COOLING SYSTEM 6 B CLOSED COOLED MODELS

Transcription

1 COOLING SYSTEM 6 B CLOSED COOLED MODELS

2 Tle of Contents Pge 262 CID / 4.3L B-1 Torque Speifitions B-1 Lurints, Selers And Adhesives.... 6B-1 Speifitions B-1 Wter Flow Digrms B-2 Engines With Coolnt Flow Thru Exhust Mnifolds (Exluding Gen +) B-2 Engines With Rw Wter Flow Thru Exhust Mnifolds B-3 Desription B-4 Sewter Pikup Pump (If Equipped) B-4 Mintenne B-4 Stern Drive Unit Sewter Pikup Pump.. 6B-4 Belt Driven Sewter Pikup Pump B-4 Output Test B-5 Removl B-6 Disssemly (Two Piee Body) B-8 Sewter Pump Disssemly (One Piee Body) B-9 Housing disssemly B-9 Clening nd Inspetion B-11 Ressemly B-11 Ressemly (Two Piee Body) B-13 Sewter Pump Ressemly (One Piee Body) B-14 Instlltion B-15 Closed Cooling Systems With Coolnt Flow Thru Exhust Mnifolds (Exluding Engines With Serpentine Belt) 6B-17 Mintining Coolnt Level B-17 Pressure Cp Mintenne B-17 Het Exhnger Repir B-18 Testing Closed Cooling System B-18 Testing Coolnt for Alklinity B-18 Pressure Testing System B-19 Testing for Cylinder Hed Gsket Lek.. 6B-20 Testing Het Exhnger B-20 Testing Pressure Cp B-20 Thermostt B-21 Removl B-21 Pge Flushing Sewter Setion of Closed Cooling System B-28 Drining Sewter Setion of Closed Cooling System B-30 Drining Preutions B-30 Filling Closed Cooling Setion B-32 Closed Cooling System With Rw Wter Flow Thru Exhust Mnifold (Engines With Serpentine Belt Only).... 6B-33 Mintining Closed Cooling System Coolnt B-33 Cheking Coolnt for Alklinity B-34 Chnging Coolnt B-34 Drining Instrutions B-34 Filling Instrutions B-35 Pressure Cp Mintenne B-37 Flushing Sewter Setion B-38 Clening Sewter Setion of Het Exhnger nd Fluid Coolers B-39 Clening Closed Cooling Setion B-40 Cold Wether or Extended Storge B-41 Sewter Setion Drining Instrutions.. 6B-41 Serpentine Drive Belt Adjustment B-44 Auxiliry Hot Wter Heter Instlltion... 6B-45 Testing B-23 Instlltion B-24 Chnging Coolnt B-26 Closed Cooling Setion B-26 Coolnt Reommendtions B-26 Chnge Intervls B-26 Drining Instrutions B-26 Clening System B-27 Closed Cooling Setion B-27 Sewter Setion B-27 6B-0 - CLOSED COOLING MODELS

3 262 CID / 4.3L TORQUE SPECIFICATIONS DESCRIPTION L. In. L. Ft. N m Het Exhnger End Cps Sewter Pump Bre Sewter Pump Brket to Blok Sewter Pump Cover 30 (41) Sewter Pump Mounting Nuts to Stmped Steel Brkets Thermostt Cover Thru Hull Pikup Nut Drin Plugs Het Exhnger Mounting Brkets Seurely Hose Clmps LUBRICANTS, SEALERS AND ADHESIVES DESCRIPTION PART NUMBER Quiksilver 2-C-4 Mrine Lurint with Teflon A3 Quiksilver Perfet Sel Quiksilver Liquid Neoprene Quiksilver Lotite Type Lotite Quiksilver Speil Lurint A1 Lotite Pipe Selnt with Teflon Otin Lolly SPECIFICATIONS Cooling System Cpity 20 (19) Thermostt Stinless Steel 160 F (71 C) Thermostt Brss 140 F (67 C) Cp Pressure 14 PSI (97 kp) CLOSED COOLING MODELS - 6B-1

4 Wter Flow Digrms Engines With Coolnt Flow Thru Exhust Mnifolds (Exluding Gen +) COOLANT FLOW RAW WATER FLOW Typil Thermostt nd Thermostt Housing Shown (All Similr) - Remove Hoses (Lift, Lower or Bend To Completely Drin). - Remove Blok Plugs (Repetedly Clen Out Holes Using A Stiff Wire Until Entire System Is Drined). - Remove Drin Plugs From Exhust Exhust Mnifold Drin Elows (Repetedly Clen Out Holes Using A Stiff Wire Until Entire System Is Drined) 6B-2 - CLOSED COOLING MODELS

5 Engines With Rw Wter Flow Thru Exhust Mnifolds COOLANT FLOW RAW WATER FLOW - Remove Hoses (Lift, Lower or Bend To Completely Drin). - Remove Blok Plugs (Repetedly Clen Out Holes Using A Stiff Wire Until Entire System Is Drined). - Remove Drin Plugs From Exhust Exhust Mnifold Drin Elows (Repetedly Clen Out Holes Using A Stiff Wire Until Entire System Is Drined) CLOSED COOLING MODELS - 6B-3

6 Desription There re severl onfigurtions of this ooling system, ut the opertion is essentilly identil. Bsilly, the system is omposed of two seprte susystems: the sewter system nd the losed ooling system. The sewter system is similr in funtion to the fn used in n utomoile euse it sors het (from the losed ooling system) s it psses through the het exhnger. The losed ooling system is similr in funtion to the rest of the ooling system in n utomoile. The oolnt reovery system keeps the reservoir full. Norml oolnt overflow into reovery ottle is pproximtely 1/2 pint (230 ml) during wrm-up. The oolnt reovery system drws oolnt k into the reservoir from the reovery ottle s the engine ools. As long s there is oolnt in the reovery ottle, the reservoir should remin ompletely full. If not, there s vuum lek, usully t the hose leving the reservoir, or the gsket under the reovery filler p. The gsket sels ginst the outer rim of the filler nek. IMPORTANT: The oolnt (ntifreeze) flows round the outside of the ooling tues while sewter flows through the inside of the ooling tues in the het exhnger. All V-6 engine exhust mnifolds re ooled y oolnt in the losed ooling system. V-6 engines operted in sewter (lkes, oens, et) hving n mient temperture ove 80 F (26 C) my hve n optionl elt driven sewter pikup pump mounted on the lok. Otherwise, the sewter pikup pump in the Alph stern drive ools the stern drive, flows through the het exhnger nd is then dishrged overord. Sewter Pikup Pump (If Equipped) Mintenne Whenever insuffiient wter flow is suspeted, sewter pikup pump should e disssemled nd inspeted y n uthorized MerCruiser Deler. Stern Drive Unit Sewter Pikup Pump NOTICE Refer to SECTION 6A for informtion nd servie proedures on Stern Drive Unit Sewter Pikup Pump. Belt Driven Sewter Pikup Pump e d Sewter PUmp - Brket - Pulley d - Inlet Hose e - Outlet Hose 6B-4 - CLOSED COOLING MODELS

7 OUTPUT TEST If n overheting prolem exists, use this test to determine if suffiient mount of wter is eing supplied to ool engine. IMPORTANT: The following informtion should e oserved efore proeeding with test: BOAT MUST BE IN THE WATER FOR THIS TEST. This test CANNOT e performed with flush-test devie nd wter hose. The ility of this test to detet prolem is gretly dependent upon the ury in whih it is performed. An error in setting the engine RPM, timing the test or mesuring the wter output will ffet the overll ury of the test nd my produe misleding results. To help ensure urte results, shop thometer with n error of less thn 5% should e used. The ot thometer definitely should not e used s its ury is questionle. A stop wth should e used to time the durtion of the test to help ensure tht the ury is mintined within one seond. An 8 U.S. qt. (7.6 L) or lrger pity ontiner should e used to mesure wter output. Due to the mnner in whih this test is performed, it my not e possile to detet mrginl ondition or high-speed wter pump output prolem. 1. Remove wter hose, whih runs etween pump outlet nd engine, nd reple with nother hose of sme dimeter, ut pproximtely 3 ft. (1 m) longer. Hose should e wire reinfored or of dequte wll thikness to prevent it from kinking when performing test. Clmp hose t pump outlet only. Do not lmp hose t engine end. - Sewter Pikup Pump - Sewter Outlet Hose Ple n 8 U.S. qt. (7.6 L) or lrger ontiner ner unlmped end of hose.! CAUTION Do not run engine for more thn 15 seonds with hose disonneted, in next step, s internl dmge to engine nd exhust system my result. 3. With ssistne of nother person, strt engine nd djust speed to extly 1000 RPM while holding unlmped end of hose on onnetion on engine. Remove hose from onnetion on engine nd diret wter flow into ontiner for extly 15 seonds. At the end of 15 seonds, diret the wter flow overord, return engine to idle nd stop engine. Reonnet hose to engine. 4. Mesure quntity of wter dishrged into ontiner nd ompre with speifitions given in hrt following. 5. Repet test four times to hek repetility of results. Belt Driven Pump Output for 15 Seond Period 7.5 U.S. Qts. (7.1 L) Minimum CLOSED COOLING MODELS - 6B-5

8 REMOVAL! CAUTION If ot is in the wter, e sure to lose seok efore removing inlet hose from pump to prevent wter from drining into ot. If ot is not fitted with seok, disonnet nd plug sewter inlet hose fter removing. IMPORTANT: The following proedure desries removl of oth pump nd mounting rket from engine. On some instlltions, however, it my e possile to remove pump with mounting rket left instlled on engine. 1. Close seok, if so equipped, or disonnet nd plug sewter inlet hose. 2. Disonnet wter inlet nd outlet hoses from pump. 3. If pump is to e disssemled, loosen the four pump pulley tthing srews. Do not remove srews t this time. 4. Remove power steering pump drive elt to llow removl of sewter pikup pump drive elt. 5. Remove pulley tthing srews, then remove pulley. 6. Remove tthing hrdwre whih seures pump re to ylinder lok. 7. Remove pump mounting rket-to-ylinder lok tthing hrdwre nd remove pump, mounting rket nd re s n ssemly. 8. Remove fsteners seuring rket nd re to pump nd remove oth from pump ody. 6B-6 - CLOSED COOLING MODELS

9 Two Piee Pump Assemly 1 - Srew (5) 2 - Wsher (5) 3 - Cover 4 - Gsket 5 - Wer Plte (Outer) 6 - Gsket 7 - Plug 8 - Impeller 9 - Body 10- Gsket 11- Wer Plte (Inner) 12- O-Ring or Qud Ring 13- Oil Sel 14- Housing 15- Bll Bering 16- Shft 17- Bll Bering 18- Snp Ring 19- Oil Sel 20- Hu One Piee Pump Assemly 1 - Srew (5) 2 - Wsher (5) 3 - One Piee Body 4 - Qud Ring 5 - Impeller 6 - Wer Plte 7 - Oil Sel 8 - Housing 9 - Bll Bering 10- Shft 11- Bll Bering 12- Snp Ring 13- Oil Sel 14- Hu CLOSED COOLING MODELS - 6B-7

10 DISASSEMBLY (TWO PIECE BODY) 1. Remove over nd ody tthing srews nd wshers Gsket (with Lrge Opening) - Wer Plte (Outer) - Gsket (with Two Openings) Slide pump ody off shft. Remove impeller from pump ody nd ruer plug from impeller. - Cover 2. Remove gsket, outer wer plte nd gsket (disrd gskets) Gsket (with Lrge Opening) - Wer Plte (Outer) - Gsket (with Two Openings) Ruer Plug - Impeller 6B-8 - CLOSED COOLING MODELS

11 2. Remove sewter pump ody nd wer plte from ering housing Qud Ring Sel SEAWATER PUMP DISASSEMBLY (ONE PIECE BODY) 1. Remove the five srews from the sewter pump ody Sewter Pump Body - Wer Plte - Bering Housing 3. Remove the impeller from sewter pump ody. HOUSING DISASSEMBLY 4. Remove gsket, inner wer plte nd qud ring sel. Disrd gsket nd qud ring sel Srews (5) - Sewter Pump Body Qud Ring Sel CLOSED COOLING MODELS - 6B-9

12 5. Press hu off shft with Universl Puller Plte nd n ror press. 7. Remove snp ring from ering housing ore nd press shft nd erings out pulley end of housing. Berings hve slip fit in housing; do not use exessive fore. - Universl Puller Plte ( ) Punture front oil sel with tool nd pry from ering housing Snp Ring B-10 - CLOSED COOLING MODELS

13 8. If erings require replement, remove erings from shft with Universl Puller Plte nd n ror press. Berings must e repled, if removed. 6. Inspet pump shft erings. 7. Inspet pump shft for grooves in surfe where sels ontt shft. Also inspet surfe where erings ontt shft for evidene of inner res turning on shft. 8. Inspet pump ody. 9. Inspet inner nd outer wer plte. 10. Inspet pump impeller for wer on sides nd tips of ldes. Also inspet ldes for rks in re where ldes flex. Reple impeller if ldes hve tken set (remin in urved position). 11. Inspet pump pulley. 12. Chek drive elt for exessive wer. REASSEMBLY If rer sels require replement, press sels from ering housing with n pproprite tool. CLEANING AND INSPECTION 1. Clen metl prts in solvent nd low dry with ompressed ir. IMPORTANT: Do not spin erings t high speed when drying with ompressed ir, s erings my e sored. 2. After lening, pply ot of light engine oil to shft nd erings to prevent rust. 3. Clen ll gsket mteril nd seler from seling surfes. 4. Inspet ering housing. Exmine surfes (where erings ontt housing) for evidene of ering outer res turning in housing. 5. Inspet sels in ering housing. Refer to exploded view lso. 1. Apply thin ot of Quiksilver Lotite 8831 to outside dimeter of two new ering housing rer sels; then instll sels in housing with sel lips fing impeller end. (Press first sel in until it ottoms out nd seond sel in until flush with housing.) - Outer (Wter )Sel - Fe of Housing IMPORTANT: It is reommended tht Shell Alvni No. 2 Grese e used when pking sel nd erings in the following steps. If Shell Alvni No. 2 Grese is not ville, it is permissile to use Quiksilver 2-4-C Mrine Lurint. With Teflon However, Quiksilver 2-4-C Mrine Lurint With Teflon is not reommended for pplitions where ontinuous high speed hevy-duty opertion will e enountered. 2. Pk vity etween sels with Shell Alvni No. 2 Grese or sustitute CLOSED COOLING MODELS - 6B-11

14 3. Using n ror press nd suitle tool, press ll erings onto shft until they set. Press on inner re of ering only. 5. Apply thin ot of Quiksilver Lotite 8831 to outside dimeter of new ering housing front oil sel nd press sel into housing (with sel lip fing inwrd) until it ottoms out. - Berings Pk erings nd vity etween erings with Shell Alvni No. 2 Grese or sustitute. Slide erings nd shft into ering housing ore nd instll snp ring. - Front Oil Sel IMPORTANT: Be sure to support impeller end of pump shft when instlling pulley hu in next step to prevent pling lod on erings. 6. Apply Quiksilver Speil Lurint 101 to pump shft. Using n ror press nd pproprite tool, press pulley hu onto pump shft to dimension shown /64 In. 6.5mm) IMPORTANT: Pulley hu must e pressed onto shft to ext dimension on pumps with stmped steel mounting rket s this estlishes proper drive elt lignment Shft with Berings - Snp Ring 6B-12 - CLOSED COOLING MODELS

15 7. Clmp ering housing in soft jw vise with flnge end up. 8. Cot qud ring sel with Quiksilver 2-4-C Mrine Lurint With Teflon nd instll into groove in housing. REASSEMBLY (TWO PIECE BODY) 9. Ple inner wer plte on housing nd lign holes. Cot oth sides of new wer plte gsket with thin film of Quiksilver Perfet Sel nd position on wer plte Wer Plte - Gsket 10. Instll impeller into pump ody y turning impeller in diretion tht it will e turning in opertion, while simultneously pushing inwrd. All impeller ldes must fe in sme diretion. - Qud Ring Sel Impeller Blde CLOSED COOLING MODELS - 6B-13

16 Impeller 11. Slide impeller nd pump ody ssemly onto shft. Position pump ody so tht holes lign with holes in wer plte, gsket nd ering housing. Instll ruer plug into end of impeller. 12. Cot oth sides of new over gsket nd wer plte gsket with thin film of Quiksilver Perfet Sel. Instll outer wer plte with new gskets on eh side, ligning holes in plte nd gskets with holes in pump ody. - Gsket (with Lrge Opening) - Wer Plte (Outer) - Gsket (with Two Openings) Instll pump over nd seure with five olts nd wshers. Torque olts to speifitions. SEAWATER PUMP REASSEMBLY (ONE PIECE BODY) 1. Lurite sewter pump impeller with wter nd sop solution. Instll impeller into housing y rotting nd pushing it into ple. Push it down until flush with housing Gsket (with Lrge Opening) - Wer Plte (Outer) - Gsket (with Two Openings) - Impeller B-14 - CLOSED COOLING MODELS

17 2. Ple wer plte over ering housing shft. 3. Ple qud ring in groove in sewter pump ody. IMPORTANT: Pump must e positioned orretly or overheting of engine my our. - Qud Ring - Sewter Pump 4. Align flts on impeller nd ering housing shft, slide sewter pump ody on shft. 5. Instll two srews in sewter pump ody holes s shown. Use these two srews to lign pump, then instll the remining srews Bolt Holes For Alignment INSTALLATION 1. Position pump in mounting rket so tht outlet onnetion will e diretly ove inlet onnetion when pump is instlled. - LH Out - At Top IMPORTANT: Flt wsher must e instlled etween mounting rket lmping osses or dmge to pump my result (if lmping srew is over-tightened) CLOSED COOLING MODELS - 6B-15

18 2. Instll pulley on pump nd seure with four srews, lokwshers nd lmping ring (some models). Tighten srews finger-tight only t this time. 3. Atth pump, mounting rket nd re ssemly to engine. Do no tighten tthing srews t this time. 4. Torque pump pulley tthing srews. 5. Position drive elt on pulleys nd djust elt tension s outlined in Drive Belt Tension Adjustment. 6. Connet sewter inlet hose to lower fitting on pump. 7. Connet outlet hose to upper fitting on pump. 8. Tighten hose lmps seurely. 9. If pplile, reinstll power steering drive elt. Adjust tension s outlined in Drive Belt Tension Adjustment. 6B-16 - CLOSED COOLING MODELS

19 Closed Cooling Systems With Coolnt Flow Thru Exhust Mnifolds (Exluding Engines With Serpentine Belt) Mintining Coolnt Level If level is low, remove fill p from oolnt reovery ottle nd dd required mount of oolnt solution. Use 50/50 mixture of ethylene glyol ntifreeze nd pure, soft wter for oolnt dditions. If frequent dditions of oolnt re required, hek fresh wter setion for leks. IMPORTANT: ALCOHOL OR METHANOL BASE ANTIFREEZE OR PLAIN WATER ARE NOT REC- OMMENDED FOR USE IN COOLING SYSTEM AT ANY TIME. In res where ethylene glyol is not ville, nd the possiility of freezing does not exist, it is permissile to use solution of rust inhiitor nd pure, soft wter (mixed to mnufturer s reommendtions). Osionlly, hek to ensure tht oolnt reovery system is funtioning properly y removing pressure p from het exhnger nd heking level. Coolnt level should e up to ottom of het exhnger filler nek. If low, exmine entire fresh wter setion (espeilly oolnt reovery system) for leks nd repir, if neessry. IMPORTANT: When reinstlling pressure p, e sure to tighten it until it ontts stops on filler nek. Coolnt Reovery Bottle - Fill Cp Before strting engine eh dy, hek to ensure tht oolnt is visile in oolnt reovery ottle. If oolnt is not visile, hek fresh wter setion of ooling system (inluding oolnt reovery system) for leks nd repir, s neessry. Refill fresh wter setion with reommended oolnt solution, s outlined under Chnging Coolnt, following. If oolnt is visile, strt engine nd run until it rehes norml operting temperture, then rehek oolnt level in oolnt reovery ottle. Coolnt level MUST BE etween the ADD nd FULL mrks (on front of ottle).! WARNING Allow engine to ool efore removing pressure p, s sudden loss of pressure ould use hot oolnt to oil nd dishrge violently. After engine hs ooled, turn p 1/4 turn to llow ny pressure to espe slowly, then push down nd turn p ll the wy off. Pressure Cp Mintenne Pressure p is designed to mintin pressure in fresh wter setion of losed ooling system one the engine hs ttined norml operting temperture. This rises the oiling point of the oolnt, therey inresing the effiieny of the ooling system. To help ensure proper opertion, p should e lened, inspeted nd pressure tested periodilly s follows:! WARNING Allow engine to ool efore removing pressure p (in next step), s sudden loss of pressure ould use hot oolnt to oil nd dishrge violently. After engine hs ooled, turn p 1/4 turn to llow ny pressure to espe slowly, then push down nd turn p ll the wy off. 10. Remove pressure p from het exhnger. 11. Wsh p with len wter to remove ny deposits or deris from seling surfes. 12. Inspet ruer sel on p for uts, rks or other signs of deteriortion. If sel is dmged, p MUST BE repled. 13. Inspet oolnt reovery gsket for deteriortion nd reple if d. CLOSED COOLING MODELS - 6B-17

20 14. Chek ondition of loking ts on p. Reple p if ts re ent or rked. Het Exhnger Repir IMPORTANT: Brze with BCUP 2 rod or silver solder. Cre must e tken not to melt other joints during repir. 1. Internl leks n e repired y rzing shut the ends of the leking tue. This is only temporry fix euse usully nother tue will strt leking fter short period of time nd this lso uses redution in ooling pity. Do not lose more thn three tues. 2. Nipples nd drins tht hve een roken off the het exhnger n e retthed y rzing. - Ruer Sel (Cp MUST BE Repled if Dmged) - Gsket (Look for Crks Under Gsket) - Loking Ts (1 Hidden) Testing Closed Cooling System 15. Refer to Testing Pressure Cp nd test pressure p s outlined. 16. Clen seling surfes on het exhnger filler nek with loth. Inspet surfes for ny dmge or deposits tht my prevent p from seling properly. 17. Clen oolnt reovery pssge in het exhnger filler nek with wire nd low out with ompressed ir. Testing Coolnt for Alklinity! WARNING Allow engine to ool efore removing pressure p s sudden loss of pressure ould use hot oolnt to oil nd dishrge violently. After engine hs ooled, turn p 1/4 turn to llow ny pressure to espe slowly, then push down nd turn p ll the wy off. - Inspet for Dmge - Clen Coolnt Reovery Pssges Reinstll pressure p, eing sure to tighten until it ontts stops on filler nek. Coolnt in fresh wter setion should e hnged every two yers nd should e heked for lklinity t lest one etween hnge intervls. To hek oolnt for lklinity, proeed s follows: 1. Otin pink litmus pper from lol supplier (drug store, pet shop, et.). 2. Remove pressure p from het exhnger nd insert one end of litmus pper into oolnt. 3. If pink litmus pper turns lue, oolnt is lkline nd need not e repled. 4. If pink litmus pper remins pink, oolnt is not lkline nd MUST BE REPLACED, s explined under Chnging Coolnt. 6B-18 - CLOSED COOLING MODELS

21 Pressure Testing System! WARNING Allow engine to ool efore removing pressure p. Sudden loss of pressure ould use hot oolnt to oil nd dishrge violently. After engine hs ooled, turn p 1/4 turn to llow ny pressure to espe slowly, then push down nd turn p ll the wy off. If oolnt setion of losed ooling system is suspeted of leking or not holding suffiient pressure, nd no visile signs of lekge n e found, perform the following test: 1. Remove pressure p from het exhnger or reservoir. 2. Clen, inspet nd pressure test pressure p, s outlined under Testing Pressure Cp, to eliminte the possiility tht p is not mintining proper pressure in system nd is using oolnt to oil over. 3. Clen inside of filler nek to remove ny deposits or deris. Exmine lower inside seling surfe for niks or other dmge. Surfe must e perfetly smooth to hieve good sel etween it nd ruer sel on p. Also hek loking ms on sides of filler nek to e sure tht they re not ent or dmged. If loking ms re ent or dmged, pressure p will not hold the proper pressure. 4. Adjust oolnt level in fresh wter setion to 1 in. (25 mm) elow filler nek. 5. Atth n utomotive-type ooling system pressure tester to filler nek nd pressurize losed ooling setion to mount speified in following hrt, sed on pressure p rting for your engine. Amount Of Pressure Pressure Cp Rting Applied To Closed Cooling System 14 PSI (97 kp) 17 PSI (117 kp) 6. Oserve guge reding for pproximtely two minutes; pressure should not drop during this time. If pressure drops, proeed with the following steps until lekge is found. 7. While mintining speified pressure on losed ooling setion, visully inspet externl portion of ooling system (hoses, gskets, drin plugs, petoks, ore plugs, irulting pump sel, et.) for lekge. Also listen losely for uling or hissing, s they usully re sure indition of lek. 8. Refer to Testing Het Exhnger in this setion nd test s outlined. 9. If no lekge ould e found in ove steps, engine is leking internlly, nd it proly is due to one or more of the following: (1) loose ylinder hed olts or dmged gsket, (2) loose intke mnifold olts or dmged gsket, (3) loose exhust elow or distriution lok retining nuts or dmged gsket, (4) rked or porous ylinder hed or lok, or (5) rked or porous exhust mnifold. Proeed s follows until lotion of internl lek is found.. Strt engine. Repressurize system to previously speified mount nd oserve pressure guge on tester. If needle in guge virtes, ompression or omustion is leking into losed ooling setion from lek in the omustion hmer. Ext ylinders, where lekge is tking ple, sometimes n e found y removing sprk plug wires (one t time) while oserving pressure guge. Virtion will derese or stop when plug wire is removed from leking ylinder. Stop engine.. Remove sprk plugs (one t time) from ylinders nd exmine for presene of oolnt. A sprk plug tht is perfetly len or milky ppering is sure indition of lek.. Drin oil from engine nd exmine for presene of oolnt. Oil usully will e milky if oolnt is present. If oolnt is present, remove engine from ot nd drop the oil pn. With engine in the upright position, repressurize losed ooling setion to previously speified mount nd exmine internl surfes of engine to lote lek. d. If no lekge n e found in ove steps, entire engine must e disssemled nd inspeted for lekge CLOSED COOLING MODELS - 6B-19

22 Testing for Cylinder Hed Gsket Lek A leking hed gsket will use omustion gs to e fored into the ooling system. The mixture of oolnt nd tiny ir ules is poor het ondutor nd will overhet n engine quikly. Compression tests or ooling system pressure hek normlly will not detet the lek euse the test pressure is fr elow the omustion pressures whih use the lek. An effetive test is s follows: IMPORTANT: Run ot in lke for this test. It is est to run the engine t or ove ruising speed during this test. Usully filed hed gsket will not use the engine to overhet elow ruising speed. 1. Instll ler plsti hose etween the reservoir nd oolnt reovery ottle. Use 2-3 ft. (61-91 m) long hose for this test. 2. Route this hose so U is formed. 3. Put enough oolnt into hose to fill the enter 4 or 5 inhes (10-13 m) of the U. 4. Oserve the U while the engine is running.. During Idle nd Wrm-Up: Some oolnt nd/or ir will leve the reservoir.. During Cruising Speed ( RPM): Coolnt nd/or ir leving the reservoir should stop fter pproximtely five minutes running t given RPM. A leking hed gsket will produe ir uling through the U, going to the oolnt reovery ottle. The frequeny nd size of the ules will depend on the size of the lek.. At Higher Speeds (4000+ RPM): Norml opertion is the sme s desried in ove. A filed hed gsket will use the ules to ome fster nd my e ompnied y violent, intermittent ursts of oolnt. It is importnt not to onfuse norml wrm-up expnsion with filed hed gsket. Norml wrm-up produes n intermittent flow of oolnt whih will stop within pproximtely five minutes t given RPM. A hed gsket lek will not stop euse the one thing tht mrks filed hed gsket is the ontinued pssge of ir. This my e ompnied y violent, intermittent ursts of oolnt leving the reservoir. If oolnt ontinues to flow (not in violent, intermittent ursts) from the reservoir t ruising speed, something else esides the hed gsket is using the engine to overhet. Testing Het Exhnger FOR INTERNAL LEAK: An internl lek will use oolnt to go into the sewter iruit when pressure is put on the losed ooling iruit. 1. Remove sewter hose from the exhnger. Do not drin the exhnger. 2. Pressurize the losed ooling iruit to PSI ( kp) with rditor tester. 3. If sewter egins to flow from the nipple there is lek. FOR BLOCKAGE: IMPORTANT: Sewter flows THROUGH the tues in the exhnger. Closed ooling oolnt flows AROUND the tues. 1. Remove end ps nd inspet for ny lokge in the sewter iruit (roken impeller ldes, weeds, et.). 2. Remove losed ooling iruit hoses nd inspet the tues just inside the nipples. Beuse the omplete exhnger nnot e inspeted, the het exhnger should e repled if lokge is suspeted. Testing Pressure Cp Pressure p is designed to mintin pressure of pproximtely its rted pity (refer to Speifitions ) in losed ooling setion one engine hs ttined operting temperture. Cp should e lened, inspeted nd pressure-tested t regulr tune-up intervls or whenever p is suspeted of mintining improper pressure s follows:! WARNING Allow engine to ool efore removing pressure p. Sudden loss of pressure ould use hot oolnt to oil nd dishrge violently. After engine hs ooled, turn p 1/4 turn to llow ny pressure to espe slowly, then push down nd turn p ll the wy off. 1. Crefully remove pressure p from reservoir or het exhnger. 2. Wsh p with len wter to remove ny deposits or deris from seling surfes. 6B-20 - CLOSED COOLING MODELS

23 3. Inspet gsket (if used) nd ruer sel on p for ters, uts, rks or other signs of deteriortion. Reple gsket, if dmged, or entire p if ruer sel is dmged. IMPORTANT: Before reinstlling p in next step, exmine lower inside seling surfe in filler nek to ensure tht it is perfetly smooth nd free of deris. Also, inspet m lok flnges on sides of filler nek to e sure tht they re not ent Ruer Sel (Cp MUST BE Repled if Dmged) - Gsket (Look for Crks under Gsket) - Loking Ts (1 Hidden) 4. Chek tht loking ts on p re not ent or dmged. 5. Using ooling system pressure tester (similr to one shown), test p to e sure tht it releses t proper pressure nd does not lek. (Refer to instrutions whih ompny tester for orret test proedure.) Cp must relieve pressure t 14 PSI (97 kp), nd must hold rted pressure for 30 seonds without going elow 11 PSI. Reple p if it fils to fll within these limits. - Inspet for Dmge - Cm Lok Flnge 6. Reinstll p on reservoir or het exhnger. Thermostt Removl Follow instrutions nd :. Drin oolnt from exhust mnifolds y removing lower hose or drin plugs from eh mnifold. Be sure to drin oth port nd strord sides. NOTE: If oolnt flow is restrited or fils to our, wire should e repetedly inserted into ll drin holes to insure there re no ostrutions in pssges. Remove petok, if neessry, to insert wire ompletely into drin hole CLOSED COOLING MODELS - 6B-21

24 . Drin engine lok y removing plug or opening petoks. Be sure to drin oth port nd strord sides. 4. Remove thermostt from thermostt housing. Port Side Shown - Drin Plug (Cylinder Blok) - Hose e d f g Drin Plug (Cylinder Blok) - Drin Plug (Exhust Mnifold) 2. Disonnet hoses from thermostt over. 3. Remove thermostt over tthing olts nd lokwshers, then remove over nd gsket. NOTE: Some engines my e equipped with Lifting Eye rket (not shown following) under thermostt over olts. Oserve orienttion so tht it my e instlled during ressemly extly s efore removl. Models Without Sleeve - Bolts - Lokwshers - Cover d - Gsket e - Thermostt (Typil) f - Housing g - Gsket With Continuity Rivets 6B-22 - CLOSED COOLING MODELS

25 Testing 1. Clen thermostt in sop nd wter to remove ny deposits or deris. 2. Inspet thermostt for orrosion or other visile dmge. 3. If thermostt is suspeted of produing insuffiient engine temperture, hek thermostt for lekge y holding it up to lighted kground. Light lekge round the thermostt vlve indites tht thermostt is not losing ompletely nd should e repled. (A smll mount of lekge t one or two points round the vlve perimeter is eptle.) d e f g h i Brss Thermostt (Stinless Steel Similr) - Chek for Light Lekge Around Perimeter of Vlve Models With Sleeve - Bolts - Lokwshers - Cover d - Gsket e - Thermostt f - Cork Gsket (DO NOT Use Perfet Sel) g - Sleeve (Turned in Lip Towrd Thermostt) h - Housing i - Plugs (2) j - Gsket With Continuity Rivets CLOSED COOLING MODELS - 6B-23

26 4. Chek opening nd losing temperture of thermostt (using tester similr to the one shown), s follows:. Fill tester to within 1 in. (25 mm) of top with tp wter. Do not use distilled wter.. Open thermostt vlve nd insert thred. Position thermostt on nylon string so tht it will e just elow wter level when suspended, then llow vlve to lose. Suspend thermostt in wter. Instlltion! CAUTION Do not operte engine without ooling wter eing supplied to the sewter pikup pump, or pump impeller will e dmged. 1. Remove thermostt housing nd gskets. Disrd gskets. 2. Clen gsket surfes on thermostt over, thermostt housing nd intke mnifold. 3. Position lower gsket (with ontinuity rivets) on intke mnifold. Ple thermostt housing on gsket. IMPORTANT: If gsket hs ontinuity rivets, do not ot with Quiksilver Perfet Sel, or udio wrning temperture swith my not work properly. 4. Instll thermostt s shown, into thermostt housing Thermometer - Nylon String - Thermostt. Ple thermometer in ontiner nd position so tht ottom of thermometer is even with ottom of thermostt. Do not llow thermometer to touh ontiner. IMPORTANT: When performing instrutions d nd e, wter must e gitted thoroughly to otin urte results. d. Plug in tester nd oserve temperture t whih thermostt opens (thermostt drops off thred). Thermostt must open t F (59-63 C). Thermostt must e ompletely open t 170 F (77 C). e. Unplug tester nd llow wter to ool to temperture 10 F (5 C) elow speified temperture on thermostt. Thermostt must e ompletely losed t this temperture. f. Reple thermostt tht fils to meet ll of the preeding tests. Brss Thermostt Stinless Steel Thermostt Instll Thermostt With This End (Down) Towrd Thermostt Housing 6B-24 - CLOSED COOLING MODELS

27 5. Position gsket on thermostt housing nd reinstll thermostt over. Instll lifting eye (not shown following) if so equipped. Torque olts to 30 l. ft. (41 N m). d d e e f f g g h Models Without Sleeve - Bolts - Lokwshers - Cover d - Gsket e - Thermostt (Typil) f - Housing g - Gsket With Continuity Rivets Models With Sleeve - Bolts - Lokwshers - Cover d - Gsket e - Thermostt f - Cork Gsket (DO NOT Use Perfet Sel) g - Sleeve (Turned in Lip Towrd Thermostt) h - Housing i - Gsket With Continuity Rivets i CLOSED COOLING MODELS - 6B-25

28 g f Closed ooling setion of losed ooling system should e kept filled yer-round with reommended oolnt solution. Do not drin losed ooling setion for storge, s this will promote rusting of internl surfes. If engine will e exposed to freezing tempertures, mke sure tht losed ooling setion is filled with n ethylene glyol ntifreeze nd wter solution, mixed to mnufturer s reommended proportions, to protet engine to lowest temperture to whih it will e exposed. If neessry, hnge oolnt. f d Coolnt Reommendtions! CAUTION Alohol or Methnol se ntifreeze or plin wter re not reommended for use in fresh wter setion of losed ooling system t ny time. Models With Serpentine Belt e Thermostt Housing - Thermostt - Qud-Ring Sel d - Srews with Lokwshers e - Thermostt Cover f - Gsket g - Bleeder Vlve 6. Connet hoses to thermostt over. Tighten hose lmps seurely.! CAUTION Avoid sewter pikup pump impeller dmge. DO NOT operte engine without ooling wter eing supplied to sewter pikup pump. 7. With ot in the wter nd/or ooling wter properly supplied to sewter pikup pump, strt engine nd inspet for leks. Chnging Coolnt NOTICE For informtion nd proedures on drining the sewter ooling system, refer to SECTION 6A. For old wether or extended storge, refer to SECTION 1B. Closed Cooling Setion It is reommended tht the oolnt setion of losed ooling system e filled with 50/50 mixture of ethylene glyol ntifreeze nd wter. In res where the possiility of freezing DOES NOT exist, it is permissile to use solution of rust inhiitor nd wter (mixed to mnufturer s reommendtions). Chnge Intervls Drin nd flush oolnt from the losed ooling system t lest every two yers or whenever exhust gses hve entered the system. Drining Instrutions! WARNING Allow engine to ool efore removing pressure p. Sudden loss of pressure ould use hot oolnt to oil nd dishrge violently. After engine hs ooled, turn p 1/4 turn to llow ny pressure to espe slowly, then push down nd turn p ll the wy off. IMPORTANT: A wire should e inserted into drin holes to ensure tht foreign mteril is not ostruting the drin holes. On lter models with two piee petok, removl of petok my e required so tht wire n e inserted ompletely into drin hole. IMPORTANT: Engine must e s level s possile to ensure omplete drining of ooling system. IMPORTANT: Closed ooling setion must e kept filled yer round with reommended oolnt. If engine will e exposed to freezing tempertures, mke sure losed ooling setion is filled with n ethylene glyol ntifreeze nd wter solution properly mixed to protet engine to lowest temperture to whih it will e exposed. 6B-26 - CLOSED COOLING MODELS

29 IMPORTANT: Do not use Propylene Glyol Antifreeze in the losed ooling setion of the engine. The following drining instrutions pply to ll engines equipped with losed ooling. The lotion of petoks tht require opening nd hoses tht require removl re represented on the following pges for the individul engines. IMPORTANT: Oserve preutions previously outlined efore proeeding. 1. Remove pressure p from oolnt tnk. 2. Drin oolnt from lotions s shown for your model nd engine. (Refer to the pproprite digrm on the following Drining Digrms pge.) 3. After oolnt hs drined ompletely, ot threds of drin plugs with Quiksilver Perfet Sel nd instll drin plugs nd hoses. Tighten lmps nd drin plugs seurely. 4. Remove oolnt reovery ottle from mounting rket nd pour out oolnt. 5. Clen system s outlined in Clening System. 6. Fill system s outlined in Filling Closed Cooling Setion. NOTICE For informtion nd proedures for drining nd flushing sewter setion of ooling system, refer to SECTION 6A. For old wether or extended storge, refer to SECTION 1B. Sewter Setion Cooling effiieny of n engine with losed ooling is gretly dependent upon het trnsfer through the tues within the het exhnger. During engine opertion, ontminnts within the sewter (suh s slt, silt, lime, et.) ollet on the inside of the tues, thus reduing het trnsfer nd gretly deresing het exhnger effiieny. It is, therefore, reommended tht the sewter setion of the het exhnger e lened t lest one every two yers or whenever deresed ooling effiieny is suspeted, s follows: IMPORTANT: It my e neessry to remove het exhnger on some models. If het exhnger is removed, e sure to refill losed ooling setion with oolnt. Clening System Closed Cooling Setion Closed ooling setion of the ooling system should e lened t lest one every two yers or whenever deresed ooling effiieny is experiened. A good grde utomotive ooling system lening solution my e used to remove rust, sle or other foreign mteril. Alwys follow mnufturer s instrutions for the lener. If losed ooling setion is extremely dirty, pressure flushing devie my e used to flush out remining deposits. Flushing should e done in diretion opposite norml oolnt flow to llow wter to get ehind deposits nd fore them out. Refer to instrutions whih ompny flushing devie for proper hookup nd flushing proedure CLOSED COOLING MODELS - 6B-27

30 1. Remove sewter drin plug from ottom of het exhnger nd llow wter to drin. After wter hs drined ompletely, ot threds of drin plug with Quiksilver Perfet Sel nd reinstll. - Bolt - End Cp - Seling Wsher d - Gsket e - Drin Plug e d Remove olts whih seure end pltes to eh end of het exhnger, then remove end pltes, sel wshers nd gskets. Disrd sel wshers nd gskets. Clen gsket mteril from end pltes nd het exhnger. 3. Clen wter pssges in het exhnger y inserting suitle size wire rush into eh pssge. Use ompressed ir to low loose prtiles out of wter pssges. 4. Apply Quiksilver Perfet Sel to oth sides of new end plte gskets, then reinstll end pltes, using new gskets nd sel wshers. (Be sure to instll sel wshers etween end pltes nd gskets.) Torque end plte olts to speifitions.! CAUTION Avoid sewter pikup pump impeller dmge. DO NOT operte engine without wter eing supplied to sewter pikup pump. 5. With ot in the wter nd/or ooling wter properly supplied to sewter pikup pump, strt engine nd inspet for leks. of Closed Cooling System If engine is operted in slty, polluted or minerl-lden wters, sewter setion of losed ooling system should e flushed periodilly (preferly fter eh use) with fresh wter to redue orrosion nd prevent the umultion of deposits in the system. Sewter setion lso should e thoroughly flushed prior to storge.! WARNING When flushing ooling system with ot out of the wter, e ertin tht re in viinity of propeller is ler nd tht no person is stnding nery. As preutionry mesure, it is reommended tht propeller e removed.! CAUTION Do not run engine ove 1500 RPM when flushing. Sution reted y sewter pikup pump my ollpse flushing hose, using engine to overhet.! CAUTION If ooling system is to e flushed with ot in the wter, seok (if so equipped) must e losed, or wter inlet hose must e disonneted nd plugged to prevent wter from flowing into ot.! CAUTION To prevent engine or stern drive unit dmge DO NOT run engine or drive unit without wter eing supplied to wter intke openings on ger housing.! CAUTION Wth temperture guge t dsh to ensure the engine does not overhet. 1. Follow instrutions pproprite to your model: NOTE: If flushing ooling system with ot in wter, rise drive unit to triler position, instll flushing tthment nd lower drive unit to full IN/DOWN position. Flushing Sewter Setion 6B-28 - CLOSED COOLING MODELS

31 . All Models: (1) Instll Quiksilver Flushing Atthment (or equivlent) over wter intke openings in ger housing. (2) Connet hose etween flushing tthment nd wter tp. - Sewter Pikup Pump - Sewter Inlet Hose Quiksilver Flushing Atthment - Grden Hose Models Equipped with Belt Driven Sewter Pikup Pump: In ddition to supplying wter to the drive (s previously outlined for All Models ), perform the following.! CAUTION If ooling system is to e flushed with ot in the wter, seok (if so equipped) must e losed, or wter inlet hose must e disonneted nd plugged to prevent wter from flowing into ot. (1) Close seok (if so equipped) or disonnet nd plug sewter inlet hose. (2) Loosen hose lmp nd remove sewter inlet hose t lotion shown. Connet n dditionl tp wter hose to inlet fitting using n pproprite dptor. 2. Prtilly open wter tp (pproximtely 1/2 mximum pity) nd llow drive unit nd ooling system to fill ompletely. Do not use full tp wter pressure. NOTE: Drive unit is full when wter is dishrged out of drive unit, nd/or sewter setion of losed ooled system is full when wter is dishrged through propeller. 3. Ple remote ontrol lever in NEUTRAL position nd strt the engine. Operte engine t idle speed in NEUTRAL ger for 10 minutes or until dishrge wter is ler, then stop engine. 4. Shut off tp wter. Remove hose nd flushing tthment from drive unit. On elt driven sewter pikup pump models, lso remove hose nd flushing tthment from pump inlet. 5. Follow instrutions or.! CAUTION If ot is in the wter, seok (if so equipped) must remin losed until engine is to e restrted, to prevent ontminted wter from flowing k into ooling system. If ot is not fitted with seok, wter inlet hose must remin disonneted nd plugged, to prevent wter from flowing into ooling system nd/or ot. As preutionry mesure, tth tg to the ignition swith or steering wheel with the wrning tht the seok must e opened or the wter inlet hose reonneted prior to strting the engine CLOSED COOLING MODELS - 6B-29

32 . If equipped with seok: Oserving preution ove, open seok.. If NOT equipped with seok: Oserving preution ove, remove plug from sewter inlet hose nd reonnet sewter inlet hose. Tighten hose lmps seurely. 2. Chek tht engine is s level s possile to ensure omplete drining of ooling system. 3. Remove drin plugs from port nd strord exhust elows (if equipped). Drining Sewter Setion of Closed Cooling System NOTICE For old wether or extended storge informtion nd proedures, refer to SECTION 1B. Drining Preutions! CAUTION If ot is in the wter, seok (wter inlet vlve), if so equipped, must e left losed until engine is to e restrted to prevent wter from flowing k into ooling system nd/or ot. If ot is not fitted with seok, wter inlet hose must e left disonneted nd plugged to prevent wter from flowing k into ooling system nd/or ot. As preutionry mesure, tth tg to the ignition swith or steering wheel of the ot with the wrning tht the seok must e opened or the wter inlet hose reonneted prior to strting the engine. - Drin Plug (Port nd Strord) 4. Remove drin plug from het exhnger IMPORTANT: Oserve the following informtion to ensure omplete drining of ooling system. Engine must e s level s possile. A wire should e repetedly inserted into ll drin holes to ensure there re no ostrutions in pssges. IMPORTANT: To prevent threds in mnifolds, elows nd ylinder loks from rusting out during storge, reinstll plugs using Quiksilver Perfet Sel on threds. Never leve drin plugs out during storge. NOTE: If possile, ple ontiner under drins nd hoses to prevent wter from drining into ot. 1. Close seok (if so equipped) or disonnet nd plug sewter inlet hose. - Drin Plug B-30 - CLOSED COOLING MODELS

33 5. If equipped with 3 in. (76 mm) or 6 in. (152 mm) risers, remove drin plug s shown from port nd strord risers (if equipped). - Drin Plug (Removed) Repetedly len out drin holes using stiff piee of wire. Do this until entire system is drined. NOTE: It my e neessry to lift, end, or lower hoses to llow wter to drin ompletely when hoses re disonneted. 7. Remove the power steering fluid ooler sewter hose, s shown. Rer Mounted Fluid Cooler Hose, From Sewter Pump (Brvo) Or From Trnsom Assemly (Alph) 8. On Engines Equipped with Belt Driven Sewter Pikup Pump: Remove sewter inlet hose, s shown. - Sewter Pikup Pump - Sewter Inlet Host Port Side Mounted Fluid Cooler - Hose, Sewter Pump to Cover Crnk engine over SLIGHTLY with strter motor to purge ny wter trpped in sewter pikup pump. DO NOT ALLOW ENGINE TO START.! CAUTION If ot is in the wter or is to remin in the wter, seok (if so equipped) must remin losed until engine is to e restrted, to prevent ontminted wter from flowing k into ooling system. If ot is not fitted with seok, wter inlet hose must e left disonneted nd plugged, to prevent ontminted wter from flowing into ooling system nd/or ot. As preutionry mesure, tth tg to the ignition swith or steering wheel with the wrning tht the seok must e opened or the wter inlet hose reonneted prior to strting the engine CLOSED COOLING MODELS - 6B-31

34 10. After sewter setion of ooling system hs een drined ompletely, ot threds of drin plugs with Quiksilver Perfet Sel nd reinstll. Tighten drin plugs seurely. Reonnet hoses nd tighten ll hose lmps seurely. If NOT equipped with seok: sewter inlet hose must remin disonneted nd plugged until engine is to e restrted. Filling Closed Cooling Setion NOTICE See Speifitions for pproximte losed ooling system pity nd oolnt reommendtion.! WARNING Do not remove oolnt p when engine is hot. Coolnt my dishrge violently.! CAUTION Alohol or Methnol sed ntifreeze or plin wter re not reommended for use in fresh wter setion of ooling system t ny time.! CAUTION Front of engine should e higher thn rer to purge trpped ir out of the system during initil filling. This will minimize the possiility of ir eing trpped in the losed ooling setion whih n use engine to overhet. 1. Remove oolnt p on het exhnger. 2. Fill losed ooling system with oolnt mixture through het exhnger fill nek until oolnt level is 1 in. (.25 mm) elow filler nek.! CAUTION! CAUTION Models with elt drive sewter pikup pump must e in the wter when running engine euse grden hose will not supply enough wter to system t higher RPM. 3. With pressure p off, strt engine nd run t fst idle ( RPM). Add oolnt solution to het exhnger, s required, to mintin oolnt level 1 in. (25 mm) elow filler nek. 4. After engine hs rehed norml operting temperture (thermostt is fully open), nd oolnt level remins onstnt, fill het exhnger to ottom of filler nek. 5. Oserve engine temperture guge to mke sure tht engine operting temperture is norml. If guge indites exessive temperture, stop engine immeditely nd exmine for use. 6. Instll pressure p on het exhnger. 7. Remove p from oolnt reovery reservoir nd fill to FULL mrk with oolnt solution. Reinstll p. 8. With engine still running, hek hose onnetion, fittings nd gskets for leks. IMPORTANT: Engine overheting is often due to ir eing trpped in losed ooling setion. Purge ir y running engine t 2000 RPM for 10 minutes.! WARNING Allow engine to ool efore removing pressure p. Sudden loss of pressure ould use hot oolnt to oil nd dishrge violently. After engine hs ooled, turn p 1/4 turn to llow ny pressure to espe slowly, then push down nd turn p ll the wy off. 9. Rehek oolnt level fter first open-throttle ot test nd dd oolnt, if neessry. 10. Mintin oolnt level in oolnt reovery reservoir etween ADD nd FULL mrks with engine t norml operting temperture. Avoid sewter pikup pump impeller dmge nd susequent overheting dmge to stern drive unit. DO NOT operte engine without wter eing supplied to sewter pikup pump. 6B-32 - CLOSED COOLING MODELS

35 Closed Cooling System With Rw Wter Flow Thru Exhust Mnifold (Engines With Serpentine Belt Only) Mintining Closed Cooling System Coolnt At lest weekly, efore strting engine, hek to ensure tht oolnt is visile in oolnt reovery ottle. If oolnt is not visile, hek oolnt setion of ooling system (inluding oolnt reovery system) for leks nd repir, s neessry. Refill oolnt setion with reommended oolnt solution, s outlined under Chnging Closed Cooling System Coolnt, following. If oolnt is visile, strt engine nd run until it rehes norml operting temperture, then rehek oolnt level in oolnt reovery ottle. Coolnt level MUST BE etween the ADD nd FULL mrks (on front of ottle). If level is low, remove fill p from oolnt reovery ottle nd dd required mount of oolnt solution. Use 50/50 mixture of ethylene glyol ntifreeze nd pure, soft wter for oolnt dditions, if frequent dditions of oolnt re required, hek oolnt setion for leks. IMPORTANT: ALCOHOL OR METHANOL BASE ANTIFREEZE OR PLAIN WATER ARE NOT REC- OMMENDED FOR USE IN CLOSED COOLING SYSTEM AT ANY TIME. In res where ethylene glyol is not ville, nd the possiility of freezing does not exist, it is permissile to use solution of rust inhiitor nd pure, soft wter (mixed to mnufturer s reommendtions).! WARNING Coolnt setion of Closed Cooling System is equipped with 16 psi (110 kp) pressure p (fill p). Before removing pressure p, following, first llow engine to ool down, s sudden loss of pressure ould use hot oolnt to oil nd dishrge violently. After engine hs ooled down, turn pressure p 1/4-turn to llow ny pressure to espe slowly, then push down nd turn p ll-the-wy off. Osionlly, hek to ensure tht oolnt reovery system is funtioning properly y removing pressure p from het exhnger nd heking level. Coolnt level should e up to ottom of het exhnger filler nek. If low, inspet entire oolnt setion (espeilly oolnt reovery system) for leks nd repir, s neessry. IMPORTANT: When reinstlling pressure p, e sure to tighten it until its ontt stops on filler nek Fill Cp CLOSED COOLING MODELS - 6B-33

36 Cheking Coolnt for Alklinity! WARNING Coolnt setion of Closed Cooling System is equipped with 16 psi (110 kp) pressure p (fill p). Before removing pressure p (in next step), first llow engine to ool down, s sudden loss of pressure ould use hot oolnt to oil nd dishrge violently. After engine hs ooled down, turn pressure p 1/4-turn to llow ny pressure to espe slowly, then push down nd turn p ll-the-wy off. Coolnt in losed ooling setion of ooling system should e hnged every two yers nd should e heked for lklinity t lest one etween hnge intervls. To hek oolnt for lklinity, proeed s follows: 1. Otin pink litmus pper from lol supplier (drug store, pet shop, et.). 2. Remove pressure p from het exhnger nd insert one end of pink litmus pper into oolnt. 3. If pink litmus pper turns lue, oolnt is lkline nd need not e repled. 4. If pink litmus pper remins pink, oolnt is not lkline nd MUST BE REPLACED, s explined under Chnging Fresh Wter Coolnt, following Crureted Engines, Strord Side (Port Side Similr) - Typil Drin Plug - Seling Wsher! CAUTION Avoid produt dmge. Do not distur the Y-fitting when removing the drin plug. There is n ignition ontrol Knok Sensor in the upper hole of the fitting. This sensor must not e loosened or removed. It is tightened to ritil speifition t the ftory. Chnging Coolnt DRAINING INSTRUCTIONS 1. Remove oolnt reovery ottle nd pour out oolnt.! WARNING EFI Engines Strord Side Coolnt setion of Closed Cooling System is equipped with 16 psi (110 kp) pressure p (fill p). Before removing pressure p, first llow engine to ool down, s sudden loss of pressure ould use hot oolnt to oil nd dishrge violently. After engine hs ooled down, turn pressure p 1/4-turn to llow ny pressure to espe slowly, then, push down nd turn p ll-the-wy off. 2. Remove pressure p from het exhnger. 3. Remove drin plugs on eh side of ylinder lok or fitting, s shown. EFI Engines Port Side - Drin Plug - from Y-fitting - Drin Plug - from Cylinder Blok B-34 - CLOSED COOLING MODELS

37 4. Disonnet het exhnger-to-irulting pump hose from pump nd llow oolnt to drin. FILLING INSTRUCTIONS! CAUTION Alohol or Methnol se ntifreeze or plin wter, re not reommended for use in oolnt setion of Closed Cooling System t ny time. Typil Engine Shown - Het Exhnger - Het Exhnger-to-Cirulting Pump Hose 5. After oolnt hs drined ompletely, reonnet hose, ut, do not tighten hose lmps. 6. With drin plugs still removed, flush losed ooling setion with plin wter until dishrge wter is ler. 7. Disonnet het exhnger-to-irulting pump hose one gin nd drin wter. 8. After wter hs drined ompletely, pply Perfet Sel to threds of drin plugs nd reinstll. Reonnet hose. Be sure to tighten drin plugs nd hose lmps seurely. Refill setion with oolnt, s explined following. It is reommended tht oolnt setion of Closed Cooling System e filled with 50/50 mixture of ethylene glyol ntifreeze nd pure, soft wter. Antifreeze MUST BE used regrdless of whether freezing tempertures re or re not expeted to provide dequte orrosion protetion. In res where ethylene glyol ntifreeze is not ville nd the possiility of freezing DOES NOT exist, it is permissile to use solution of rust inhiitor nd pure, soft wter (mixed to mnufturer s reommendtions). NOTE: Coolnt setion pity is pproximtely 4 U.S. Gllons (15 L). 1. Fill oolnt setion of Closed Cooling System with oolnt mixture s follows:. Open leeder vlve on thermostt housing.. Fill with oolnt mixture through het exhnger fill nek until oolnt ppers t leeder vlve opening.. Close leeder vlve seurely. d. Continue filling until oolnt level is into filler nek nd egins to flow into oolnt reovery ottle plsti tuing CLOSED COOLING MODELS - 6B-35

38 ! CAUTION DO NOT operte engine without wter flowing thru sewter pikup pump, s pump impeller my e dmged nd susequent overheting dmge to engine or stern drive unit my result. Front of engine should e higher thn rer to purge trpped ir out of the system during initil filling. This will minimize the possiility of ir eing trpped in the losed ooling setion whih n use engine to overhet. IMPORTANT: This losed ooling system flows oolnt t high rte. Higher idle speeds inrese dispersion of trpped ir into system mking it more diffiult to purge trpped ir. Operte t idle during filling nd ir purging when speified. 2. Strt engine nd run AT IDLE. Add oolnt solution to het exhnger, s required, to mintin oolnt level t filler nek. After engine hs rehed norml operting temperture (thermostt is fully open), nd oolnt level remins onstnt, fill het exhnger until oolnt level is into filler nek nd egins to flow into oolnt reovery ottle plsti tuing. 3. Remove p from oolnt reovery reservoir nd fill to Full mrk with oolnt solution. Reinstll p. 4. Lift reovery ottle nd plsti tuing ove het exhnger filler nek. Allow oolnt to flow down through tuing to purge ir through filler nek fitting. 5. Instll pressure p on het exhnger. 6. With engine still running, hek hose onnetions, fittings nd gskets for leks. Also oserve engine temperture guge to mke sure tht engine operting temperture is norml. If guge indites exessive temperture, stop engine immeditely nd exmine for use.! WARNING Allow engine to ool down efore removing pressure p. Sudden loss of pressure ould use hot oolnt to oil nd dishrge violently. After engine hs ooled down, turn p 1/4-turn to llow ny pressure to espe slowly, then, push down nd turn p ll-the-wy off. 7. Rehek oolnt level fter first open-throttle ot test nd dd oolnt, if neessry. 8. Mintin oolnt level in oolnt reovery reservoir etween Add nd Full mrks with engine t norml operting temperture. Coolnt setion of Closed Cooling System should e kept filled yer round with reommended oolnt solution. DO NOT drin oolnt, fresh wter setion, for storge, s this will promote rusting of internl surfes. If engine will e exposed to freezing tempertures, mke sure tht oolnt setion is filled with ethylene glyol ntifreeze nd wter solution, mixed to mnufturer s reommended proportion, to protet engine to lowest temperture to whih it will e exposed. 6B-36 - CLOSED COOLING MODELS

39 Pressure Cp Mintenne! WARNING Allow engine to ool down efore removing pressure p (in next step), s sudden loss of pressure ould use hot oolnt to oil nd dishrge violently. After engine hs ooled down, turn p 1/4-turn to llow ny pressure to espe slowly, then, push down nd turn p ll-the-wy off. Pressure p is designed to mintin pressure of pproximtely 16 psi (110 kp) in oolnt setion of Closed Cooling System one the engine hs ttined norml operting temperture. This rises the oiling point of the oolnt, therey inresing the effiieny of the ooling system. To help ensure proper opertion, p should e len, inspeted nd pressure tested (t intervls speified in hrt), s follows: 1. Remove pressure p from het exhnger. 2. Wsh p with len wter to remove ny deposits or deris from seling surfes. 3. Inspet ruer sel on p for uts, rks or other signs of deteriortion. If sel is dmged, p MUST BE repled. 4. Inspet oolnt reovery gsket for deteriortion nd reple if d. 5. Chek ondition of loking ts on p. Reple p, if ts re ent or rked. 6. Hve pressure p pressure-tested y your lol serviing deler. 7. Clen seling surfes on het exhnger filler nek with loth. Inspet surfes for ny dmge or deposits tht my prevent p from seling properly. 8. Clen oolnt reovery pssge in het exhnger filler nek with wire nd low out with ompressed ir. 9. Reinstll pressure p, eing sure to tighten until its ontts stops on filler nek Pressure Cp Seling Surfes - Coolnt Reovery Pssge Ruer Sel - Coolnt Reovery Gsket - Loking Ts (1 Hidden) CLOSED COOLING MODELS - 6B-37

40 Flushing Sewter Setion If ot is operted in slty, polluted or minerl-lden wters, sewter setion of ooling system should e flushed periodilly (preferly fter eh use) to remove orrosive wter nd nd prevent the umultion of deposits in the system. Sewter setion lso should e thoroughly flushed prior to storge. To flush sewter setion of ooling system, proeed s follows: IMPORTANT: If ooling system is to e flushed with ot in the wter, wter inlet vlve (if so equipped) MUST BE losed, or wter inlet hose MUST BE disonneted nd plugged, to prevent wter from flowing into ot nd/or ooling system. IMPORTANT: If vlve is to e instlled for the purpose of drining or flushing sewter setion, vlve MUST hve n internl ross-setionl re equl to or greter thn wter inlet hose to prevent restriting wter flow during norml opertion. A 1-1/4 in. (32mm) or lrger rss ll vlve or gte vlve is reommended. 1. Disonnet wter inlet hose from end of sewter pikup pump. 2. Using pproprite onnetor, onnet ity wter tp to pump inlet onnetion nd prtilly open wter tp (pproximtely 1/2 minimum pity). DO NOT use full ity wter pressure.! CAUTION DO NOT run engine ove 1500 RPM, s sution reted y sewter pikup pump my ollpse wter supply hole, interrupting wter flow nd using engine to overhet.! CAUTION Wth temperture guge t dsh to ensure tht engine does not overhet. 3. Ple the remote ontrol lever in neutrl position nd strt engine. Operte engine t idle speed in neutrl ger for 10 minutes or until dishrge wter is ler, then stop engine. 4. Shut off wter tp. Remove flushing onnetor from pump inlet nd reonnet wter inlet hose. Be sure to tighten hose lmp seurely. IMPORTANT: If ot is in the wter, DO NOT open wter inlet vlve until engine is to e restrted, to prevent ontminted wter from flowing k into engine. If ot is not fitted with vlve, leve wter inlet hose disonneted nd plugged. As preutionry mesure, tth tg to the ignition swith or steering wheel with the wrning tht the seok must e opened or the wter inlet hose reonneted prior to strting the engine.! WARNING When flushing ooling system with ot out of the wter, e ertin tht re in viinity of propeller is ler nd tht no person is stnding nery. As preutionry mesure, it is reommended tht propeller e removed. 6B-38 - CLOSED COOLING MODELS

41 Clening Sewter Setion of Het Exhnger nd Fluid Coolers During opertion, ontminnts in the sewter my ollet on tues within the het exhnger nd fluid oolers reduing their ooling effiieny. This will use oolnt temperture to grdully rise until n overheting ondition exists. To prevent this from hppening, the sewter setion of het exhnger, nd fluid oolers should e lened t lest one yer or whenever grdul rise in temperture is oserved on wter temperture guge. Clen sewter setion of het exhnger nd oolers. 1. Refer to Cold Wether or Extended Storge - Sewter Setion Drining Instrutions nd drin sewter setion. 2. Remove end over, tthing srew, O-ring nd ruer gsket, from port nd strord ends of het exhnger. d 3. Follow pproprite instrutions or : d. On Engines Without Cool Fuel System: Proeed to Step 4.. On Engines With Cool Fuel System: Disonnet the fore nd ft sewter hoses from Cool Fuel System ooler. Typil Engine With Cool Fuel System - Cool Fuel System - Cooler of Cool Fuel System - Sewter Hose From Sewter Pump d - Sewter Hose To Het Exhnger Disonnet hoses from ends of power steering ooler Strord End Cover Shown (Port Similr) - End Cover - Srew - O-Ring d - Ruer Gsket - Power Steering Fluid Cooler - Sewter Hose From Sewter Pump - Sewter Hose To Het Exhnger Remove ny deris from vities on ends of het exhnger nd fluid oolers CLOSED COOLING MODELS - 6B-39

42 6. Clen tues (pssges) in het exhnger nd oolers y running suitle wire rush through eh tue. 9. Instll ll hoses previously disonneted. Tighten hose lmps seurely. 10. Strt engine nd hek for leks. - Wire Brush, Sized To Fit Pssge Rinse out het exhnger nd fluid ooler tues with tp wter from hose to remove loosened prtiles. 8. Instll end overs on het exhnger s follows:. Clen gsket mting surfes on end overs of het exhnger.. Inspet gskets nd O-rings for dmge nd reple if neessry.. Reinstll end overs with omponents shown. Torque end over srews to 1 to 1-1/2 turns pst hnd tight. Clening Closed Cooling Setion Closed Cooling setion of ooling system should e lened whenever deresed ooling effiieny (due to internl deposits) is experiened. A good grde utomotive ooling system lening solution, tht is omptile with opper nd st iron my e used to remove rust, sle or other foreign mteril. Mnufturer s instrutions of prtiulr lener eing used, should e refully followed to ensure sfe nd effetive lening opertion. If oolnt setion is extremely dirty, pressure flushing devie my e used to flush out remining deposits. Flushing should e done in diretion opposite norml oolnt flow (with thermostt removed) to llow wter to reh ehind deposits nd fore them out (refer to Cooling System Wter Flow Digrm, following). Follow instrutions whih ompny flushing devie for proper hookup nd flushing proedure. d End Cover (Het Exhnger) - Srew - O-ring d - Ruer Gsket 6B-40 - CLOSED COOLING MODELS

43 Cold Wether or Extended Storge 1. Remove drin plug from port nd strord exhust mnifolds.! CAUTION Sewter setion of ooling system MUST BE COMPLETELY drined for winter storge, or immeditely fter old wether use, if the possiility of freezing tempertures exist or if the ot is to e stored for n extended period. Filure to omply my result in trpped wter using freeze nd/or orrosion dmge to engine Sewter Setion Drining Instrutions IMPORTANT: Oserve the following informtion to ensure omplete drining of ooling system. Strord Side (Port Side Similr) - Drin Plug 2. Disonnet het exhnger-to-strord exhust mnifold hose t mnifold. Lower hose nd llow to drin. Engine must e s level s possile. A wire should e repetedly inserted into ll drin holes to ensure there re no ostrutions in pssges. It my e neessry to lift, lower or end disonneted hoses to llow wter to drin ompletely.! CAUTION If sewter setion of the Closed Cooling System is to e drined with ot in the wter, seok (wter inlet vlve), if ot is so equipped, must e losed or wter inlet hose MUST BE disonneted from sewter pikup pump nd plugged, to prevent wter from flowing into ooling system nd/or ot. IMPORTANT: If seok (wter inlet vlve) is to e instlled for drining purpose, vlve used MUST hve n internl ross-setionl re equl or greter thn wter inlet hose to prevent restriting wter flow during norml opertion. A 1-1/4 in. (32mm) or lrger rss ll vlve or gte vlve is reommended. Typil Strord Hose Shown - Strord Exhust Mnifold - Strord Hose CLOSED COOLING MODELS - 6B-41

44 3. Follow instrutions or :. On Engines With Cool Fuel System: Remove drin plug from Cool Fuel System sewter pipe. 4. Repetedly len out drin holes using stiff piee of wire. Do this until entire system is drined. 5. Remove end over, tthing srew, O-ring nd ruer gsket, from port nd strord ends of het exhnger. IMPORTANT: Use ompressed ir to low ny remining wter from tues in the het exhnger d - Cool Fuel System Cooler - Sewter Pipe Drin Plug. On Engines Without Cool Fuel System: Remove drin plug from port side sewter pipe Typil Engine nd Het Exhnger Shown - End Cover - Srew - O-ring d - Ruer Gsket Sewter Pipe - Sewter Pipe Drin Plug 6B-42 - CLOSED COOLING MODELS

45 6. Follow instrutions or :. On Engines WITHOUT Engine Mounted Sewter Pump: Proeed to Step 7.. On Engines Equipped WITH Engine Mounted Sewter Pump: (1) Disonnet wter inlet nd outlet hose from sewter pump. Lower hoses nd llow to drin. Reonnet hoses nd tighten lmps seurely. (2) Crnk engine over slightly, with strter motor, to purge ny wter trpped in sewter pikup pump. Do not llow engine to strt. 7. After ooling system hs drined ompletely, reinstll drin plugs nd onnet ll sewter hoses. Tighten eh seurely.! CAUTION If ot is in the wter, wter inlet vlve (if so equipped) MUST e left losed until engine is to e restrted, to prevent wter from flowing k into ooling system. If ot is not fitted with vlve, wter inlet hose MUST BE left disonneted nd plugged. As preutionry mesure, tth tg to the ignition swith or steering wheel with the wrning tht the vlve MUST BE opened or the hose reonneted prior to strting the engine. - Sewter Pump - Sewter Pump Inlet Hose - Sewter Outlet Hose CLOSED COOLING MODELS - 6B-43

46 Serpentine Drive Belt Adjustment 1. Loosen 5/8 in. loking nut on djustment stud. Leve wrenh on djustment stud Typil -5/8 In. Loking Nut -Adjustment Stud Belt Routing WITH Power Steering nd WITHOUT Engine Mounted Sewter Pump 2. Instll drive elt on pulleys. Route elt for your type of power pkge. 3. Belt defletion is to e mesured on the elt t the lotion tht hs the longest distne etween two (2) pulleys. 4. Use 5/16 in. soket nd tighten djusting stud until the orret defletion of 1/4 in. (6 mm) (with moderte thum pressure, on the elt t lotion indited y rrow nd dshed lines of the elt) is otined t lotion shown Belt Routing WITHOUT Power Steering nd WITHOUT Engine Mounted Sewter Pump Belt Routing WITH Power Steering nd Equipped WITH Engine Mounted Sewter Pump Belt Routing WITHOUT Power Steering nd Equipped WITH Engine Mounted Sewter Pump Typil -5/8 In. Loking Nut -Adjustment Stud 5. Operte the engine for short period of time. Rehek elt djustment. 6B-44 - CLOSED COOLING MODELS

47 Auxiliry Hot Wter Heter Instlltion IMPORTANT: When onneting in heter or hot wter heter, ertin requirements must e met. Supply hose (from engine to heter) nd return hose (from heter to engine) MUST NOT EXCEED 5/8 in. (15.8 mm) I.D. (inside dimeter). Engine with Closed Cooling System: Heter MUST BE LOWER thn fill p on the het exhnger. If the heter is higher thn the fill p on the het exhnger nd some oolnt is lost in the system, n ir poket my form in the losed ooling system. This, in turn, n use the engine to overhet. Mke heter onnetions ONLY t lotions desried in the following instrutions. Chek omplete system for leks fter heter is onneted into ooling system. Chek for overheting ondition (of engine) fter heter is onneted. 1. Refer to Chnging Coolnt - Drining Instrutions ; drin losed ooling system. 2. Inspet for pproprite lotion of supply hose t following: NOTE: Hot wter heter supply hose n e onneted t severl different lotions. On some models, there my e other essories nd options tht re utilizing these hot wter supply lotions. One of the following should e ville for use when instlling hot wter heter system. IMPORTANT: Do not reposition engine temperture swith; it must remin where instlled y ftory. SUPPLY HOSE CONNECTION - ENGINES WITH RAW WATER OR CLOSED COOLING SYSTEM Primry Lotion - Plug - Reduer Bushing - Hose Connetor Rw Wter Cooling Models - Alternte Lotion - Lotion for Hot Wter Supply (Instll Byonet Fitting Here) CLOSED COOLING MODELS - 6B-45

48 RETURN HOSE CONNECTION - ENGINES WITH RAW WATER OR CLOSED COOLING SYSTEM Erlier Style Quiksilver Kit Lotion - T-Fitting Lter Style Quiksilver Kit Lotion - Pipe Plug - Hose Connetor - T-Fitting d - Hose Clmps 6B-46 - CLOSED COOLING MODELS

49 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE CLOSED COOLING MODELS - 6B-47

50 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 6B-48 - CLOSED COOLING MODELS