 5.25-125. Wastegate Connections

5.25 -- 66 FORM 6296 First Edition

 COOLING SYSTEM

INTERCOOLER INSTALLATION
WATER INLET
1. Wrap one lifting strap around intercooler assembly.
Strap should be positioned in recess below rail support
bracket flanges (on both sides) (see Figure 5.25-128).

WATER OUTLET SUPPORT RAIL FLANGE LIFTING STRAP

Figure 5.25-126. Intercooler Inlet And Outlet Elbows Figure 5.25-128. Lifting Intercooler

14. Disassemble free ends of Flexmaster elbow cou-

plings on intercooler cooling water supply and return
pipes. Fit new rubber seals into concave side of each
retainer. Slide assemblies up onto cooling water inlet
and outlet pipes at front of intercooler (see
Figure 5.25-127). Seals will hold retainers in place until
intercooler is installed.
CLAMP BOLT
The intercooler assembly weighs approximately
423 lb. (192 kg). Use a suitable lifting device and
exercise caution during removal or installation to
avoid severe personal injury or death.
2. Raise intercooler slightly. Install 3/4 in. hex nuts
on four mounting studs. Run each nut up stud until
bottom of nut is 1-3/4 in. from upper boss (see
Figure 5.25-129).

SEAL RETAINER
STUD BOSS

BRACKET

CLAMP

RUBBER SEAL

ELBOW COUPLING

Figure 5.25-127. Flexmaster Elbow Coupling

3/4² WASHER/HEX NUT STUD

Figure 5.25-129. Intercooler Mounting -- Rear Left

FORM 6296 First Edition 5.25 -- 67

COOLING SYSTEM

3. Position a 3/4 in. washer over two slots in each

intercooler mounting bracket. UPPER OIL
TUBE
4. Gently lower intercooler, so that four studs slide
through mounting bracket slots (and 3/4 in. washers).
Be sure water inlet and outlet pipes at front of intercooler
assembly slip into sleeves of Flexmaster elbow cou-
plings on cooling water supply and return pipes (see
Figure 5.25-127).

5. Install 3/4 in. washers and hex nuts on four intercool-

er mounting studs. Run nuts upward towards bottom of
mounting brackets.

6. Install front clamps on Flexmaster elbow couplings

attached to cooling water supply and return pipes (see
Figure 5.25-127). Tighten all clamp bolt hex nuts. WATER SUPPLY TUBE

Turbocharger Oil Supply/Drain Tube Connection

Installation
1. Apply 3M Scotch-Gripâ 847 Rubber and Gasket
Adhesive to mating surfaces. See manufacturer’s
recommendations. Install drain tube on each turbochar-
ger center housing (see Figure 5.25-130).
Figure 5.25-131. Turbocharger Connections
6. Attach two tube clips to turbocharger oil supply tubes
(one above and another below union tube fitting).
Remove two capscrews (3/8 in. x 1-1/4 in.) from each
intercooler air inlet/outlet bonnet (see Figure 5.25-132).
Using longer capscrews (3/8 in. x 2-1/2 in.) with lock
washers, washers and 1 in. spacers, fasten turbochar-
ger oil supply tubes to intercooler.

7. Secure tube clip left oil supply tube to front slot in rail
support bracket.

UNION TUBE
FITTING UPPER TURBO
OIL SUPPLY TUBE

OIL DRAIN TUBE

ASSEMBLY

Figure 5.25-130. Turbocharger Oil Drain Tube

2. Apply 3M Scotch Gripâ 847 Rubber and Gasket

Adhesive to flanges of upper oil supply tubes (see
Figure 5.25-131).
3. Position new gaskets on contact cement. Allow
gasket adhesive to cure. See manufacturer’s
recommendations.
4. Secure upper oil supply tubes to top flange of center
housing with two allen head capscrews and lock
washers.
5. Tighten fitting between upper and lower oil supply
tubes.
5.25 -- 68
LOWER TURBO TUBE
OIL SUPPLY TUBE CLIP/SPACER
Figure 5.25-132. Turbo Oil Supply Tube -- Rear Left
Wastegate Tube Connection Installation
1. Install wastegate water supply tube to empty port of
male branch tee tube fitting (left side of rear intercooler
core assembly) (see Figure 5.25-125).
2. Install wastegate water return tube to empty port of
male branch tee tube fitting (right bank side of rear
intercooler core assembly) (see Figure 5.25-125).
FORM 6296 First Edition
 COOLING SYSTEM

3. Install two water supply tubes to wastegate water AUXILIARY WATER PIPE SYSTEM
inlet ports (male elbow tube fitting - right bank; male INSTALLATION
connector tube fitting - left bank) (see Figure 5.25-125).
VHP Series Four auxiliary water piping runs along the
NOTE: The word “Water” appears just above the water manifold.
wastegate base flange between the water inlet and outlet
1. Install intercooler water tubes rear support on water
ports, the side with the petcock being the outlet port.
manifold 3/8 in. fasteners (see Figure 5.25-134). Inter-
4. Install two water return tubes to wastegate water mediate support is attached to breather system support
outlet ports (male connector tube fitting - right bank; installed on water manifold with 3/8 in. fasteners.
male elbow tube fitting - left bank).
5. Install free end of compressor discharge pressure
BREATHER SUPPORT
sensing tubes to “Air” port at side of each wastegate INTERMEDIATE
SUPPORT
(male elbow tube fitting - both banks).
REAR
Compressor Discharge Tube Connection SUPPORT
Installation
1. Position tube across top of intercooler and install
compressor discharge tube (3/4 in. tube OD) to right
bank turbo air outlet elbow (male connector tube fitting).

2. Install opposite end of right bank compressor

discharge tube to bottom port of Y-branch (male
connector tube fitting) (see Figure 5.25-133).

BRACE AND
LEFT BANK TUBE CLIP
COMPRESSOR
DISCHARGE 45° Y-BRANCH
TUBE FITTING
Figure 5.25-134. Intercooler Water Tube Supports
RIGHT BANK
BRACE AND COMPRESSOR
TUBE CLIP DISCHARGE 2. Disassemble one side of a Flexmaster elbow cou-
TUBE pling (see Figure 5.25-135). With concave side facing
outward, slide seal retainer onto removed end of return
pipe (upper).

BOLT CLAMP

SEAL RETAINER

RIGHT BANK
TURBO OUTLET LEFT BANK
ELBOW TURBO OUTLET
ELBOW RUBBER SEAL
INTERCOOLER

Figure 5.25-133. Y-Branch ELBOW COUPLING

3. Remove tube clip from support bracket on upper rear
right side of intercooler. Attach right bank compressor
discharge tube and fasten clip to bracket (see
Figure 5.25-133).
4. Install compressor discharge tube (3/4 in. tube OD)
between left bank turbo air outlet elbow (male elbow
tube fitting) and angular port on Y-branch (male
connector) (see Figure 5.25-133).
FORM 6296 First Edition
Figure 5.25-135. Flexmaster Elbow Coupling
3. Seat a new rubber seal in hollowed face of retainer.
Install sleeve with free (assembled) end of elbow facing
upward, but tilted slightly toward left bank. Wrap open
clamp around seal retainer and flared end of elbow.
Finger tighten clamp bolt until intercooler is installed.
5.25 -- 69
COOLING SYSTEM

4. Repeat procedure on supply pipe (lower). Install

sleeve with free (assembled) end of elbow pointing INTERMEDIATE SUPPORT
upward.

5. Install 90° Flexmaster elbows onto intercooler water

inlet and outlet elbows (see Figure 5.25-136).

FLEXMASTER ELBOWS

FLEXMASTER
COUPLINGS

Figure 5.25-138. Intercooler Water Tube Support

8. Install tube support bracket onto front segment of LB

exhaust manifold with 1/2 in.--13 fasteners (see
Figure 5.25-139). Loosely install a U-bolt around front
Figure 5.25-136. Intercooler Water Elbows
water outlet tube to bracket.
6. Install rear intercooler water inlet and outlet tubes in
Flexmaster elbows (see Figure 5.25-137). Loosely TUBE SUPPORT
install retaining U-bolts. BRACKET

REAR INTERCOOLER
WATER OUTLET TUBE

Figure 5.25-139. Front Auxiliary Water Tube Support

REAR INTERCOOLER
WATER INLET TUBE
Figure 5.25-137. Rear Intercooler Water Tubes
7. Install Flexmaster couplings onto rear water tubes.
Install front intercooler water inlet and outlet tubes in
Flexmaster couplings (see Figure 5.25-138). Loosely
install retaining U-bolts through intermediate support
bracket.
9. Front auxiliary water intercooler tube with customer
connection flange is supported with a clamp supported
by a bracket attached to water manifold front support
(see Figure 5.25-140). Slide clamp in place on tube
before installation.
10. Install tube in elbow in oil cooler bonnet (see
Figure 5.25-141).

5.25 -- 70 FORM 6296 First Edition

 COOLING SYSTEM

12. Support front water tube with a clamp and support

bracket attached to left exhaust manifold end cover (see
Figure 5.25-143).

SUPPORT BRACKET
AND CLAMP

CLAMP SUPPORT
BRACKET

Figure 5.25-140. Auxiliary Water Outlet Tube Support

SUPPORT CLAMPS

Figure 5.25-143. Front Inlet Water Tube Supports

13. Apply pipe thread sealant to threads of pipe nipple

and install to pipe elbow (see Figure 5.25-144).

PIPE ELBOW

WATER
OUTLET TUBE

Figure 5.25-141. Mounted Oil Cooler Tube

11. Secure front intercooler water inlet tube to Flexmas-

ter coupling at intermediate support (see
Figure 5.25-138). Secure tube to front support with
U--bolt. Do not fully tighten (see Figure 5.25-142).

INTERCOOLER
WATER INLET TUBE

Figure 5.25-144. Auxiliary Water Flexible Hose

14. Apply pipe thread sealant to threads of union

adapter. Thread union adapter into auxiliary water pump
outlet port pipe elbow (see Figure 5.25-145).

BREATHER SYSTEM
TUBE

Figure 5.25-142. Water Manifold Front Support

FORM 6296 First Edition 5.25 -- 71

COOLING SYSTEM

AUXILIARY WATER PUMP AND BRACKET

FLEXIBLE HOSE
AUXILIARY WATER PUMP AND BRACKET
REMOVAL

Always wear protective clothing when draining the

cooling systems on a heated engine. Slowly loosen
the air bleed petcocks to relieve any excess pres-
sure. Escaping steam and/or hot water can result in
severe personal injury or death.
HOSE PIPE 1. Refer to “Jacket Water And Auxiliary Water Circuits --
FITTING UNION ADAPTER ELBOW
Drain And Flush” in this section and drain cooling
Figure 5.25-145. Intercooler Water Supply Pipe system.

2. Refer to “Auxiliary Water Pump Drive Belt Replace-

Do not turn the hose hex ment” in this section and remove auxiliary water pump
on the auxiliary water belts.
pump side. Turning the hex will twist the hose and
may result in damage to the hose fitting or seal 3. Refer to “Safety Guards Removal” in this section and
and/or personal injury. remove safety guards from auxiliary water pump.

15. Hold flexible hose hex nut (auxiliary water pump 4. Disconnect water lines to water pump.
side) and turn hex nut on union adapter to thread free NOTE: Matchmark all parts during removal to aid in the
end of hose into auxiliary water pump outlet port pipe installation procedure.
elbow.
5. Remove four nuts, lock washers, washers, caps-
16. Remove lower outside capscrew from intake man- crews, and auxiliary water pump from auxiliary water
ifold flange (1/2 in.--13 x 2 in. with lock and flat washers) pump bracket (see Figure 5.25-147).
at front left corner of engine. Slide capscrew through
round hole in hose support brace. Reinstall capscrew.
Attach hose clip to flexible hose. Fasten clip to slotted
hole in support brace (one capscrew 1/2 in.--13 x 3/4 in. PIPE FITTING
with lock washer, flat washer and hex nut).

17. Apply pipe thread sealant to threads and apply to

tube elbows to be installed in intercooler water outlet
(see Figure 5.25-146). Elbows are used to return water
from turbocharger water cooled center sections. Apply
pipe thread sealant and install air bleed petcocks in rear
intercooler water tubes. AUXILIARY
WATER PUMP
BRACKET
AIR BLEED
PETCOCK
DRAIN
AUXILIARY COCK
PULLEY WATER PUMP

Figure 5.25-147. Auxiliary Water Pump

6. Loosen two socket head set screws and remove

auxiliary water pump pulley and woodruff key from pump
shaft.
TURBOCHARGER
WATER OUTLET 7. Remove drain cock from auxiliary water pump.
TUBES
8. If required, remove grease fitting and instruction
Figure 5.25-146. Auxiliary Water Connections plate from auxiliary water pump.

5.25 -- 72 FORM 6296 First Edition

 COOLING SYSTEM

9. Remove lock nut and washer from anchor stud and
idler pulley bracket (see Figure 5.25-149).
10. Remove lock nut and washer from rear of idler
pulley shaft.
11. Remove idler lever and adjusting lever assemblies
with idler pulley shaft as one piece from auxiliary water
pump bracket.
16. Remove adjusting lever and woodruff key from idler
pulley shaft.
17. Remove elastic stop nut, washer, anchor stud and
washer from threaded rod.
18. Remove two thin hex nuts from threaded rod.
19. Remove elastic stop nut, two spacers and pivot rod
and threaded rod from idler lever.

20. Remove four capscrews, lock washers, washers

Always wear safety glasses when removing retain- and auxiliary water pump bracket from crankcase (see
ing (snap) rings. Verify the correct retaining ring Figure 5.25-148).
pliers is used and the pliers is in good condition. If
the retaining ring slips off the pliers when being
installed or removed, it can be propelled with
enough force to cause a serious eye injury. Disre-
garding this information could cause serious per-
sonal injury.

12. Remove retaining ring from idler pulley shaft.

13. If required, remove idler pulley and shaft bearing
from idler lever.
14. Remove idler lever and woodruff key from idler Figure 5.25-148. Auxiliary Water Pump Bracket
pulley shaft.
21. If required, press out two bushings from auxiliary
15. Remove capscrew and lock washer from adjusting water pump bracket.
lever.

IDLER
LEVER
LOCK NUT

IDLER
PULLEY
IDLER
SHAFT/BEARING PULLEY
SHAFT

LOCK NUT

SPACER

ADJUSTING LEVER
ROD PIVOT
SPACER
WASHER
THIN NUTS

WASHERS ANCHOR
LOCK NUT STUD

Figure 5.25-149. Auxiliary Water Pump Idler And Adjusting Lever

FORM 6296 First Edition 5.25 -- 73

COOLING SYSTEM

AUXILIARY WATER PUMP AND BRACKET 8. Install idler lever on idler shaft with capscrew and
INSTALLATION lock washer.
NOTE: Matchmark all parts during removal to aid in the
installation procedure.

1. If removed, press two bushings into auxiliary water Always wear safety glasses when removing retain-
pump bracket (see Figure 5.25-148). ing (snap) rings. Verify the correct retaining ring
pliers is used and the pliers is in good condition. If
2. Install auxiliary water pump bracket on crankcase the retaining ring slips off the pliers when being
with four capscrews, washers and lock washers. installed or removed, it can be propelled with
enough force to cause a serious eye injury. Disre-
3. Install pivot rod, two spacers, elastic stop nut, garding this information could cause serious per-
threaded rod and thin nut on adjusting lever (see sonal injury.
Figure 5.25-150).
9. Install retaining ring on idler shaft.
HEX HEAD CAPSCREW
IDLER LEVER 10. Install idler shaft, adjusting lever, and idler lever as
one assembly on auxiliary water pump bracket with
washer and lock nut.
THREADED 11. Install auxiliary water pump bracket on crankcase
ROD ADJUSTING
LEVER with four washers, lock washers and capscrews.

12. Install stud anchor to auxiliary water pump bracket

ELASTIC STOP
LOCK NUT with lock nut and washer (see Figure 5.25-149).

13. If removed, install grease fitting and instruction

LOCK plate on water pump.
WASHER
14. Install drain cock on auxiliary water pump.
SPACER
15. Install auxiliary water pump pulley and woodruff key
SPACER ELASTIC STOP on auxiliary water pump shaft. Tighten two socket head
LOCK NUT
set screws on auxiliary water pump pulley (see
PIVOT ROD
Figure 5.25-147).
THIN HEX LOCK NUT
16. Install auxiliary water pump on auxiliary water pump
bracket with four capscrews, washers, lock washers and
PLAIN WASHER nuts.
STUD ANCHOR
17. Connect water lines to auxiliary water pump.
PLAIN WASHER
18. Refer to “Auxiliary Water Pump Drive Belt Replace-
Figure 5.25-150. Adjusting/Idler Lever Assembly ment” in this section and replace auxiliary water pump
belts.
4. Remove capscrew and lock washer from idler shaft.
19. Refer to “Safety Guards Installation” in this section
5. Install thin nut, washer, stud anchor, washer and and install safety guards on auxiliary water pump.
elastic stop nut on threaded rod.
20. Refer to “Jacket Water And Auxiliary Water Cir-
6. Install adjusting lever on idler shaft with woodruff key, cuits -- Drain And Flush” in this section and refill cooling
lock washer and capscrew. systems.

7. If removed, install idler pulley and shaft bearing on

idler lever.

5.25 -- 74 FORM 6296 First Edition