200 BENCH PROCEDURES

Refer to Figure 5-67.

1.Remove coolant inlet end cap (20) by removing six capscrews (19).

2.Remove coolant outlet end cap (2) by removing six capscrews (26).

3.Remove bundle (22) from coolant inlet end of housing (24).

4.Remove O-ring (3) from coolant outlet end of housing.

5.Clean gasket material from all surfaces.

200 Bench Procedures

Inspection

Refer back to Figure 5-67.

1.Visually inspect housing (24) for cracks which may cause a leak. Replace housing if damaged.

2.Check oil cooler bundle (22) for leaks by pressurizing with air to 80 psi (552 kPa) and submerging it in water. If a leak is detected, replace with new bundle.

Assembly

Refer back to Figure 5-67.

Lubricate and install O-ring (3) in groove at coolant outlet end of oil cooler housing (24).

1.Apply Permatex gasket sealer on coolant inlet flange before installing gasket (23).

2.Install gasket (23) on coolant inlet end of housing (24).

3.Apply Permatex gasket sealer on top of gasket.

4.Install bundle (22). If necessary, tap bundle with soft-faced hammer to seat bundle past O-ring (3).

The alignment notch in the bundle end flange must be positioned at the top for proper installation.

5.Apply Permatex gasket sealer on bundle end.

6.Place gasket on bundle end.

7.Apply Permatex gasket sealer on top of gasket (21) before installing inlet cap (20).

8.Install coolant inlet end cap and secure with six capscrews (19).

9.Torque coolant inlet end-cap capscrews to 20 lb-ft (27 N•m) using torque wrench J 24405 or equivalent.

10.Apply Permatex sealant to both sides of gasket (25) and install on mounting flange (4) of housing.

11.Install coolant outlet end cap (2) with six capscrews (26).

12.Torque coolant outlet end-cap capscrews to 20 lb-ft (27 N•m) using torque wrench J 24406 or equivalent.

Refer to Figure 5-68.

13.Pressure-check oil cooler for leaks by installing a test plate (4) with air fitting (3) as follows: a.Position a rubber gasket (5) and test plate (4) on mounting flange (1) and secure with mounting capscrews (2). b.Install a steel plate (2) with a rubber gasket on oil outlet opening. Secure to housing (1) with two capscrews (3). c.Connect air line and pressurize to 80 psi (552 kPa). Submerge in water to check for leaks.

Refer to Figure 5-69.

200 Bench Procedures

When pressure-testing complete oil cooler assembly using an in-line pressure regulator, apply pressure at 2–5 psi (14–34 kPa) maximum. Then gradually increase pressure, checking for leaks until 80 psi (552 kPa) is reached.

[215 SW] WATER PUMP

The water pump is a belt-driven centrifugal or impeller type, and is located on the front of the engine. The water pump pulley is belt-driven by the crankshaft pulley.

During engine operation, the impeller spins in proportion to engine speed. The spinning impeller blades create a negative pressure (suction) at the water pump inlet port and a positive pressure at the outlet port. Engine coolant is drawn into the water pump from the radiator, through the lower radiator hose. The impeller motion forces coolant to circulate through the engine block, cylinder head, and back to the radiator.

To perform water pump service other than replacement, refer to the COOLING 7.0 manual.

[219 MU] OIL PUMP

The shaft and pumping gear on oil pumps manufactured after February 1996 are a onepiece design. Earlier models have a gear pressed onto a keyed shaft. The shafts are interchangeable and replacement with a new (one-piece) shaft is recommended as oil pump gear-to-housing contact is reduced, resulting in longer pump life.

Disassembly

Refer to Figure 5-70.

1.Remove pick-up tube and screen assembly (not shown).

2.Remove oil pump housing cover (7) from oil pump housing (4).

3.Remove oil pressure relief valve cap (13).

4.Remove oil pressure relief valve spring (12) and plunger (11).

5.Slide oil pump idler gear (14) off shaft.

6.Turn oil pump upside down and remove oil pump shaft nut (1) and washer (2).

7.Using a press, remove drive gear (3) and key (5) from pumping gear and shaft assembly (6).

8.Remove pumping gear and shaft assembly from housing.

9.Remove oil pump inlet flange plate (9) and gasket (8) from housing by removing capscrews (10).

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