ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 008-113   Coolant Return Junction Block

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

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

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

CAUTION  Use caution when draining the coolant system that coolant is not spilled or drained into the bilge area. The coolant must be disposed of in accordance with local environmental regulations.

• Disconnect the batteries. Refer to Procedure 013-009.
• Drain the engine coolant. Refer to Procedure 008-018.

NOTE: Some QSL9 marine engines are keel cooled and some are sea water (heat exchanger) cooled. These first two steps apply to the keel cooled engine.

Loosen the hose clamps at the marine gear oil cooler.

Remove the expansion tank coolant fill tube from the coolant return junction.

Loosen the hose clamps at the water pump inlet connection.

Remove the p-clip and the coolant return tube from the engine.

NOTE: This step applies to the QSL9 sea water (heat exchanger) cooled engine.

Disconnect the engine coolant return from the heat exchanger and the water pump inlet port.

Remove the coolant return pipe.

Remove the two capscrews at the water pump inlet port.

Loosen the clamps at the heat exchanger connection.

Remove the coolant return tube from the water pump inlet port and the heat exchanger.

Clean the inlet connection of the coolant return junction.

Inspect the connection ends for cracks or other damage.

NOTE: These steps apply to the QSL9 keel cooled engine.

Install the coolant return tube to the water inlet connection and the marine gear oil cooler.

Install the p-clip over the tube and to the exhaust manifold.

Position the hose clamps and tighten.

NOTE: This step applies to the QSL9 sea water (heat exchanger) cooled engine.

Install the coolant return to the water pump inlet port and heat exchanger outlet.

Tighten the hose clamps.

NOTE: This step applies to the QSL9 sea water (heat exchanger) cooled engine and the QSL9 keel cooled engine.

Install the expansion tank fill line tube to the coolant return junction and tighten the hose clamp.

Install a new o-ring onto the coolant tube, if a flanged tube.

Install the tube onto the heat exchanger first.

Install the tube onto the water pump inlet port.

Install the two mounting capscrews and tighten.

• Fill the engine with coolant. Refer to Procedure 008-018.
• Connect the batteries. Refer to Procedure 008-113.

Operate the engine and check for leaks.