ISM, ISMe, and QSM11 – 008-061   Water Manifold

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

Remove or disconnect the following:

• Drain the cooling system. Refer to Procedure 008-018.
• Air inlet pipe to the turbocharger. Refer to Procedure 010-080.
• Coolant vent lines. Refer to Procedure 008-017.
• EGR valve coolant return line. Refer to Procedure 011-030.
• EGR cooler coolant vent lines. Refer to Procedure 011-031.
• Turbocharger coolant return line. Refer to Procedure 010-041.
• EGR cooler connection heat shield. Refer to Procedure 011-032.

Remove both the water manifold return tube capscrews and water manifold return tube.

Remove and discard both o-rings.

Remove the water manifold mounting capscrew and loose washer as well as studded capscrew and loose washer.

Remove the water manifold.

Remove the turbocharger coolant return fitting.

Remove the cylinder head vent fitting.

Remove the EGR valve coolant return fitting.

Remove the EGR cooler coolant vent T-fitting.

Inspect threads on all fittings for damage.

Inspect the fittings for damaged o-rings. Replace the o-rings, if damaged.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Clean the water manifold return tube and water manifold with solvent.

Dry with compressed air.

Inspect the water manifold return tube and water manifold for cracks or damage. Replace the component, if cracked or damaged.

CAUTION  Do not use petroleum products on the coolant plumbing o-rings. The o-rings will swell and cause the connection to leak.

Lubricate the o-rings with vegetable oil, clean engine coolant, or soapy water.

Install the turbocharger coolant return fitting.

Install the cylinder head vent fitting and the EGR valve coolant return fitting into the water manifold.

Install the EGR cooler coolant vent line T-fitting. Do not tighten the EGR cooler coolant vent line T-fitting until after the EGR cooler coolant vent lines have been installed and torqued to the T-fitting.

Start the mounting capscrew and loose washer and the studded capscrew and loose washer through the water manifold, lift bracket, and air intake in the rocker housing.

Do not torque the water manifold capscrews until all the EGR cooler coolant vent lines, the EGR valve return line, and the coolant vent lines have been installed.

Install the EGR cooler coolant vent lines. Refer to Procedure 011-031.

Tighten the EGR cooler coolant vent line T-fitting to the water manifold.

Install the coolant vent lines. Refer to Procedure 008-017.

Install the EGR valve coolant return line. Refer to Procedure 011-030.

Tighten the capscrew and studded capscrew of the water manifold.

CAUTION  Do not use petroleum products on the coolant plumbing o-rings. The o-rings will swell and cause the connection to leak.

Install both o-rings into the water manifold return tube.

Install the water manifold return tube and capscrews to the thermostat housing support and the water manifold.

Install or connect the following:

• EGR cooler connection heat shield. Refer to Procedure 011-032.
• Turbocharger coolant return line. Refer to Procedure 010-041.
• Air inlet pipe to the turbocharger. Refer to Procedure 010-080.
• Fill the cooling system. Refer to Procedure 008-018.
• Operate the engine until it reaches a temperature of 82°C [180°F] and check for coolant leaks.