Cooling System. Table of Contents. Section 6A - All Models. All Models

Transcription

1 Cooling System All Models Tle of Contents Setion 6A - All Models Speifitions...6A-3 Flow Speifitions... 6A-3 Sewter Inlet Speifitions...6A-3 Generl Informtion... 6A-3 Sewter Pump Identifition... 6A-4 Sewter Inlet Hose... 6A-4 Sewter Pump Output Test... 6A-4 Colleting Wter Pressure Dt... 6A-5 CDS Connetion to the Engine...6A-6 Sewter Pump Pulley Alignment... 6A-6 Through the Hull Sewter Pikup System... 6A-7 Sewter Striner... 6A-8 Sewter Pikup...6A-8 Seok... 6A-9 Sewter Striner... 6A-10 Sewter Striner Mounting Requirements...6A-10 Sewter Striner Instlltion...6A-10 Clening the Sewter Striner, if Equipped...6A-11 Wter Heter Instlltion... 6A-11 Supply Hose Connetion TKS Models... 6A-12 Supply Hose Connetion MPI Models...6A-12 Models with Closed Cooling... 6A-12 Return Hose Connetion... 6A-13 Brss Sewter Pump... 6A-13 Sewter Pump Exploded View... 6A-13 Removl...6A-14 Disssemly... 6A-14 Clening nd Inspetion... 6A-15 Assemly... 6A-15 Instlltion...6A-21 Wter Cirulting Pump... 6A-22 Removl...6A-22 Clening nd Inspetion... 6A-22 Instlltion...6A-22 Air Atuted Drin System...6A-24 Air Mnifold nd Air Pump Exploded View...6A-24 Generl Informtion... 6A-26 Testing... 6A-26 Air Mnifold...6A-26 Exhust Mnifold Drin Chek Vlve... 6A-26 Chek Vlve...6A-27 Wter Distriution Housing... 6A-28 Removl...6A-28 Clening nd Inspetion... 6A-28 Instlltion...6A-28 6 A 90-8M AUGUST 2013 Pge 6A-1

2 Lurint, Selnt, Adhesives Tue Ref No. Desription Where Used Prt No. 9 Lotite 567 PST Pipe Selnt 19 Perfet Sel 66 Lotite 242 Thredloker Hose fitting threds nd plsti plug threds Wter-irulting pump gsket nd the threds of the tthing fsteners Impeller housing over or sewter pump tutor housing srew threds Q Lotite 609 Outer dimeter of the front sel Otin Lolly RTV 587 Ultr Blue Silione Seler Merury 25W-40 Syntheti Blend 4-Stroke Engine Oil 142 Lotite 598 RTV Selnt Speil Tools Seling surfes nd srew shft Outer dimeter of the erings Sewter pump shft Wer plte on the sewter pump housing over or the tutor housing K01 Otin Lolly Computer Dignosti System (CDS) 4520 Bosh Automotive Servie Solutions Monitors ll eletril systems for proper funtion, dignostis, nd lirtion purposes. For dditionl informtion, priing, or to order the Computer Dignosti System ontt: or ll: USA Cnd Europe Austrli (03) Power Steering Pump Pulley Remover SPX J Removes the pulley on the DHB power steering pumps nd wter pumps with smller shfts Pulley Pusher Instller A Instlls the pulley onto the power steering pump. Air Line Cutter Cuts wter drin system ir lines without ollpsing them Pge 6A M AUGUST 2013

3 Speifitions Flow Speifitions Alph Sterndrive Models Model Cooling RPM Minimum flow Minimum pressure All 4.3L models Sewter ooling L/min (13 gl/min) 35 kp (5 psi) All 4.3L models Closed ooling L/min (28 gl/min) 138 kp (20 psi) Brvo Sterndrive Models Model Cooling RPM Minimum flow Minimum pressure All 4.3L models Sewter ooling L/min (13 gl/min) 69 kp (10 psi) All 4.3L models Closed ooling L/min (28 gl/min) 138 kp (20 psi) Sewter Inlet Speifitions Sewter Inlet Speifitions Sewter inlet hose Sewter pikup Seok (ABYC requirement) Sewter striner (optionl) 32 mm (1 1/4 in.) I.D. (wire reinfored) Low restrition with 32 mm (1 1/4 in.) onnetions Generl Informtion A Merury MerCruiser engine hs either sewter ooling system or losed ooling system. On engines with sewter ooling, the engine is ooled entirely y the wter in whih the ot is eing operted. Closed ooling systems use two ooling iruits, one of whih mimis the sewter ooling system. The seond iruit uses mixture of fresh wter nd oolnt/ ntifreeze. Both types of systems re designed to mintin the engine operting temperture t pproximtely 71 C (160 F) for optimum performne, fuel eonomy, nd durility. NOTE: Sewter ooling is sometimes referred to s rw wter ooling or stndrd ooling. Closed ooling is lso known s fresh wter ooling. The ooling system must reeive suffiient mount of sewter under ll operting onditions to operte properly. The design nd instlltion of the sewter supply system is the ot mnufturer's responsiility. NOTICE Without suffiient ooling wter, the engine, the wter pump, nd other omponents will overhet nd suffer dmge. Provide suffiient supply of wter to the wter inlets during opertion. 90-8M AUGUST 2013 Pge 6A-3

4 Sewter Pump Identifition Brss sewter pump without ir-tuted drin vlve Brss sewter pump with ir-tuted drin vlve Sewter Inlet Hose Use 32 mm (1 1/4 in.) I.D. wire reinfored hose tht is ple of supporting 34 kp (10 in. Hg) of vuum to prevent the sewter inlet hose from ollpsing from the sewter pump sution. The hose should e oil nd sewter resistnt. Use the shortest hose length possile, with miniml ends to mximize flow. All onnetions must e seured with hose lmps. Fsten the hoses to mintin proper routing nd to prevent hfing or ontt with other moving prts. - Sewter inlet hose - Sewter outlet hose to ooler Sewter Pump Output Test IMPORTANT: Note the following: The ot must e in the wter for this test. This test nnot e performed with flush test devie nd wter hose. 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. Perform this test urtely or prolems my not e deteted. An error in setting the engine RPM, timing the test, or mesuring the wter output will ffet the overll ury of the test nd my produe misleding results. To help ensure urte results: Use shop thometer with n error rte of less thn 5%. Do not use the ot thometer s it my not hve the neessry preision. Use stop wth to time the durtion of the test to help ensure tht ury is mintined. Use 9.5 L (10 US qt) or lrger pity ontiner to mesure the wter output. If the engine overhets, use this test to determine if suffiient mount of wter is eing supplied to ool the engine: 1. Models with engine mounted sewter pumps: Remove the wter hose tht is etween the pump outlet nd the engine, nd reple it with nother hose of the sme dimeter ut pproximtely 1 m (3 ft) longer. The hose should hve dequte wll thikness to prevent it from kinking when performing the test. Clmp the hose t the pump outlet only. Do not lmp the hose t the engine ooler end Pge 6A M AUGUST 2013

5 2. Models with sterndrive mounted sewter pump (Alph Models): Remove the wter inlet hose, whih is etween the giml housing wter tue nd the engine, nd reple it with nother hose of the sme dimeter ut pproximtely 1 m (3 ft) longer. The hose should e of dequte wll thikness to prevent it from kinking when performing the test. Clmp the hose t the giml housing wter tue only. Do not lmp the hose t the engine end. - Wter tue - Hose lmp - Wter hose 3. Ple 9.5 L (10 US qt) or lrger ontiner ner the unlmped end of the hose With the ssistne of nother person, using shop thometer, strt the engine nd djust the speed to extly 1000 RPM while holding the unlmped end of the hose on the onnetion on the engine. Remove the hose from the onnetion on the engine nd diret the wter flow into the ontiner for extly 15 seonds. At the end of 15 seonds, diret the wter flow overord, return the engine to idle nd stop the engine. Reonnet the hose to the engine. 5. Mesure the quntity of wter dishrged into the ontiner nd ompre with the speifitions given in the following hrt. NOTE: Vlues listed re minimum dishrge quntities. Typil vlues t 1000 RPM re pproximtely 1.4 times those listed. Engine Mounted Sewter Pump Output for 15 Seond Period Model Brvo model with sewter ooling Brvo model with losed ooling nd n externl wter pikup All inord nd tow sport models Minimum Quntity 7.1 L (7.5 US qt) 9.0 L (9.5 US qt) 9.0 L (9.5 US qt) Alph Sterndrive Sewter Pump Output for 15 Seond Period Model Alph models 6. Repet the test four times to onfirm the results. Colleting Wter Pressure Dt Minimum Quntity 4.7 L (5.0 US qt) Use the Merury Computer Dignosti System (CDS) to ollet wter pressure dt on models equipped with wter pressure sensor. Computer Dignosti System (CDS) Bosh Automotive Servie Solutions IMPORTANT: On sewter ooled Alph sterndrive models, ollet the wter pressure dt etween the trnsom nd the sewter inlet on the power ssisted steering fluid ooler. IMPORTANT: On Alph nd Brvo sterndrive models with losed ooling, the wter pressure dt must e olleted within 152 mm (6 in.) of the sewter pump inlet. Speifitions Refer to Flow Speifitions t the eginning of this setion. 90-8M AUGUST 2013 Pge 6A-5

6 CDS Connetion to the Engine For omplete informtion out seleting the pproprite engine interfe les, onneting CDS to the engine, nd system progrm opertion, refer to the CDS softwre help system provided with the CDS progrm. CDS Help is quik ess referene tool tht provides omprehensive informtion on ll of the vrious topis relted to the Merury Mrine Computer Dignosti System inluding proper CDS onnetion to the engine. Sewter Pump Pulley Alignment 1. Ple strightedge ross the sewter pump pulley nd the rnkshft pulley. 2. The outer fe of the sewter pump pulley my e slightly in front of or ehind the outer fe of the rnkshft pulley, ut the two fes should e lmost prllel. - Crnkshft pulley - Strightedge - Sewter pump pulley The sewter pump pulley must e prllel within 1.5 mm (1/16 in.) of the strightedge. If it is not, reple the rket. Sewter Pump Brket Replement 1. Instll the pump onto the new rket. Tighten the sewter pump to rket fsteners to the speified torque. Desription Nm l in. l ft Sewter pump tthment fsteners NOTE: If the originl sewter pump rket hd wshers etween it nd the engine ylinder lok, disrd them. The new rket does not use wshers etween it nd the ylinder lok. NOTE: A stiffening t hs een dded to the new rket. Consequently, the lotion of the mounting stud nd olt hs to e hnged. 2. Move the stud from the lower ylinder lok hole to the one tht hd the olt in it. 3. Instll the rket onto the stud nd then rotte it to instll the originl olt through the lower rket hole. 4. Tighten the sewter pump rket fsteners to the speified torque. Desription Nm l in. l ft Sewter pump rket fsteners Instll the serpentine elt nd djust it until there is 13 mm (1/2 in.) defletion etween the two upper pulleys. Pge 6A M AUGUST 2013

7 Through the Hull Sewter Pikup System IMPORTANT: Use 32 mm (1 1/4 in.) I.D. wire reinfored hose tht is ple of supporting 34 kp (10 in. Hg) vuum when sution is reted y the sewter pump impeller. f e Typil instlltion shown with through-the-hull sewter pikup - Sewter pikup nd seok - Hose lmp - Sewter hose to sewter striner d - Quiksilver sewter striner e - Sewter hose to engine f - Sewter pump hose onnetor (if equipped) g - Below sewter pump level IMPORTANT: Do not instll the sewter pikup diretly in line with the propeller, s the pikup my rete turulene nd llow ir to flow into the propeller slipstrem. This will use propeller ventiltion nd will dversely ffet ot performne. IMPORTANT: Mke grdul ends in the sewter hoses to void kinks. Hoses must not ome in ontt with steering system omponents, engine oupler, or driveshft. The sewter pikup must e lrge enough to permit suffiient sewter flow to engine sewter pump for dequte engine ooling. The sewter pikup lso must supply positive hed while underwy. g The sewter pikup should e loted s lose to the sewter pump inlet s possile nd in n re where n uninterrupted, solid strem of sewter will flow when the ot is underwy. d M AUGUST 2013 Pge 6A-7

8 Sewter Striner A sewter striner is reommended if the ot is operted in n re with high deris ontent. Use 32 mm (1 1/4 in.) I.D. wire reinfored hoses on the inlet nd outlet sides of the striner fittings. The striner must e sized to minimize restrition (refer to Speifitions) nd to provide resonle servie intervl. Lote the striner in n re tht is essile for serviing. If the ot is not equipped with seok, the striner should e loted ove the wterline to prevent sewter entry into the ot when serviing. The striner must hve provision to llow drining in freezing tempertures Sewter Pikup Typil sewter striner Either through trnsom or through hull sewter pikup n e used. Selet the pikup lotion to minimize the length of the 32 mm (1 1/4 in.) I.D. wire reinfored sewter inlet hose, while providing n optimum lotion for sewter pikup. The lotion should e in n re tht provides solid, ir free flow of sewter under ll operting onditions. Avoid res with distured sewter flow, suh s those ehind or in lose proximity to the propeller. Lotions tht re too fr forwrd or outord should lso e voided s these re prone to ertion prolems t high ot trim ngles nd while turning. IMPORTANT: Do not instll the sewter pikup diretly in line with the propeller, s the pikup my rete turulene nd llow ir to flow into the propeller slip strem. This will use propeller ventiltion nd will dversely ffet ot performne. Openings in sewter pikup should e mximum of pproximtely 3 mm (1/8 in.) to prevent lrge deris from entering nd logging the ooling system. IMPORTANT: Use sewter striner if the sewter pikup openings exeed 3 mm (1/8 in.). Some industry stndrds nd regultions require tht the pikup e onneted into the ot's onding system to minimize stry urrent orrosion. Refer to pplile stndrds nd regultions for more detils. Pge 6A M AUGUST 2013

9 IMPORTANT: An externl sewter pikup must hve n integrl seok Sewter pikup with n integrl seok g d e h f Trnsom pikup - Hose fitting pply Lotite 567 to the threds - Nut (4) - Gsket d - O ring (4) e - Wsher (4) f - Srew (4) g - Plsti plug pply Lotite 567 to the threds h - Pikup pply RTV 587 to the seling surfes i - Sreen j - Srew (2) pply RTV 587 to the shft i j 7558 Tue Ref No. Desription Where Used Prt No Seok Lotite 567 PST Pipe Selnt RTV 587 Ultr Blue Silione Seler Hose fitting threds nd plsti plug threds Seling surfes nd srew shft The Amerin Bot nd Yht Counil (ABYC) nd other industry stndrds nd regultions require the use of seok on ertin types of pplitions to stop the entry of sewter in the event of lek in the ooling system. Refer to pplile stndrds nd regultions for speifi requirements. The seok lso llows the sewter to e shut off when serviing the engine. 90-8M AUGUST 2013 Pge 6A-9

10 The seok must provide minimum restrition to sewter flow (refer to Speifitions). A ll vlve or gte vlve is reommended. The ll vlve is most ommon nd is typilly equipped with lever type hndle tht opertes in 90 r. This design gives ler indition of whether the vlve is open or shut. Industry stndrds require tht the seok e rigidly tthed to the hull t the sewter pikup. The seok's lotion should e essile for quik, esy opertion Sewter Striner Sewter Striner Mounting Requirements Typil seok Use properly sized striner to mintin n dequte supply of wter for ooling the engine. Mount the sewter striner in lotion tht will llow esy ess for serviing, nd mintenne. Mount the sewter striner in virtion free lotion. Do not mount the sewter striner on the engine. If not equipped with seok, mount the sewter striner ove the sewter line to prevent sewter entry into the ot when serviing. Use 32 mm (1 1/4 in.) I.D. wire reinfored hose. Do not llow hoses to ontt hot or moving prts on the engine. Sewter Striner Instlltion Refer to the mnufturer's instrutions for detiled instlltion, opertion, nd mintenne. IMPORTANT: Use the following guidelines when instlling Merury sewter striner. 1. Position the sewter striner in n pproprite lotion, elow the level of the sewter pump. 2. Ensure tht the rrow tht indites the diretion of sewter flow points towrd the sewter pump. 3. Instll the sewter striner using flt wshers nd lg olts. - Sewter striner - Arrow inditing diretion of wter flow - Mounting olt hole lotion (olts not shown) Pge 6A M AUGUST 2013

11 Clening the Sewter Striner, if Equipped NOTICE All Models An open sewter striner or seok during some servie or mintenne proedures n introdue wter into the ot, using dmge or sinking the ot. Alwys lose the wter supply from the sewter pump, wter inlet, or seok when performing servie or mintenne on the ooling system. 1. With the engine off, lose the seok, if equipped, or remove nd plug the sewter inlet hose. 2. Remove the srews, wshers, nd over. 3. Remove the striner, drin plug, nd seling wsher. 4. Clen ll the deris from the striner housing. Flush oth the striner nd housing with len wter. 5. Chek the over gsket nd reple when dmged or if it leks. 6. Reinstll the striner, drin plug, nd seling wsher.! CAUTION Sewter leking from the sewter striner ould use exess wter in the ilge, dmging the engine or using the ot to sink. Do not overtighten the over srews, or the over my wrp nd introdue sewter into the ilge. 7. Instll the sel nd over using the srews nd wshers. Do not overtighten the over srews. f - Srews nd wshers - Cover with glss - Striner d - Housing e - Drin plug nd seling wsher f - Sel d e Open the seok, if equipped, or remove the plug nd reonnet the sewter inlet hose. 9. Upon first strting the engine, hek for leks or ir in the system tht would indite n externl lek. Wter Heter Instlltion IMPORTANT: When onneting in heter or wter heter: The supply hose (from engine to heter) nd return hose (from heter to engine) must not exeed 16 mm (5/8 in.) inside dimeter (I.D.). Mke heter onnetions only t the lotions shown. Refer to the mnufturers' instrutions for omplete instlltion informtion nd proedures. Do not reposition the engine temperture swith. NOTICE Bloking the oolnt flow t the heter n use redued engine performne or overheting. Chek for ontinuous oolnt flow from the engine to the wter irulting pump. 90-8M AUGUST 2013 Pge 6A-11

12 Supply Hose Connetion TKS Models - Lotion for hot wter supply - Thermostt housing Supply Hose Connetion MPI Models - Lotion for hot wter supply - Thermostt housing Models with Closed Cooling Thermostt housing - Lotion for hot wter supply Pge 6A M AUGUST 2013

13 Return Hose Connetion IMPORTANT: A speil fitting, , my e used if the hex of the stndrd hose r fitting ontts the wter pump housing, not llowing the fitting to turn efore the fitting is tight. All Models Stndrd fitting - Speil fitting Brss Sewter Pump Sewter Pump Exploded View Sewter pump without ir tutor 1 - Sewter pump impeller housing over 2 - Blue drin plug (2) 3 - Wer plte (only on urrent models) 4 - O ring 5 - Impeller 6 - Sewter pump rket 7 - Sewter pump impeller housing 8 - Rer oil sel 9 - Bering shft ssemly 10 - Sper (models with snp ring) 11 - Snp ring (urrent models) 12 - Tolerne ring (erly models) 13 - Front sel 14 - Pulley 90-8M AUGUST 2013 Pge 6A-13

14 Sewter pump with ir tutor 1 - Sewter pump tutor housing 2 - Blue drin plug (2) 3 - Wer plte (only on urrent models) 4 - O ring 5 - Impeller 6 - Sewter pump rket 7 - Sewter pump impeller housing 8 - Rer oil sel 9 - Bering shft ssemly 10 - Sper (models with snp ring) 11 - Snp ring (urrent models) 12 - Tolerne ring (erly models) 13 - Front sel 14 - Pulley Removl 1. Drin the sewter setion of the ooling system. 2. Remove oth of the hoses from the ft side of the sewter pump. 3. For models equipped with n ir tuted drin vlve:. Disonnet the vent hose from the top of the drin vlve.. Disonnet the ir hoses from the drin vlve, y pushing in nd holding the plsti ring round the ir hose, nd pulling the ir hose out of the fitting. IMPORTANT: If elt is to e reused, it should e instlled in the sme diretion of rottion s efore. 4. Remove the serpentine drive elt. 5. Remove the sewter pump nd rket ssemly. Disssemly! CAUTION Removing the snp ring from the top of the ir tuted drin vlve n llow the omponents to ome prt forefully, resulting in injury or produt dmge. Do not try to repir the vlve or remove the snp ring. 1. Remove the sewter pump mounting rket. 2. Remove the sewter pump pulley using n pproprite puller. Power Steering Pump Pulley Remover SPX J Remove the sewter pump impeller housing over or the sewter pump tutor housing, if pplile. 4. Remove the O ring. 5. Remove the impeller. 6. Remove the sel from the front of the sewter pump housing. 7. Remove the tolerne ring or snp ring (whihever is present). 8. Press the ering shft ssemly out of the housing from the impeller side. 9. Remove the rer oil sel. Pge 6A M AUGUST 2013

15 Clening nd Inspetion! WARNING All Models Spin drying erings with ompressed ir n use serious injury or deth. The erings n explode, even if spun t very slow speeds. Do not llow the erings to spin when drying with ompressed ir. 1. Clen the metl prts in solvent nd dry with ompressed ir. 2. Clen the gsket mteril nd selnt from the seling surfes. 3. Inspet the ering housing. Exmine the surfes where the erings ontt the housing for evidene of the ering outer res turning in the housing. 4. Inspet the sels in the ering housing for signs of dmge or leks. 5. Rotte the ering shft in the ering housing. Reple the ering shft ssemly if the erings feel rough or if either end of the shft woles. 6. Inspet the impeller housing nd impeller housing over surfes where the impeller rides. Reple the impeller housing if signifint grooves exist. 7. If equipped with wer plte, inspet the wer plte for grooves nd reple s neessry. 8. If not equipped with wer plte, inspet the fe of the impeller housing over for grooves. The fe of rss impeller housing over n e resurfed to remove grooves. Remove mximum of 1.0 mm (0.040 in.) of mteril. 9. Inspet the pump impeller nd reple it if ny of the following onditions exist: Wer on the ends nd tips of the ldes Crks in the re where the ldes flex Crks in the impeller hu Blde set (ldes remin urved) 10. Inspet the pump pulley for ends or rks. 11. Inspet the serpentine elt for exessive wer. Assemly IMPORTANT: Rer oil sel is superseded y 8M However, the two sels re not instlled in the sme mnner. Using the illustrtions elow, onfirm the rer oil sel prt numer prior to ssemling the sewter pump. Rer oil sel with smooth outside dimeter (862037) - Bk of the sel (spring side) - Smooth outside dimeter - Front of the sel Rer oil sel with grooved outside dimeter (8M ) - Bk of the sel (spring side) - Grooved outside dimeter - Front of the sel M AUGUST 2013 Pge 6A-15

16 1. For the rer oil sel with smooth outside dimeter (862037), orient the k (spring side) of the sel towrd the impeller housing. Orienttion of the rer oil sel with smooth outside dimeter (862037) - Sewter pump impeller housing - Smooth outside dimeter of the rer oil sel - Front of the rer oil sel d - Bk of the sel (spring side) e - Shft ering d e 2. For the rer oil sel with grooved outside dimeter (8M ), orient the front of the sel towrd the impeller housing Orienttion of the rer oil sel with grooved outside dimeter (8M ) - Sewter pump impeller housing - Grooved outside dimeter of the rer oil sel - Bk of the rer oil sel (spring side) d - Shft ering d 3. Using suitle mndrel, press the sel to set it in the housing Press - Suitle mndrel - Housing Lurite the ering shft nd the outer dimeter of the erings with len engine oil. Pge 6A M AUGUST 2013

17 Tue Ref No. Desription Where Used Prt No. 139 Merury 25W-40 Syntheti Blend 4-Stroke Engine Oil Outer dimeter of the erings K01 IMPORTANT: The ering shft ssemly should slip esily into the ering housing using only miniml fore. 5. Instll the ering shft ssemly into the impeller housing. The end of the shft with flt surfes should extend into the impeller vity. Clen ny ssemly lue or oil from the forwrd end of the impeller housing. Bering shft ssemly 6. Insert the tolerne ring (erly models) or snp ring (urrent models) into the impeller housing Tolerne ring (erly models) 7. Apply Lotite 609 to the outer dimeter of the front sel. Do not llow dhesive to ontt the sel portion or the ering shft ssemly. Tue Ref No. Desription Where Used Prt No. 68 Lotite 609 Outer dimeter of the front sel Otin Lolly 90-8M AUGUST 2013 Pge 6A-17

18 8. Instll the front sel onto the ering shft ssemly nd slide it down until it ontts the end of the impeller housing. Front sel 9. Use suitle mndrel tht will press the front sel without ontting the ering shft. Press the front sel into ple. Wipe wy exess dhesive Hollow mndrel on press - Front sel - Front sel seted IMPORTANT: Only use the inner wer plte with the shorter impeller. This impeller is olored ornge on lternte vnes. The plte nd shorter impeller ome s set. Stndrd length impellers re lso ville. 10. Lurite the impeller with sopy wter. Align the flt surfes of the impeller hu nd ering shft, nd instll the impeller into the impeller vity. Impeller instlled Pge 6A M AUGUST 2013

19 11. Instll the O ring into the groove in the impeller housing rer fe O-ring instlled in groove 12. If the housing over or tutor housing hs wer plte, nd the plte is not lredy instlled:. Apply 3 mm (1/8 in.) ed of Lotite 598 to the housing over. Composite housing over with wer plte - Stinless steel wer plte - Bed of dhesive (ehind the wer plte) Brss tutor housing with wer plte - Stinless steel wer plte - Atutor housing - Lrge t d - Smll t e - Adhesive on the tutor housing e d Tue Ref No. Desription Where Used Prt No. 142 Lotite 598 RTV Selnt Wer plte on the sewter pump housing over or the tutor housing Otin Lolly IMPORTANT: Position the wer plte on the housing over or tutor housing nd tth the ssemly to the impeller housing within five minutes of pplying the Lotite Instll the stinless steel wer plte. 90-8M AUGUST 2013 Pge 6A-19

20 13. Align nd instll the impeller housing over or the sewter pump tutor housing (if equipped) onto the impeller housing ssemly. Sewter pump tutor housing is not shown - Impeller housing over - Sewter pump Apply Lotite 242 to the threds of the impeller housing over or the sewter pump tutor housing srews. Tue Ref No. Desription Where Used Prt No. 66 Lotite 242 Thredloker 15. Instll the four srews nd tighten to speifition. Impeller housing over or sewter pump tutor housing srew threds Sewter pump rket srew (2) - Impeller housing over srew (4) - Sewter pump rket Desription Nm l in. l ft Impeller housing over or sewter pump tutor housing srews Instll the sewter pump rket onto the sewter pump ssemly. Instll the two long srews through the rket nd into the sewter pump ssemly. Tighten the srews to the speified torque. Desription Nm l in. l ft Sewter pump rket to sewter pump ssemly srews Pge 6A M AUGUST 2013

21 17. Apply Lotite 242 to the threds of the remining sewter pump rket srew tht tthes the sewter pump rket to the top of the sewter pump ssemly. Instll nd tighten the srew to speifition Sewter pump rket long srew Tue Ref No. Desription Where Used Prt No. 66 Lotite 242 Thredloker Impeller housing over or sewter pump tutor housing srew threds Desription Nm l in. l ft Sewter pump rket to sewter pump ssemly srews Lurite the sewter pump shft with len engine oil, nd instll the sewter pump pulley onto the shft using n pproprite pulley instller. Ensure tht the end of the shft is even with the fe of pulley hu. Sewter pump pulley instlled Tue Ref No. Desription Where Used Prt No. 139 Merury 25W-40 Syntheti Blend 4-Stroke Engine Oil Sewter pump shft K01 Pulley Pusher Instller A1 Power Steering Pump Pulley Remover SPX J Instll the lue drin plugs in the sewter pump over or tutor housing, if removed. Instlltion 1. Fsten the sewter pump nd rket to the engine. Tighten the olts to speifition. 90-8M AUGUST 2013 Pge 6A-21

22 Desription Nm l in. l ft Sewter pump rket olt Instll the sewter inlet nd outlet hoses. Tighten the hose lmps seurely. 3. For models equipped with n ir tuted drin vlve:. Instll the vent hose onto the top of the drin vlve. NOTE: The ir lines for the ir tuted drin vlve re two different sizes.. Instll the pproprite ir lines into the pproprite fittings on the ir tuted drin vlve y fully inserting the ir lines into the fittings. Pull on the ir lines to ensure tht they re properly instlled. IMPORTANT: If elt is to e reused, it should e instlled in the sme diretion of rottion s efore. 4. Instll the serpentine drive elt. NOTICE Without suffiient ooling wter, the engine, the wter pump, nd other omponents will overhet nd suffer dmge. Provide suffiient supply of wter to the wter inlets during opertion. 5. Supply ooling wter to the engine. 6. Strt the engine nd hek for leks. Wter Cirulting Pump Removl NOTE: The wter irulting pump pulley on wrm mnifold models with losed ooling is new design nd nnot e repled with previous Merury MerCruiser wter irulting pump pulley. 1. Allow the engine to ool. 2. Drin the sewter or losed ooling setion of the engine. 3. Remove the hoses tthed to the wter irulting pump. 4. With the drive elt instlled to prevent rottion, loosen the wter irulting pump pulley olts. IMPORTANT: If elt is to e reused, it must e instlled in the sme diretion of rottion s efore. 5. Mrk the diretion of elt rottion nd remove the serpentine drive elt. 6. Remove the wter irulting pump olts nd pulley. 7. Remove the fsteners nd the wter irulting pump. - Wter irulting pump - Fsteners Clening nd Inspetion 1. Clen ll gsket mteril nd selnt from the seling surfes. 2. Chek the ering for exessive ply. 3. Chek the ering for norml noise when turning the shft. 4. Chek the pump ody for rks. 5. Chek the sel for signs of leking. Instlltion Cot oth sides of the new wter irulting pump gskets nd the threds of the tthing fsteners with Perfet Sel. Pge 6A M AUGUST 2013

23 Tue Ref No. Desription Where Used Prt No. 19 Perfet Sel 2. Instll the new wter irulting pump gskets onto the ylinder lok. 3. Instll the wter irulting pump. Tighten the olts to speifition. Wter-irulting pump gsket nd the threds of the tthing fsteners Q02 Desription Nm l in. l ft Wter irulting pump fsteners Instll the wter irulting pump pulley onto the wter irulting pump. Tighten the olts seurely. 5. Reonnet the hoses to the wter irulting pump. Tighten the hose lmps seurely. 6. Instll the serpentine drive elt nd djust the elt tension. 7. Fill the losed ooling system, if equipped. NOTICE Without suffiient ooling wter, the engine, the wter pump, nd other omponents will overhet nd suffer dmge. Provide suffiient supply of wter to the wter inlets during opertion. 8. Supply ooling wter to the engine. 9. Strt the engine nd hek for leks. 90-8M AUGUST 2013 Pge 6A-23

24 Air Atuted Drin System Air Mnifold nd Air Pump Exploded View Pge 6A M AUGUST 2013

25 Ref. No. Qty. Desription 1 1 Pump 2 1 Air pump rket 3 1 Srew 4 1 Air mnifold ssemly 5 1 Servie point p 6 2 Srew 7 2 Wsher 8 2 Green ir hose (olor my differ in lter prodution models) 9 2 Gry ir hose (olor my differ in lter prodution models) All Models Air Mnifold nd Air Pump Exploded View 90-8M AUGUST 2013 Pge 6A-25

26 Generl Informtion The ir tuted drin system uses ompressed ir to move piston tht pulls plug out of drin port or moves drin tue to expose hole to wter pssge llowing wter to drin into the engine omprtment. All of the drin lotions re rrnged to llow ny deris to e ontinully flushed wy from the drins during norml engine opertion. A feedk mehnism provides positive indition of proper piston movement. When eh piston moves fr enough in its ylinder, port is unovered tht llows ompressed ir to flow k to the ir mnifold nd use the green inditor to extend. The drins re losed y opening the mnul relese vlve tht releses the ompressed ir from the system. The mnul relese vlve lso funtions s n utomti pressure relief vlve tht opens t pproximtely kp (70 psi), therey proteting the ompressed ir iruit from dmge due to exess pressure. Testing! CAUTION Wter n enter the ilge when the drin system is open, dmging the engine or using the ot to sink. Remove the ot from the wter or lose the seok, disonnet nd plug the sewter inlet hose, nd ensure the ilge pump is opertionl efore drining. Do not operte the engine with the drin system open.! CAUTION Removing the snp ring from the top of the ir tuted drin vlve n llow the omponents to ome prt forefully, resulting in injury or produt dmge. Do not try to repir the vlve or remove the snp ring. 1. Remove the ot from the wter. 2. Using the hnd pump or other ir soure, pump ir into the system until oth of the green inditors extend nd the mnul relese vlve opens to relieve exess pressure. If one or oth of the green inditors hve not extended when the relief vlve opens, the orresponding ir tuted drin vlve hs not opened nd my e seized. 3. Relese the ompressed ir from the ir iruit y pulling up on the mnul relese vlve ring. 4. Ensure oth of the ir tuted drin vlves hve losed y verifying tht wter is no longer drining from either vlve. If wter ontinues to drin from n ir tuted drin vlve fter the ir pressure hs een relesed, the vlve is seized nd must e repled. Air Mnifold Removl 1. Remove the ir mnifold ssemly from the ir mnifold rket. Retin the wshers nd srews. NOTE: The ir lines re rrnged in pirs of one gry nd one green ir line for eh drin vlve. To void reonneting these hoses inorretly, note whih side of the ir mnifold eh pir of ir lines is onneted to efore removing them from the ir mnifold. 2. Disonnet the ir lines from the ir mnifold. Push in nd hold the plsti ring round the ir line nd pull the ir line out of the fitting. Instlltion 1. Connet eh pir of ir lines to the proper side of the ir mnifold y fully inserting the ir lines into the fittings on the ir mnifold. 2. Instll the ir mnifold ssemly onto the ir mnifold rket using the wshers nd srews. Tighten the srews to the speified torque. Desription Nm l in. l ft Air mnifold ssemly to rket srew Test the drin system for proper opertion. Exhust Mnifold Drin Chek Vlve Generl Informtion Engines with 3 point drin, single point drin, nd ir tuted drin systems re equipped with drin hek vlves on the exhust mnifolds. The hek ll within the vlve is fored upwrd y wter pressure from the sewter pump. This sels the drin fitting. Pge 6A M AUGUST 2013

27 When there is no wter pressure from the sewter pump, suh s when the engine is off, the hek ll flls down into the grooved drin fitting. This llows wter to drin from the exhust mnifold nd elow Chek Vlve Generl Informtion A hek vlve is loted in the wter supply hose etween the power steering ooler nd the ool fuel ooler. The hek vlve prevents hot wter from settling in the fuel ooler nd using fuel to vporize when the engine is turned off L MPI with multipoint drin, S/N 0M nd ove L MPI with losed ooling nd esy drin, S/N 0M nd ove 90-8M AUGUST 2013 Pge 6A-27

28 Wter Distriution Housing Removl 1. Drin the sewter setion of the ooling system. 2. On n Alph mnul single point drin, remove the drin rod from the wter distriution housing.. Remove the C lip from the drin rod. Retin the C lip.. Turn the drin rod hndle ounterlokwise until the drin rod threds ler the lignment rket. Pull the drin rod stright up to remove. d - Drin rod with lue hndle - C lip - Drin rod threds d - Drin rod lignment rket e - Brket for the wter distriution housing f - Wter distriution housing ssemly e f On n ir tuted single point drin, remove eh ir line from the wter distriution housing y pressing on the ir vlve fitting's relese lotion nd pulling the line out. Relese lotion on the ir vlve fitting 4. Disonnet the hoses from the wter distriution housing. 5. Remove the olt nd nut tthing the wter distriution housing nd rket to the engine. 6. Remove the rket from the wter distriution housing. Clening nd Inspetion 1. Clen the wter distriution housing with wter nd dry with len loth or ompressed ir. 2. Inspet the housing for leks, rks, or orrosion dmge. Reple, if neessry. Instlltion 1. Align the wter distriution housing with the rket. 2. Instll nd tighten the srews to speifition in the order listed.. Top right srew. Top left srew Pge 6A M AUGUST 2013

29 . Bottom srew d e - Top right srew - Top left srew - Bottom srew d - Brket for the wter distriution housing e - Wter distriution housing ssemly Desription Nm l in. l ft Wter distriution housing rket srews Instll the rket nd wter distriution housing to the engine. Do not tighten the olt nd nut t this time. 4. On mnul single point drin:. To otin orret lignment, leve the hoses disonneted from the wter distriution housing during instlltion.. Position the wter distriution housing ssemly to lign with the drin rod.. Insert the drin rod into the wter distriution housing to omplete the lignment. - Wter distriution housing - Drin rod - Drin rod hndle d. Ensure tht the rod is orretly ligned. The rod must srew in nd out of the wter distriution housing esily nd with miniml pressure. e. Instll the C lip onto the drin rod Drin rod lignment rket - C lip M AUGUST 2013 Pge 6A-29

30 5. Tighten to speifition the olt nd nut tht seure the wter distriution housing rket to the engine. Desription Nm l in. l ft Wter distriution housing rket olt nd nut On n ir tuted single point drin, onnet the ir lines to the ir mnifold. IMPORTANT: Ensure tht the ir lines re routed to void shrp ends nd ontt with moving prts. NOTE: The ir line must remin ylindril. The ir line must not e distorted when ut. The end of the ir line must e within 1 mm (0.04 in.) of squre.. Using n ir line utter, ut the ulk ir line to the pproprite length. - Air line utter - Air line Air Line Cutter Connet the ir lines from the ir mnifold ssemly to the sewter pump onnetors nd the wter distriution housing onnetors y inserting the end of the ir lines pproximtely 6 mm (1/4 in.) onto the onnetors.. Connet the 3/16 in. O.D. ir lines into the lower onnetors on the ir mnifold, the wter distriution housing, nd the sewter pump. d. Connet the 5/32 in. O.D. ir lines into the upper line onnetors on the ir mnifold, the wter distriution housing, nd the sewter pump. e. Connet the 5/16 in. O.D. vent tue onto the wter distriution housing ir tutor. Seure the tue with le ties. 7. Pull on the lines to ensure tht eh ir line is seurely onneted. 8. Seure the ir lines with le ties Connet the hoses to the wter distriution housing. Seurely tighten the hose lmps. d e g f - Lower sewter pump ir tutor ir line onnetor (3/16 in.) - Upper sewter pump ir tutor ir line onnetor (5/32 in.) - Vent tuing onnetion (5/16 in.) d - Upper wter distriution housing ir tutor ir line onnetor (5/32 in.) e - Lower wter distriution housing ir tutor ir line onnetor (3/16 in.) f - Upper ir mnifold ssemly ir line onnetor (5/32 in.) g - Lower ir mnifold ssemly ir line onnetor (3/16 in.) Pge 6A M AUGUST 2013