Install Heat Exchanger Core

RG6067-UN-23JAN92

Inspect Heat Exchanger End Cap

RG9848-UN-06JAN99

Install Heat Exchanger

A - O-Rings

B - End Cap

C - Housing

Thoroughly inspect condition of end cap sealing O-rings (A). Sealing O-rings may be reused if not excessively worn or damaged during disassembly. Replace sealing rings as necessary.

Lubricate front and rear end cap O-rings with clean multi-purpose grease.

On 4045D Engines:

1. Install front end cap, install cap screws and evenly tighten until end cap (B) is about 6.4 mm (0.25 in.) from housing (C). Index end cap in same position as removed.

2. Install heat exchanger core from rear of engine. Make sure core is properly seated in front end cap to avoid cutting O-ring.

3. Install rear end cap with heat exchanger core properly seated in cap and cap properly indexed in same position as removed.

4. Install and evenly tighten rear end cap screws until cap contacts housing. Evenly tighten front end cap screws until cap contacts housing. Tighten front and rear end cap screws to 24 N˙m (18 lb-ft).

5. Connect all water piping and tighten hose clamps securely. Fill cooling system with the proper amount and concentration of ethylene-glycol base antifreeze.

6. Open sea cock, start engine and check for leaks.

On 4045T, 6068T and 6068SFM50 Engines:

1. Install rear end cap, install cap screws and evenly tighten until end cap (B) is about 6.4 mm (0.25 in.) from housing (C). Index end cap in same position as removed.

2. Install heat exchanger core from front of engine. Make sure core is properly seated in rear end cap to avoid cutting O-ring.

3. Install front end cap with heat exchanger core properly seated in cap and cap properly indexed in same position as removed.

4. Install and evenly tighten front end cap screws until cap contacts housing. Evenly tighten rear end cap screws until cap contacts housing. Tighten front and rear end cap screws to 24 N˙m (18 lb-ft).

5. Connect all water piping and tighten hose clamps securely. Fill cooling system with the proper amount and concentration of ethylene-glycol base antifreeze.

6. Open sea cock, start engine and check for leaks.

On 6068SFM75/AFM75 Engines:

RG15325-UN-19JUL07

Install Core and Rear End Cap

RG15326-UN-19JUL07

Install Front End Cap

A - Rear End Cap

B - Front End Cap

1. Insert two O-rings into front and rear end caps.

2. Lubricate ends of tube bundle lightly with clean multi-purpose grease.

NOTE: For proper orientation of the tube bundle, the core divider plate must be in line with inlet end cap divider slot with arrow pointing in the correct direction.

3. Install rear end cap (A) over tube bundle with core divider plate in slot on cap.

4. Guide heat exchanger core into heat exchanger tank. Align core divider vertically with stamped note indicating “This side up”. (Core shown separated from cap for illustration purposes.)

5. Fasten rear end cap and core to tank with bolts and washers. Tighten bolts to 24 +/- 3 N˙m (18 +/- 2 lb-ft).

6. Install front end cap (B) over core and bolt to tank. Ensure core holes are aligned with heat exchanger tank holes. Tighten bolts to 24 +/- 3 N˙m (18 +/- 2 lb-ft).

7. Connect all water piping and tighten hose clamps securely. Fill cooling system with the proper amount and concentration of ethylene-glycol base antifreeze.

8. Open sea cock, start engine and check for leaks.