13. Install the water pump housing assembly to the fixture. See Figure

SERIES 60 SERVICE MANUAL 13. Install the water pump housing assembly to the fixture. See Figure 4-120. Figure 4-120 Water Pump Impeller Installation Set-Up (FM) NOTICE: The extension must contact and support the shaft when installing the water seal and impeller to prevent damage to the bearings. 14. Turn the adjustor wheel to raise the extension until it contacts the drive shaft in the water pump housing. 15. Apply Loctite primer (Locquic Primer N, Part No. 764) by swabbing onto the I.D. of the rotor of the seal. 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 4-60-02rev 4-63

4.3 WATER PUMP (FRONT MOUNTED) (FM) 16. Install a new water seal over the drive shaft and seat it in the water pump housing. See Figure 4-121. Figure 4-121 Water Seal Insertion (FM) 17. Position tool J 35988-1A, part of tool set J 35988-B, over the water seal. See Figure 4-122. Figure 4-122 Water Seal Installation (FM) 4-64 From Bulletin 4-60-02rev 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION

SERIES 60 SERVICE MANUAL 18. Press the water seal into the housing until the flange of the seal case contacts the water pump housing a full 360. Remove tool J 35988-1A, part of tool set J 35988-B. 19. With the water pump housing still housed in toolj 35988-2, part of tool set J 35988-B, and located on a press bed, install the water pump impeller to the end of the drive shaft. Position the impeller so that the machined end is parallel with the housing machined face. See Figure 4-123. Figure 4-123 Water Pump Impeller Installation (FM) 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 4-60-02rev 4-65

4.3 WATER PUMP (FRONT MOUNTED) (FM) 20. Press the impeller on until it is flush with the end of the drive shaft. See Figure 4-124. Figure 4-124 Water Pump Impeller Location (FM) 21. Turn the housing over and place it face (impeller side) down on fixturej 35988-2, part of tool set J 35988-B. 4-66 From Bulletin 4-60-02rev 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION

SERIES 60 SERVICE MANUAL 22. Install the Woodruff key to its slot in the drive shaft. Tap the key with a brass hammer to seat it squarely in the slot. See Figure 4-125. Figure 4-125 Woodruff Key Installation (FM) 23. Install the water pump drive gear to the drive shaft, indexing the slot in the gear with the Woodruff key. NOTICE: Extension tool J 35988-3, part of tool set J 35988-B, must support the shaft. This is necessary to prevent damage to the bearings when pressing the gear onto the shaft. 24. Turn the adjustor wheel to raise the extension toolj 35988-3, part of tool set J 35988-B, until it contacts the shaft. 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 4-60-02rev 4-67

4.3 WATER PUMP (FRONT MOUNTED) (FM) 25. Using the small end of toolj 35988-1A, part of tool set J 35988-B, press the drive gear down onto the drive shaft until it touches the bearings. See Figure 4-126. Figure 4-126 Water Pump Drive Gear Installation (FM) 26. Install locknut to the drive shaft threads. See Figure 4-127. Figure 4-127 Locknut Installation (FM) 4-68 From Bulletin 4-60-02rev 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION

SERIES 60 SERVICE MANUAL 27. Using J 35988-5, part of tool set J 35988-B, with a breaker bar to hold the gear and shaft, tighten the locknut with a torque wrench to 203-230 N m (150-170 lb ft) torque. 4.3.6.1 Assembly Integrity Test Verify the assembly integrity as follows: 1. Turn the pump over and install J 35687 into the tapped holes provided in the impeller. 2. Clamp J 35988-5, part of tool set J 35988-B, (legs up) in a vise and position the lightening holes in the drive gear over the legs of the tool. 3. Using a 1/2 in.-drive torque wrench in the hole provided in the center of J 35687, apply 68 N m (50 lb ft) torque in either direction. [a] The gear and impeller must withstand 68 N m (50 lb ft) torque without slipping. [b] If the torque specification is not satisfied, disassemble water pump and replace the impeller. Refer to section 4.3.3. 4. Using a dial indicator with magnetic base, measure the total run-out of the water pump drive gear at four places, at 90 degree intervals. Maximum allowable run-out is 0.0635 mm (0.0025 in.). See Figure 4-128. Figure 4-128 Measuring Water Pump Drive Gear Runout (FM) [a] [b] If specifications are exceeded, disassemble the water pump and check for burrs or foreign particles. Refer to section 4.3.3. If specifications are with limits, reuse part. 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin 4-60-02rev 4-69

4.3 WATER PUMP (FRONT MOUNTED) (FM) 4.3.7 Installation of Front Mounted Water Pump Install the water pump as follows: 1. Coat the two seal rings with clean engine oil. Install the larger seal ring to the groove in the water pump housing. Install the smaller seal ring to the groove in the water pump cover. Coat the water pump drive gear with clean engine oil. 2. Install the water pump to the engine, meshing the water pump drive gear with the bull gear. 3. Install the three water pump housing-to-gear case cover bolts. Tighten the bolts alternately and evenly to draw the water pump straight into the engine. Torque the bolts to 30-38 N m (22-28 lb ft). 4. Measure the gear backlash. Refer to section 1.21.2..1. 5. Install the water pump cover to the water pump with two bolts. Torque the bolts alternately and evenly to draw the cover straight into the water pump housing. Torque the bolts to 30-38 N m (22-28 lb ft). 6. Slide the coolant hoses into position and tighten the hose clamps. 7. Fill the cooling system. Refer to section 13.13.4 of engine maintenance. 4-70 From Bulletin 4-60-02rev 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION

4.4 CHARGE AIR COOLER RAW WATER PUMP (KEEL-COOLED COMMERCIAL MARINE) 4.4 CHARGE AIR COOLER RAW WATER PUMP (KEEL-COOLED COMMERCIAL MARINE) The centrifugal-type water pump circulates raw water through the charge air cooler (CAC) on keel-cooled marine engines. The drive end of the pump shaft is supported by a sealed double-row combination radial and thrust ball bearing. The pump shaft serves as the inner race of the bearing. The pump is mounted to the rear end of the gear case on the intake side of the engine. The drive coupling, pressed on the end of the pump shaft, has an integral oil thrower that shrouds the flange end of the pump body and deflects the oil away from the bearing. See Figure 4-129. 1. To Charge Cooler 5. Bolt 2. Hose 6. Water Pump 3. Pump Cover 7. Inlet Flange 4. Drain Cock 8. Clamp Figure 4-129 CAC Water Pump Mounting NOTE: The high capacity water pump has a shaft bearing assembly, unitized seal assembly, drive coupling, and ceramic insert. 4-72 From Bulletin 4-60-02rev 6SE483 0204 Copyright 2002 DETROIT DIESEL CORPORATION