2004
Fresh Water
Cooling Installation
Instructions Direct Drive
Kit RK147050

L591001This Page Was
Intentially
Left Blank

L591001TABLE OF CONTENTS
1 - FWC Kit Installation Instructions - Direct Drive ...........................................................................
Table of Contents ........................................................................................................................ 1
Installation Notes and Recommendations ........................................................................................ 2
Figure 1-1, Parts Deleted, Raw Water System, Direct Drive .............................................................3-6
Figure 1-2, Parts Added, Raw Water System, Direct Drive ............................................................7-10
FWC Kit Installation, Direct Drive Systems ............................................................................... 11-18
2 - Fresh Water Cooling Water Flow Diagram ................................................................................. 19

L591001
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1FWC KIT INSTALLATION INSTRUCTIONS - RK147050
INSTALLATION NOTES AND
RECOMMENDATIONSNOTE: Some Excaliburs may have the remote oil filter
relocated to the front of the exhaust elbow. If yourengine has the remote oil filter located to the front of theengine; skip steps 17-26 of this procedure. In addition,items 36-42 of the kit will not be used.

PCM Technical Support, Warranty and Dealer
Assistance:••••

Phone: (803) 345-0050
Fax: (800) 321-3797
E-mail: mschneider@pleasurecraft.com
E-mail: dsoutherland@pleasurecraft.com

REFERENCES:
L510013

Marine Illustrated Parts Manual Model
MP5.0/5.7L MY 2002 - 2004

L510010-04

Owner’s Operation and Maintenance
Manual

NOTE: Use pipe sealant with Teflon on all fittings
being installed during these procedures. Loctite™ 565,
PST Pipe Sealant, Part No. 56541 or equivalent isrecommended.

WARNING
Do not remove cooling system filler cap whenthe engine is hot. Allow the engine to cool andthen remove the pressure cap slowly, allowing thepressure to vent. Hot coolant, under pressure, may
discharge violently and cause severe burns.

DIRECT DRIVE INSTALLATION
Installation of the fresh water cooling system, on directdrive applications, will require the relocation of theremote oil filter and oil lines. Provisions should be madeto recover oil spilled from the lines.
An oil and filter change is not required, but it isrecommended at this time. Draining the oil and changing
the filter at the beginning of the procedure will help
minimize oil spillage, and insure proper oil level. Add oil
and check for proper operating level at the completionof the procedure. This will insure proper oil level in theengine after installation is complete.

2

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FIGURE 1-1 5.7L, SERPENTINE, DIRECT DRIVE - R/W

1
5
17

10

3

2

7

16

11

15
12

6

17

18

18
8

13

9

4

14

19
22

20
25

21
24

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3

FIGURE 1-1 (cont.) 5.7L, SERPENTINE, DIRECT DRIVE - R/W

26
29 30 31
27 28

34

35 36

32

33

4

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PARTS DELETED - 5.7L, SERPENTINE, DIRECT DRIVE - R/W
FIGURE 1-1
ITEMPART NUMBER

DESCRIPTION

1

R045160

Hose, r/w pump to tstat housing

1

2

RS3858Clamp, 1 1/4”

2

3R025031

Housing, tstat, lower

1

4

RM0121

Gasket, tstat housing, lower

1

5

R026002

Thermostat, 160º F

1

6

RM0258Gasket, tstat housing, upper

1

7

R025033

Housing, tstat, upper

1

898333080

Bolt, tstat housing

29RS2179Lock washer, tstat housing

2

1098223035

Bolt, tstat housing

11193920000

Lock Washer, tstat housing

1

12

R020002

Sender, water temperature

1

13

TBD

Plug, intake, (water temp sender)

1

14

TBD

Plug, bypass, circulating pump

1

15

R045048

Hose, r/w supply to engine

1

16RS3852

Clamp, 1 3/4”

2

17R045107

Hose, r/w dump

218RS3851

Clamp, 1”

4

19R060060

Hood

1

20

R143141

Decal, hood, “PCM Excalibur”

1

21

R143142

Decal, hood, “Excalibur”

2

22

R143143

Decal, hood, spec

1

23(NS)

R143158

Decal, hood, “3 Star” emission

1

24

R090143

Bracket, shift cable1

25

R128001C

Cover, hose clamp tip (black)

8

26

R090190A

Bracket, oil header

1

27RS0302

Bolt, brkt, oil header

3

28

RS2180

Lock Washer, brkt, oil header

329RS0282

Bolt, oil header

330RS2179Lock Washer, oil header

3

31RS1027Nut, oil header

3

32RA045120C

Oil Lines

2

33

R024184

Fitting, oil line adapter

2

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QUANTITY

5PARTS DELETED - 5.7L, SERPENTINE, DIRECT DRIVE - R/W
FIGURE 1-1

6

ITEM

PART NUMBER

DESCRIPTION

34

R096144

Bracket, plug wire clip

2

35

RS0285Bolt, riser, short

2

36

RS2179Lock Washer, riser

2

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QUANTITYFIGURE 1-2 5.7L, SERPENTINE, DIRECT DRIVE - F/W
23
18 19 20

24

37 38
22

37 38

17
21

18 19 20

36

29
39 40

28
8
9
27

7

25

3

13

4

5
41

11

6
15
16

12
14
2
1

30

31

42

33

32

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7

FIGURE 1-2 (cont.) 5.7L, SERPENTINE, DIRECT DRIVE - F/W

26
25

15
48 49

16

8
28

10
56

11

29

51
30

52

12

55

50
46
47

54

53

59
57

43
59

58

35

58
44

61

2A

45
60
1
34

8

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PARTS ADDED - 5.7L, SERPENTINE, DIRECT DRIVE -F/W
FIGURE 1-2
ITEMPART NUMBER

DESCRIPTION

1

R045146

Hose, f/w supply, circ. pump to H.E.

1

2

RS3852

Clamp, 1 3/4”

1

2A

RS3868Clamp, 1 1/2”

1

3

R025015A

Housing, water neck outlet

1

4

RM0121

Gasket, water neck outlet

1

5

RS6531

Bolt, water neck outlet

2

693200000

Lock Washer, water neck outlet

2

7

R024055

Elbow, 1/8 NPT X 1/4 vent hose

1

8

R045144

Hose, f/w return, H.E. to water neck1

9RS3858Clamp, 1 1/4”

110RS3868Clamp, 1 1/2”

1

11

R045163

Hose, r/w supply, r/w pump to H.E.

1

12RS3858Clamp, 1 1/4”

2

13R020003

Sender, water temperature

1

14

R024217

Fitting, circ. pump, bypass

1

15

R045086

Hose, bypass, 5/8” X 31”

1

16

RS3864

Clamp, 5/8”

2

17R090295

Bracket, degas bottle

1

1898223016

Bolt, brkt, degas bottle

2

19RS2672

Lock Washer, brkt, degas bottle

2

20

RS7068Flat Washer, brkt, degas bottle

2

21

R146001

Degas Bottle

1

22

R034045

Cap, degas bottle

1

23

R143166

Decal, bottle, top, “Open Slowly”

1

24

R143153

Decal, bottle, side, “Engine Coolant Fill”

1

25

R045132

Hose, coolant vent, 1/4” X 30”

1

26

R127087

Clamp, Oetiker

1

27RS3870Clamp, 1/4”

1

28

R045164

Hose, f/w fill129

RS3854

Clamp, 3/4”

230

R060061B

Hood

1

31

R143141

Decal, hood, “PCM Excalibur”

1

32

R143142

Decal, hood, “Excalibur”

2

33

R143143

Decal, hood, spec

1

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QUANTITY

9PARTS ADDED - 5.7L, SERPENTINE, DIRECT DRIVE -F/W
FIGURE 1-2

10

ITEM

PART NUMBER

DESCRIPTION

34

R090143A

Bracket, shift cable1

35

R128001C

Cover, hose clamp tip (black)20

36

R090257

Bracket, oil header

1

37RS0286

Bolt, brkt, oil header

2

38

RS2179Lock Washer, brkt, oil header

23998333020

Bolt, oil header

340

RS2179Lock Washer, oil header

3

41RA045120D

Hose, oil line

2

42R024184

Fitting, oil adapter, 90°, 1/2 NPT X 5/8

2

43

R090266

Bracket, heat exchanger

1

44

RS0304

Bolt, brkt, heat exchanger

2

45

RS2180

Lock Washer, brkt, heat exchanger

2

46

R094040

Isolator, rubber, adhesive

1

47

RA147050

Heat Exchanger

1

48

R025039

Thermostat Housing

1

49

R026007

Thermostat, 170° F

1

50

R045162

Hose, tstat housing to H.E., 2 1/2”

151RS3860Clamp, 2 1/2”

252(NS)

R143155

Decal, “Protective Anode”

1

53(NS)

R143156

Decal, “Raw Water Drain”

1

54(NS)

R143157

Decal, “Fresh Water Drain”

1

55

R143158

Decal, “3 Star” emission

1

56

R094041

Isolator, rubber

2

57

RS3857

Clamp, 4”2

58

R045151

Hose, r/w dump, 1”

2

59

RS3851

Clamp, 1”

4

60

R101013

Wire, H.E. ground1

61

RS1078Nut, w/lock washer, H.E. grd. stud1

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QUANTITYFWC KIT INSTALLATION INSTRUCTIONS - DIRECT DRIVEFWC KIT INSTALLATION - DIRECT DRIVEREMOVEWIRE
TEMP
SENDER

1. Disconnect the negative battery terminal cable.
IMPORTANT: If an oil change is going to be performedin conjunction with this procedure; drain oil and change
filter at this time. Do not refill the oil until you are
instructed to do so later in this procedure.

REMOVECLAMP

REMOVE
CLAMPSREMOVE
CLAMP

2. Remove the hood (Figure 1-1, item 19) from theengine. The hood is not required to complete theinstallation. Save the hood retention nuts for
installation of the new hood later in thisprocedure.
3. Remove the thermostat housing, watertemperature sender, and associated hoses.

Figure 1-3 Disconnect Points - Steps 3a, 3b.

NOTE: The complete thermostat housing with hoses,
temperature sender, and thermostat can be removed as
an assembly. (Figure 1-1, items 1-18)
a. Disconnect the wire connected to thewater temperature sender (Figure 1-1,
item 12), located in the lower
thermostat housing.
b. Loosen the hose clamps of the raw
water dump hoses at each exhaust
manifold connection; the raw water
pump hose at the raw water pump, andthe raw water supply to engine hose at
the circulating pump. Refer Figure 1-3.

INTAKE
MANIFOLD
PLUG

T-STAT
HOUSING
BOLTS

CIRC.
PUMP
PLUG

Figure 1-4 Disconnect Points - Steps 3c, 4, 5.
c. Remove the two bolts and lockwashers (Figure 1-4) attaching thethermostat housing assembly to theintake manifold.
d. Remove, from the engine, thethermostat assembly, all hoses andclamps. Clean thermostat gasket fromthe intake manifold. None of theseparts are required to complete theinstallation. Refer Figure 1-5.
4. Remove and discard the plug located top, centerof the circulating pump. Refer Figure 1-4.
5. Remove and discard the plug located right, frontof the intake manifold. Refer Figure 1-4.

Figure 1-5 Parts removed - Steps 3-5.

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11FWC KIT INSTALLATION INSTRUCTIONS - DIRECT DRIVE
NOTE: Use pipe sealant with Teflon on all fittings
being installed during these procedures. Loctite™ 565,
PST Pipe Sealant, Part No. 56541 or equivalent isrecommended.
6. From the kit, install the Bypass Fitting(Figure 1-2, item 14) into the circulating pump,where the plug was removed.
7. From the kit, install the Water Temperature
Sender (Figure 1-2, item 13) into the intake
manifold, where the plug was removed, andreconnect the temperature sending wire to thesensor. This is the wire disconnected in step 3a.

DEGAS
BOTTLE
MOUNT

8. Remove 90° hose fittings from the front of eachexhaust manifold and the plug fitting from the rearof each exhaust manifold.
Install the hose fittings in the rear of each exhaust
manifold, with the hose barb facing inboard.
Install the plugs in the front of each exhaust
manifold.

Figure 1-6 Degas Bottle Bracket Mounting Location

9. From the kit, install the Degas Bottle Bracket
using (2) Bolts (*metric), (2) Lock washers, and(2) Flat washers (Figure 1-2, items 17-20). The
bracket is installed to the existing bracket on the
starboard side of the intake manifold.
10. From the kit, install the Water Neck Outlet using(2) Bolts, (2) Lock washers, and Gasket(Figure 1-2, items 3-6), provided.
11. From the kit, install the Vent Hose Fitting(Figure 1-2, item 7) into the Water Neck Outlet.
The hose barb should be positioned to
starboard, approximately parallel with the waterneck outlet.
12. From the kit, install the Fresh Water Supply
Hose (Figure 1-2, item 1) to the circulating
pump using 1-3/4” Hose Clamp(Figure 1-2, item 2). The F/W Supply Hose will
route to the rear of the engine along the lower
starboard side, below the exhaust manifold.
13. From the kit, install the Fresh Water Return
Hose (Figure 1-2, item 8) to the Water neckOutlet using 1-1/4” Hose Clamp(Figure 1-2, item 9). The F/W Return Hose will
route to the rear of the engine along the top,
starboard side of the engine, inside of the oil fill,
and outside of the Degas Bottle Bracket installedin step 12. The open end of the hose will point
to the port side of the engine.

12

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F/W
RETURN
HOSE

WATER
TEMP
SENDERVENT
HOSE &FITTINGR/W
SUPPLYHOSE

BYPASSHOSE &FITTINGF/W
SUPPLY
HOSE

Figure 1-7 Hose and Fitting Locations

FWC KIT INSTALLATION INSTRUCTIONS - DIRECT DRIVE
14. From the kit, install the Bypass Hose,
5/8” X 31”, (Figure 1-2, item 15), onto the
Bypass Fitting on the circulating pump, using
5/8” Hose Clamp (Figure 1-2, item 16). This
hose will route up and to the rear of the engine
on the port side of the throttle body.

F/W
RETURN
HOSE

15. From the kit, install the Raw Water Supply Hose,(Figure 1-2, item 11) 90° end, to the raw water
pump using 1-1/4” Hose Clamp(Figure 1-2, item 12). This hose will route to therear of the engine along the top port side of theintake manifold.
16. From the kit, obtain the Degas Bottle, Degas
Bottle Cap, “Open Slowly” Decal, “Engine
Coolant Fill” Decal, Coolant Vent Hose
(1/4” X 30”), Fresh Water Fill Hose, 1/4” Oetiker
Hose Clamp, 1/4” Hose Clamp, and 3/4” Hose
Clamp (Figure 1-2, items 21-29).
a. The cap end of the degas bottle isthe front of the degas bottle. On theupper starboard, forward, outside
corner of the degas bottle, above the“MIN”/”MAX” marks, affix the “Engine
Coolant Fill” Decal here. Affix the“Open Slowly” decal just behind the
cap.

VENT
HOSE &FITTINGWATER
TEMPSENDER

R/W
SUPPLYHOSE

BYPASSHOSE &FITTINGF/W
SUPPLY
HOSE

Figure 1-8 Hose and Fitting Locations

VENT
HOSE
ATTACHED

b. Attach the Coolant Vent Hose to the
top nipple fitting on the degas bottle
using the 1/4” Oetiker Hose Clamp.
c. Attach the Fresh Water Fill Hose to thebottom hose outlet of the degas bottle.
d. Install the Degas Bottle Cap on the
Degas Bottle. With the cap towards
the front of the engine, route the
Coolant Vent Hose down and under
the Degas bottle so the end of the hose
is toward the front of the engine. Routethe vent hose inside of the oil fill andattach it to the Vent Hose Fitting on
the Water Neck Outlet using 1/4” Hose
Clamp. (Figure 1-2, item 27) Seat theDegas Bottle on the Degas Bottle
Bracket.

L591001
RK147050

DEGAS
BOTTLECAP

DEGAS
BOTTLEDECALS

Figure 1-9 Degas Bottle Assembly

WARNING
Do not remove cooling system filler cap whenthe engine is hot. Allow the engine to cool andthen remove the pressure cap slowly, allowing thepressure to vent. Hot coolant, under pressure, may
discharge violently and cause severe burns.

13

FWC KIT INSTALLATION INSTRUCTIONS - DIRECT DRIVE
17. On the port exhaust riser, remove the (2) forward
retaining bolts and lock washers. From the kit,
install the Remote Oil Filter Bracket using (2)Bolts and (2) Lock washers(Figure 1-2, items 36-38).

NOTE: Some Excaliburs may have the remote oil filter
relocated to the front of the exhaust elbow. If yourengine has the remote oil filter located to the front of theengine; skip steps 17-26 of this procedure. In addition,items 36-42 of the kit will not be used.

NOTE: The following procedure involves the removal of
the remote oil header, oil lines, and remote oil adapter
housing. Have materials in place to absorb any oil
spilled.

OUT

18. Disconnect oil lines from the oil header. Keepthe ends of the lines elevated to reduce oilspillage.

IN

19. Remove the (3) oil header mounting bolts,
lock washers, and nuts. Relocate the oil header
to the new Oil Header Bracket (step 17). The
notch in the bracket locates the rib of the oilheader to allow for easier mounting.
From the kit, Use (3) Bolts (*metric) and (3)lock washers (Figure 1-2, items 39-40),
mount the oil header to the new bracket.

OIL
HEADER

BRACKET
MOUNTING
BOLTS

Figure 1-10 Oil Header and Bracket - New Location

20. Remove the oil lines from the Oil Bypass
Adapter and discard.
21. Remove the outboard oil adapter fitting anddiscard.
22. Remove the oil bypass adapter attaching fitting
and oil line fitting as an assembly. The oil
adapter housing will come free at this time. Set
the housing aside keeping the O-rings in the
housing clean and free of dirt. Retrieve theoil adapter housing O-ring from the engine if it
did not come with the housing. Place it in thegroove of the housing. Remove and discard theoil fitting from the oil adapter housing attachingfitting.
23. Reattach the oil bypass adapter. Hand
tighten the oil bypass adapter fitting, then tighten
1/4 turn more. Install the new oil fitting(Figure 1-2, item 42) into the oil bypass attachingfitting. The oil connection needs to face forward.
Do not allow the oil bypass attaching fitting totighten further while installing the new oil fitting.

Figure 1-11 Oil Adapter and Fittings

CAUTION
Do not over tighten the oil bypass adapter fitting.
Damage to the engine can occur.

14

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FWC KIT INSTALLATION INSTRUCTIONS - DIRECT DRIVE
24. Install the second new oil fitting(Figure 1-2, item 42) into the outboard port of theoil bypass adapter, orientating the oil connection
forward.
25. Route the new oil lines (Figure 1-2, item 41)
inboard of the front port engine mount. The oilline connected to the center fitting of the oil
adapter housing will connect to the output of theoil header; the oil line connected to the outboard
fitting of the oil adapter housing will connect tothe input of the oil header. Secure theseconnections. Refer to Figure 1-12 for proper
routing; Figure 1-10 and 1-13 for proper
connections at the oil header and oil adapter.

OIL LINESROUTED UNDER
AND BEHIND MOUNTCAUTION

Figure 1-12 Oil Line Routing

Severe engine damage can occur if the oil lines are
not connected properly.
26. Remove the old remote oil header bracket.
Discard the bracket, (3) bracket mounting bolts,(3) lock washers, and (1) plug wire retaining clip
bracket.
27. From the kit, install the Heat Exchanger Ground
Wire (Figure 1-2, item 60) to the ground bolt
located in the upper left bell housing retaining
bolt. (located behind shift cable bracket) Refer
to Figure 1-14

OUTPUTFROMHEADER

INPUT
TO
HEADER

28. Remove the existing shift cable bracket andinstall the new shift cable bracket, from the kit.
(Figure 1-2, item 34) Be sure to reconnect theshift cable onto the new bracket.

Figure 1-13 Oil Line Connections at Adapter
Housing

29. Remove and save the stud bolt in the upper
center position of the bell housing. This will
release a ground wire and the main engine
harness 10-pin connector bracket. Relocate the
10-pin connector bracket to the lower bolt that
attaches the top mount starter block off plate.
Refer Figure 1-14.

NEW LOCATIONGROUND WIRE
REUSE WIRE CLIP BOLTHEAT EXCHANGERGROUND WIRELOCATION

30. Remove the starboard plug wire retaining clip
bracket. Discard the bracket. Use the bolt andlock washer to attach the ground wire (step 29)
to the lower inboard hole on the starboard head.
Be sure to remove the paint from around themounting hole so that a good ground isachieved. Reinstall the stud bolt (step 29) backinto the upper center hole of the bell housing.

GROUND STUD,GROUND WIRE
10-PIN BRACKETWIRE CLIP IS TO BEREMOVED - - BOLT &WASHER REUSED

Figure 1-14 FWC Service Points - Rear of Engine

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15FWC KIT INSTALLATION INSTRUCTIONS - DIRECT DRIVE
31. From the kit, cut the rubber isolator, withadhesive, into thirds. Affix the isolator onto theHeat Exchanger Bracket in the center andinboard of each of the mounting clamp holes.

HEAT EXCHANGERBRACKET MOUNTINGLOCATION

32. From the kit, mount the Heat Exchanger Bracket
to the bell housing using (2) bolts and (2)lock washers. (Figure 1-2, items 43-45)
33. From the kit, obtain the Heat Exchanger,
Thermostat housing, Thermostat, Thermostat
Housing to Heat Exchanger Hose, and (2) 2-1/2
Hose Clamps. (Figure 1-2, items 47-51) Install
the Thermostat into the Heat Exchanger withthe spring portion of the Thermostat facing up.
Place the Tstat Housing to H.E. Hose over the
H.E. fitting with the (2) hose clamps in place but
not tight. Seat the Thermostat Housing into
the hose, making sure that it contacts thethermostat and fits into the collar of the H.E.
fitting. The Tstat Housing Bypass fitting should
be facing the front of the engine. Tighten the(2) hose clamps securing the upper hose section
to the Tstat Housing and the lower hose section
to the H.E.

10-PIN BRACKETNEW MOUNTLOCATION

Figure 1-15 Bracket Locations - Rear Of Engine

T-STATASSEMBLY

RUBBERISOLATORHEATEXCHANGER

Mount the Heat Exchanger assembly to the H.E.
Bracket using (2) 4” Hose Clamps(Figure 1-2, item 57). Do not fully tighten theclamps, at this time.
34. From the kit, install the (2) Raw Water Dump
Hoses, using (4) 1” Hose Clamps, to the H.E. 1”
outboard fittings and to the 90° fittings installed
in rear ports of the exhaust manifolds.
NOTE: The starboard r/w dump hose may need to
be trimmed slightly, at the H.E. side, to prevent it fromrubbing on the corner of the starboard head.

10-PINRELOCATED

NEW
SHIFT
BRACKET

Figure 1-16 FWC Assembly Locations - Rear ofEngineBYPASS
HOSE

35. Connect the Fresh Water Supply Hose (fromthe circ. pump) to the H.E. lower starboard fitting
using 1-1/2” Hose Clamp (Figure 1-2, item 2A).
36. Connect the Fresh Water Fill Hose (from theDegas Bottle) to the H.E. upper starboard 3/4”
fitting using 3/4” Hose Clamp(Figure 1-2, item 29).

H.E. BRKT.
MOUNTING
BOLTS

F/W FILLHOSE

R/W
SUPPLY
HOSE

R/W
DUMP
HOSE

F/W
RETURNHOSE

H.E.
GROUNDSTUD

F/W
SUPPLYHOSE

37. Connect the Fresh Water Return Hose (from theWater neck Outlet) to the H.E. thermostat
housing 1-1/2” fitting using 1-1/2” Hose Clamp(Figure 1-2, item 10).

Figure 1-17 Hose Connections - Rear of Engine

16

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FWC KIT INSTALLATION INSTRUCTIONS - DIRECT DRIVE
38. Connect the Bypass Hose (from circ. pump) to
the H.E. thermostat housing 5/8” fitting using the5/8” Hose Clamp (Figure 1-2, item 16).
39. Connect the Raw Water Supply Hose (from theraw water pump) to the H.E. 1-1/4” fitting, upper
port side of the H.E., using 1-1/4” Hose Clamp(Figure 1-2, item 12).
40. Ensure that the H.E. r/w and f/w drains arefacing straight down. From the kit, install arubber isolator (Figure 1-2, item 56) under eachof the H.E. mounting clamp, then tighten clamps
securing the H.E. to the H.E. Mounting Bracket.
41. From the kit, use the Nut w/lock washer(Figure 1-2, item 61) to secure the ground wire
to the H.E. ground stud.
42. From the kit, affix decals (Figure 1-2, items
52-55, Figure 1-2 also shows approximate
location of the decals) to the Heat Exchanger.

•

DEX-COOL™ IS AN ETHYLENE GLYCOL
BASED PRODUCT, THEREFORE, BOIL AND
FREEZE PROTECTION ARE MEASURED IN
THE SAME FASHION AS CONVENTIONALCOOLANTS.

TO FULLY REALIZE ITS MANY ADVANTAGES,
DEX-COOL™ MUST NEVER BE MIXED WITHCONVENTIONAL COOLANTS.
DEX-COOL™ can become contaminated byinadvertently topping-off with conventional coolant,
adding conventional coolant to the system or evenif fill/drain containers are shared between coolants.
If contamination occurs, the cooling system must be
immediately drained and flushed, and refilled with DEXCOOL™. No short-term damage will occur, however, theservice interval will be reduced from 5 years to 2 years.
The fresh-water cooling side of the cooling system
must be filled with a 50/50 mixture of DEX-COOL™
(or equivalent, which meets GM6277M) extended life
antifreeze and water solution.

43. Remove the engine block drain plugs and drain
any remaining water from the engine block.
Reinstall block drain plugs.

IMPORTANT: More than 50% antifreeze solution cancontribute to an overheating condition.

44. Make sure that all drain plugs are properly
installed.

WARNING

IMPORTANT: If the engine oil was drained at the
beginning of this procedure, you will need to replace
the oil in the engine at this time. Add 4 quarts of oil
to the engine. Do not add any more oil until after you
have run the engine.

Do not remove cooling system filler cap whenthe engine is hot. Allow the engine to cool andthen remove the pressure cap slowly, allowing thepressure to vent. Hot coolant, under pressure, may
discharge violently and cause severe burns.

FILLING FRESH-WATER COOLING SYSTEM

45. Reconnect negative terminal of the battery.

A new extended life engine coolant known as DEXCOOL™ is recommended for use in your engine. It
is imperative to note the following about DEX-COOL™
engine coolant:

46. Remove the pressure cap from the Degas Bottle.

•

IT IS PINK IN COLOR TO DISTINGUISH IT
FROM CONVENTIONAL COOLANT.

•THE SERVICE CHANGE INTERVAL ON
ENGINES BUILT WITH DEX-COOL™ IS 5YEARS.

•

47. Prepare 5 gallons of DEX-COOL™ 50/50
solution. Fill the system with antifreeze solution
until the system is filled. Degas Bottle will be fullto the top of the bottle.

TO MAINTAIN FULL CORROSIONPROTECTION DURABILITY, DEX-COOL™
MUST NOT BE MIXED WITH CONVENTIONAL(CONTAINING SILICATE) ENGINE COOLANTS.

L591001
RK147050

48. Start the engine and operate at idle speed(800-1000 RPM) to purge any air from thesystem. When the coolant level remains
constant, install the pressure cap on the Degas
Bottle.

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FWC KIT INSTALLATION INSTRUCTIONS - DIRECT DRIVE
49. Continue to run the engine until it reaches
normal operating temperature. Check for oil
leaks, fresh water coolant leaks, and raw waterleaks at all fittings and connections. Correct
leaks, as required.
50. Continue to run the engine at operating
temperature. Check the Degas Bottle for theproper level and add coolant if necessary.

WARNING
Do not remove cooling system filler cap whenthe engine is hot. Allow the engine to cool andthen remove the pressure cap slowly, allowing thepressure to vent. Hot coolant, under pressure, may
discharge violently and cause severe burns.
NOTICE: It is not necessary to remove pressure cap
to check coolant levels. Check Degas Bottle daily andkeep filled to the ‘MAX” level indicated on the bottle.
51. With the engine stopped, check engine oil level.
Add oil until level reads “Full” on the dipstick. Do
Not overfill.
52. From the kit, install the Hose Clamp Covers,(Figure 1-2, item 35), on all hose clamp ends.
53. From the kit, affix decals (Figure 1-2, items
31-33) to the new hood and attach the hood tothe engine with the retention nuts removed instep 2.
Installation of the Fresh Water Cooling Kit on a Direct
Drive application is complete.

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L591001
RK147050

= Drain Locations= RAW WATER FLOW

= FRESH WATER FLOWFIGURE 2-1, FWC WATER FLOW DIAGRAM

Figure 2-1 Fresh-Water Cooling System (5.7L)

L591001
RK147050

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