service bulletin B.M.W. D190/D150 Models Overheating Check for Internal Engine Cooling Problems: Check The Following Points First:

Transcription

1 servie ulletin TO: SERVICE MANAGER TECHNICIANS PARTS MANAGER B.M.W. D190/D150 Models Overheting The models listed ove re B.M.W. prodution for whih MerCruiser is responsile for servie. When experiening n overheting ondition with these engines, MerCruiser suggests tht the following proedures re used. Chek The Following Points First: Cooling system t proper level. (1/2 3/4 [12 20mm] elow filler nek) Mlfuntion of instruments (guges, senders, wires, grounds, et.) Chek engine temperture with n urte independent instrument Pressure hek ooling system nd p using n utomotive ooling system pressure tester, if ville. 14 PSI (100 kp). Reple with new p, nek nd oolnt reovery ottle Cp P/N Nek P/N Coolnt Reovery Kit P/N 71587A7 And Hose P/N NOTE: A new style p nd nek must e used on ll ooling systems. The old style p, eing single sel type, is vulnerle to leking. The oolnt ottle Is for over-flow only nd must remin empty when engine is old. Engine irulting pump mlfuntion Loose lterntor elt? Impeller vnes worn? Impeller shft sel filure? Impeller lerne to pump housing? (.038mm.50mm) Reple with new style pump (Dte Code 7/87) P/N (Figure 6C) Engine oolnt onentrtion? (50/50 mix) NOTE: 34 F ( 37 C) indites 50/50 mix. Printed in U.S.A Wter intke loked (Figure 1 & 2) Propeller ventiltion? Interferene of keel? Inlet hose ollpsing? (Chek during opertion) Injetion timing orret? Chek for Internl Engine Cooling Prolems: No Exhust gses entering losed ooling system? Remove 1 in. (25mm) plug from rer of exhust mnifold (Figure 10B) nd instll wter pressure guge. If higher pressure is otined thn listed, exhust gses exist in system. Mke ompression test for hed gsket lekge. Coolnt System Pressure 800 RPM (Idle) 6 PSI (41 kp) 3800 RPM (WOT) 20 PSI (137 kp) OR Reple hose etween het exhnger nd engine irulting pump with ler plsti hose. (Figure 14B) Wth for gs ules. Exhust gses existing in the losed ooling system my lso e determined y using omustion lek tester. NOTE: Snp-on Tools hs Comustion Lek Tester ville for testing oolnt for exhust gses. (Blok Comustion Lek Tester P/N GA170B) Snp on tools re redily ville in Europe. For the nerest deler or distriutor, ontt the home offie in the U.S.A. Snp-On Tools Kenosh, WI Phone Fx Telex SNAP-ON-KNE Air entering sewter ooling system? Reple hose etween het exhnger nd exhust elow with ler hose. (Figure 14C) Wth for ir ules

2 Chek if vent hole in het exhnger diretly under filler p is open. (Figure 14A) Chek thermostts for proper opening degrees. 170 F 178 F (77 C 81 C). (Figure 11D) Chek vent line from turohrger to expnsion tnk (Figure 12C) nd from wter mnifold to expnsion tnk (Figure 9B) re open. All Previous Steps Cheked nd/or Completed nd Engine Still Overheting, it will e Neessry to Clen nd Flush the Closed Cooling System. Following re proedures for lening nd flush- Ing the system. 1. Drin fresh wter iruit of the engine. 2. Completely flush the ooling iruit using n lkline sed engine lener. Follow the instrution on the ontiner for proper use. NOTE: Reommended Cleners Quiksilver Cooling System Clener P/N Cterpillr Cooling System Clener (Cterpillr Trtor Co.) John Deere Cooling System Clener (Deere & Co.) Nlprep 2001 (Nlo Chemil Co.) Pek Professionl Cooling System Clener (Northern Pestrohemil Co.) Restore (Fleetgurd In.) 3. To drin flushed engine remove hose etween irulting pump nd het exhnger. (Figure 14B) 4. Remove plug (Figure 10B). Connet len wter supply to the mnifold where plug ws removed. 5. Flush the system until the exiting wter is len. NOTE: Flushed wter will exit from the irulting pump hose nd het exhnger. 6. Reinstll plug fter flushing is omplete. 7. Remove irulting pump nd inspet impeller nd housing for vittion. (Figure 6A) Also inspet for shft defletion nd worn or leking sels. Reple old style pump (New Pump Dte Code 7/87 nd Aove, Figure 6C) 8. Remove oth sewter inlet nd outlet overs loted on the port nd strord side of the het exhnger. (Figure 11E & F) 9. Remove the inner ore of the oil nd wter exhnger using tool P/N (Figure 5B) NOTE: Not using the tool will use dmge to the ore flnge. 10. Inspet oolnt ore for ny dmge or restritions. Reple if neessry. 11. Any rown sle or green slime found on the oolnt ore must e removed.! WARNING WEAR PROTECTIVE CLOTHING AND PROPER EYE PROTECTION WHEN USING ACID SOLUTION.. Sumerge the ore into 20% solution of phosphori id nd wter or 20% solution of muriti id nd wter.. Leve in solution for 20 minutes minimum, or until len.. Remove nd rinse the ore thoroughly. d. Or hve lol rditor servie shop len the ore. 12. Remove ll gsket mteril on the ore flnge, end p nd housing fe. Inspet inside the exhnger luminum housing nd len if neessry. 13. Before instlling exhnger ores into housing, it will e neessry to rimp oth ffles loted on the side of exhngers.. Following re illustrtions showing orret nd inorret ffle. (Sketh C, Item B).. The side ffle must hve 10 degree ngle from the ore. The rimp pplied to the ffle must lso hve 10 degree ngle, 1/4 in. (6mm) deep. (Sketh C, Item C).. Atthed is drwing of the tool needed to rimp the ffles of the ore. (Sketh A & B) NOTE: There re two different tools shown in the drwing. (Sketh A) Tool A is permnent type tool for repetitive use. Tool B, eing simpler, uses two piees of flt stok steel of the orret length pressed together y two vise grips. (Sketh B) NOTE: The ffle 10 degree 1/4 in. (6mm) rimp pplied t the tip of the side ffles removes ny wve in the ffle. d. Bffles on rer of oth oolnt nd oil exhnger ores must e ent down. Cution must e tken not to dmge ore. (Figure 15)

3 e. Instll ruer ffle on the end of oth ores. (Figures 16,17) Ruer Bffles Coolnt Side P/N Oil Side P/N Lurite nd instll new O-rings on exhnger ore. 15. Apply Selnt or Lotite Mster Gsket P/N on oth sides of the ores seling surfes nd refully instll ore into luminum housing, eing reful not to dmge O-rings. 16. Instll len end p nd tighten olts seurely. 17. Instll irulting pump using new gsket. 18. Mke ll hose onnetions nd fill the system with Quiksilver Pre-mixed Anti-freeze P/N A2 (Dte ode 11/88) or n equivlent low-silite rnd (1/2 3/4 [12 20mm] elow filler nek). 19. Deerte ooling system y running engine t idle for 1 2 minutes with filler p removed. Stop engine nd top off oolnt per item 18 preeding. Reple p nd run engine 5 10 minutes t RPM. Allow engine to ool. Rehek oolnt level nd top off s required. NOTE: Using nti-freeze other thn Quiksilver Engine Coolnt low silite 50/50 pre-mixed oolnt with proper dditives nd mnuftured for diesel engines must e used. SKETCH A WELD WELD 1 in. (25mm) 3/4 in. (19mm) 10 in. (254mm) 2 REQUIRED 10 in. (254mm) 1 REQUIRED 3.0 in. (76mm) 1/2 in. (13mm) 3/16 in. (5mm) 1/16 in. (1mm) SKETCH B SCALE 1/2 in. = 1 in. (12.7mm = 25.4mm) 1 in. (25mm) 10 in. (254mm) 2 REQUIRED 3/16 in. (5mm) SCALE 1/2 in. = 1 in. (12.7mm = 25.4mm)

4 SKETCH C INCORRECT ITEM A CORRECT /4 in. (6mm) ITEM B ITEM C 50029

5 Following re illustrtions of Cooling System Chekpoints referred to in previous instrutions. - Figure 1 5 refer to the rw wter iruit. - Figure 6 14 refer to the fresh wter iruit A - Impeller Worn - Worn Sel - Shft Defletion Figure 3. Se Wter Pump 50359A - Chek Striner for Restrition Figure 1. Rw Wter Filter - Chek Core for Restrition Figure 4. After Cooler Mnifold 50362B 50360B - Chek wter Pik-Up for Restrition - O-Rings Leking, Not Seling - Inlet Hose Tore or Kinked Figure 2. B.M.W. Stern Drive - Chek Core for Restrition - Exhnger Puller (P/N ) Figure 5. Wter/Coolnt Het Exhnger

6 Chek Impeller for Cvittion - Chek for Shft Defletion/Sel Wer - Dte Code (7/87 or Newer) Figure 6. Engine Cirultion Pump Chek Belt for Slipping or Loose Figure 8. Belt Tension Wter Pssge Restrited - Vent Line Plugged Figure 9. Wter Mnifold to Cylinder Heds Chek Thermostt for Corret Temperture Opening - Thermostt nd Cover Seling Figure 7. Thermostts Housing 50361C - Wter Pssges Restrited - Remove Plug for Exhust Pressure Chek Figure 10. intke/exhust Mnifold

7 f d Reple with New Doule Lip Sel Cp nd Nek - Coolnt Exhnger - Oil Exhnger d - Dul Thermostts e - Rw Wter Outlet f - Rw Wter Inlet (Not Shown) Figure 11. Het Exhnger Tnk e 50360C - Wter Pssges Restrited - Gsket Leking - Vent Line Restrited Figure 12. Turo Chrger

8 COOLING SYSTEM 1. Fresh wter pump 9. Expnsion tnk 2. Engine lok (upper setion of liners) 10. Rw wter inlet 3. Cylinder heds 11. Rw wter filter 4. Wter mnifold 12. Rw wter pump 5. Exhust mnifold 13. Het exhnger Wter/oil 6. Exhust gs turine 14. Exhust pipe (wter sleeve) 7. Het exhnger Wter/wter 15. Rw wter outlet 8. Thermostts 16. Interooler Figure 13. Wter/Coolnt Flow

9 Het exhnger, old wter/wter Closed ooling wter/wrm Sewter Engine oil Vent Hole Must Not Be Restrited (View Through Filler Nek with Cp Removed) - Instll Cler Hose (Fresh Wter) - Instll Cler Hose (Se Wter) Figure 14. Het Exhnger Flow 4 1. Het exhnger, wter/wter 2. Het exhnger, oil/wter 3. Expnsion Tnk 4. Thermostts 5. To wter pump ster 6. From exhust plenum hmer 7. To wter pump 8. From wter mnifold (pressure return pss) 9. From sewter pump 10. To exhust gs end pipe 11. From oil temperture sender 12. To oil filter

10 Bend Bffle Over Core As Shown. DO NOT Dmge Core. - Coolnt Core - Oil Core Figure Bffle Instlled on Coolnt Core (Full Corners) P/N Figure Bffle Instlled on Oil Core (Nothed Corners) P/N Figure