M11 Series – Service Manual – 001-053   Water Header Plate, Cylinder Block

Drain the cooling system. Refer to Procedure

008-018.

Remove the intake piping.

Remove the alternator belt and the alternator. Refer to the following:

Procedure 013-005,
Procedure 013-001.

Remove the following components:

• Lubricating oil cooler (1), Procedure 007-003
• Coolant filter and filter head (2), Procedure 008-007
• Coolant heater housing (3), Procedure 008-011
• Turbocharger (4), Procedure 010-033.
• Coolant thermostat housing (5), Procedure 008-014
• Coolant thermostat housing support (6), Procedure 008-015.

Remove the water header plate (7) and gasket (8).

Use a wire brush and a gasket scraper to clean the water header plate and the cylinder block gasket surface.

Inspect the water header plate and the cylinder block gasket surface for cracks or other damage.

Install two guide pins, Part No. 3376488, in the top row of the water header plate mounting capscrew holes.

Use a new gasket, and install the water header plate and capscrews.

Remove the two guide pins, and install the other two capscrews.

NOTE: The capscrews are

not tightened to their final value until all related components are installed.

Install the following components:

• Coolant heater housing (3),

  Procedure 008-012

• Coolant filter head and filter (2),

  Procedure 008-007

• Coolant thermostat housing support and gasket (6),

  Procedure 008-015.

Tighten all capscrews in the sequence shown.

Install the following components:

• Lubricating oil cooler (1),

  Procedure 007-003

• Turbocharger (4),

  Procedure 010-033

• Coolant thermostat housing (5),

  Procedure 008-014.

Install the intake piping.

Install the alternator and alternator belt. Refer to the following:

Procedure 013-001,
Procedure 013-005.

Fill the cooling system.

Refer to Procedure 008-018.

Operate the engine until it reaches a temperature of 80°C [180°F]
and check for coolant leaks.