2002 - 2003
Fresh Water
Cooling Installation
Instructions Direct Drive
Kit RK147046

L591003

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Intentially
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L591003

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 .............................................................3-4
Figure 1-2, Parts Added, Raw Water System, Direct Drive ..............................................................5-7
FWC Kit Installation, Direct Drive Systems .................................................................................. 8-15
2 - Fresh Water Cooling Water Flow Diagrams .......................................................................... 16-17

L591003
RK147046

1

FWC KIT INSTALLATION INSTRUCTIONS - RK147046
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.

INSTALLATION NOTES AND
RECOMMENDATIONSPCM Technical Support, Warranty and Dealer
Assistance:•••

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.

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

REFERENCES:
The following manuals are required to effectively perform
this installation procedure. If you do not have a copy ofeach of these manuals, obtain copies prior to beginning
this installation procedure.
L510013

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

L510010-03

Owner’s Operation and Maintenance
Manual

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 13-22 of this procedure. In addition,items 24-30 of the kit will not be used.

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 INSTALLATIONIMPORTANT: Thoroughly read these instructions
before beginning this installation procedure. Due
to model variations between ‘02 and ‘03 modelyears, continuing product improvements, and O.E.M.
considerations, variations exist. If the motor you
are installing the kit on is already equipped with acrank mounted raw water pump, you will skip steps
11 and 12 and step 33 of this procedure. Kit items
17-22, 45-46 will not be used. Other variations are
addressed within the text of this procedure.
Installation of the fresh water cooling system, on somedirect drive applications, will require the relocation of thetransmission oil cooler and transmission oil cooler lines.
Provisions should be made to recover oil spilled fromthe lines.

2

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

DESCRIPTIONQUANTITY

1

R045135A

Hose, r/w pump to tstat housing

1

2

RS3858Clamp, 1 1/4”

2

3

R090082

Clamp, strap

1

4RS1527Nut, strap clamp attaching

1

5

R025031

Housing, tstat, lower

1

6

RM0121

Gasket, tstat housing, lower

1

7

R026002

Thermostat, 160º F

1

8

RM0258Gasket, tstat housing, upper

1

9R025033

Housing, tstat, upper

1

1098333080

Bolt, tstat housing

2

11

RS2179Lock Washer, tstat housing

2

1298223035

Bolt, tstat housing

11393920000

Lock Washer, tstat housing

1

14

R020002

Sender, water temperature

1

15

TBD

Plug, intake, (water temp sender)

1

16

R045048

Hose, r/w supply to engine

1

17RS3852

Clamp, 1 3/4”

2

18R045107

Hose, r/w dump

2

19RS3851

Clamp, 1”

4*20R045021F

Hose, trans. oil cooler to r/w pump

1

*21

RS5858Clamp, 1 1/4”

2

*22

R090082

Clamp, strap

1

23

R060060

Hood

1

24

R143141

Decal, hood, “PCM Excalibur”

1

25

R143142

Decal, hood, “Excalibur”

2

26

R143143

Decal, hood, spec

1

*27

R143158

Decal, hood, “3 Star” emission

1‘03 MY, ONLY, SN 430913 and higher
28

R090143

Bracket, shift cable

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1

3

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

DESCRIPTIONQUANTITY

29

R090190A

Bracket, oil header

130RS0302

Bolt, brkt, oil header

3

31

RS2180

Lock Washer, brkt, oil header

3

32RS0282

Bolt, oil header

3

33

RS2179Lock Washer, oil header

3

34

RS1027Nut, oil header

335RA045120C

Oil Lines

2

36

R024184

Fitting, oil line adapter

2

37

R096144

Bracket, plug wire clip

2

38

RS0285Bolt, riser, short

2

39

RS2179Lock Washer, riser

2*40RS0279Bolt, 10-Pin Bracket attaching

1*41

RS2179Lock Washer, 10-Pin Bracket attaching

1*42

RA045007B

Hose, transmission oil

1*43RA045007K

Hose, transmission oil

1*44RS0306

Bolt, trans. cooler attaching

1*45

RS2180

Lock Washer, trans. cooler attaching

1*46

RS1028Nut, trans. cooler attaching

1

IMPORTANT: ITEM NUMBERS MARKED WITH AN “*” MAY OR MAY NOT BE DELETED
DEPENDING ON YOUR ENGINE CONFIGURATION. BE SURE TO READ ALL INSTRUCTIONSTHOROUGHLY BEFORE PERFORMING THE FWC KIT INSTALLATION INSTRUCTIONS.
REFER TO MANUAL L510013 FOR PARTS BREAKOUT.

4

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

DESCRIPTION

1

R020003

Sender, water temperature

1

2

R090260

Bracket, coolant fill riser

1

398223016

Bolt, fill riser brkt attaching

2

4

RS2672

Lock Washer, fill riser brkt, attaching

2

5RS7068Flat Washer, fill riser brkt, attaching

2

6

R034047

Coolant Fill Riser

1

7

R034006A

Cap, coolant fill riser

1

8RS0252

Bolt, fill riser mounting

2

9RS2179Lock Washer, fill riser mounting

2

10

RS1026

Nut, fill riser mounting

2

11

R025015A

Housing, FWC thermostat

1

12

R026002F

Thermostat, 160° F

1

13

R047189

O-Ring, thermostat housing

1

14RS6531

Bolt, thermostat housing attaching

2

15

RS2179Lock Washer, thermostat housing attaching

2

16

R024055

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

1

*17

R090013A

Bracket, trans. oil cooler mounting

1*18

RS0302

Bolt, cooler clamp to brkt attaching

1*19

RS2180

Lock Washer, cooler clamp to brkt attaching

1*20

RS1028Nut, cooler clamp to brkt attaching

1*21

RA045007S

Hose, transmission oil to cooler, 17”1*22RA045007T

Hose, transmission oil to cooler, 31”

1

23

R090143A

Bracket, shift cable1*24

R090257

Bracket, oil header

1*25RS0286

Bolt, brkt, oil header

2*26

RS2179Lock Washer, brkt, oil header

2*2798333020

Bolt, oil header

3*28

RS2179Lock Washer, oil header

3*29RA045120D

Hose, oil line

2

*30

R024184

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

2

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QUANTITY

5PARTS ADDED - 5.7L, V-BELT, DIRECT DRIVE -F/W
FIGURE 1-2

6

ITEM

PART NUMBER

DESCRIPTION*31

R090265

Bracket, heat exchanger

1*32

RS0281

Bolt, (-265) brkt, heat exchanger attaching

2*33

RS2179Lock Washer, (-265) brkt, heat exchanger

2*34

R090266

Bracket, heat exchanger

1*35

RS0304

Bolt, (-266) brkt, heat exchanger attaching

2*36

RS2180

Lock Washer, (-266) brkt, heat exchanger

2

37

R101013

Wire, H.E. ground1

38

R094040

Isolator, rubber, adhesive

1

39

RA147046

Heat Exchanger

1

40

R094041

Isolator, rubber

2

41

RS3857

Clamp, 4”2

42

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

43

R045025

Hose, r/w dump, 1”2

44RS3851

Clamp, 1”

4*45R045113

Hose, trans. oil cooler to r/w pump

1

*46

RS3858Clamp, 1 1/4”

2

47

R045146

Hose, circ. pump to H.E.

1

48

RS3852

Clamp, 1 3/4”, circ. pump

1

49

RS3868Clamp, 1 1/2”, H.E.

1

50

R045102A

Hose, r/w pump to H.E.

1

51

RS3858Clamp, 1 1/4”

2

52

R045124

Hose, coolant fill riser to H.E.

1

53

RS3851

Clamp, 1”

2

54

R045144

Hose, t-stat housing to H.E.

1

55

RS3858Clamp, 1 1/4”

2

56

R045132

Hose, coolant fill riser to t-stat housing

157

RS3870Clamp, 1/4”

2

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QUANTITY

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

DESCRIPTIONQUANTITY

58

R045139

Hose, overflow bottle to coolant fill riser

1

59

R127084

Clamp, 1/4”

2

60

R146002

Coolant Overflow Bottle w/cap

1

61RS0282

Bolt, overflow bottle mounting

2

62

RS2673

Flat Washer, overflow bottle mounting

2

63

RS2179Lock Washer, overflow bottle mounting

2

64

RS1027Nut, overflow bottle mounting

2

65

R060061A

Hood

1

66

R143141

Decal, hood, “PCM Excalibur”

1

67

R143142

Decal, hood, “Excalibur”

2

68

R143143

Decal, hood, spec

1

*69

R143158

Decal, hood, “3 Star” emission

1‘03 MY, ONLY, SN 430913 and higher

IMPORTANT: ITEM NUMBERS MARKED WITH AN “*” MAY OR MAY NOT BE USEDDEPENDING ON YOUR ENGINE CONFIGURATION. BE SURE TO READ ALL INSTRUCTIONSTHOROUGHLY BEFORE PERFORMING THE FWC KIT INSTALLATION INSTRUCTIONS.
REFER TO MANUAL L510013 FOR PARTS BREAKOUT.

L591003
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7

FWC KIT INSTALLATION INSTRUCTIONS - DIRECT DRIVEFWC KIT INSTALLATION - DIRECT DRIVEINTAKE
MANIFOLD
PLUG

1. Disconnect the negative battery terminal cable.
IMPORTANT: If an oil change is going to be
performed in conjunction with this procedure; drain
oil and change filter at this time. Do not refill theoil until you are instructed to do so later in thisprocedure.
2. Remove the hood (Figure 1-1, item 23) from theengine. The hood is not required to complete
the installation. Save the hood retention nuts
for installation of the new hood later in thisprocedure.
3. Remove the thermostat housing, watertemperature sender, and associated hoses.

T-STAT
HOUSING
BOLTS

Figure 1-3 Disconnect Points - Steps 3 - 4.
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.

NOTE: The complete thermostat housing with hoses,
temp sender, and thermostat can be remove as an
assembly. (Figure1-1, items 1-22)
a. Disconnect the wire connected to
the water temperature sender (Figure
1-1, item 14), 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, theraw water pump hose retaining clamp
and retaining nut on the lower port studof the circulating pump, and the raw
water supply to engine hose at thecirculating pump.
c. Remove the two bolts and lockwashers (Figure 1-3) 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.
4. Remove and discard the plug located right, frontof the intake manifold. Figure 1-3.

8

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RK147046

5. From the kit, install the Water Temperature
Sender (Figure 1-2, item 1) into the intake
manifold, where the plug was removed, andreconnect the temperature sending wire to thesensor. This is the wire disconnected in step 3a.
6. Remove 90° hose fittings from the (engine) frontof each exhaust manifold and the plug fitting fromthe rear of 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. Be sure to clean the threads of eachfitting, then apply PST prior to installation.

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.
FILL
RISER
MOUNT

7. From the kit, install the Coolant Fill Riser Bracket
using (2) Bolts (*metric), (2) Lock washers, and(2) Flat washers (Figure 1-2, items 2 - 5). The
bracket is installed to the existing bracket on the(engine) starboard side of the intake manifold.
8. From the kit, install the Coolant Fill Riser onto the
Coolant Fill Riser Bracket using (2) bolts, (2) lockwashers, and (2) nuts (Figure 1-2, items 6-10).
The fill riser is mounted on the exhaust elbow
side of the bracket. Install pressure cap onto fillriser.

Figure 1-4 Coolant Fill Riser Bracket Location

9. From the kit, install the Thermostat, O-ring, andThermostat Housing using (2) Bolts, (2) Lockwashers, (Figure 1-2, items 11 - 15).

12. Relocate the Transmission Oil Cooler fromits rear, starboard location to engine port front
motor mount.

10. From the kit, install the Vent Hose Fitting(Figure 1-2, item 16) into the Thermostat
Housing. The hose barb should be positioned
to starboard, approximately parallel with the
Thermostat Housing outlet.

a. Disconnect water hoses connected to the
input and output of the cooler. The water
hose connected to the output of the cooler
should be removed completely from theengine. You will have to release the hose
clamp securing the hose to the starboard
side of the engine by removing the bolt andlock washer securing it at the starboard front
engine mount; after the clamp is removed
reinstall the bolt and lock washer into themotor mount.

* IMPORTANT: STEPS 11 - 12 ARE ONLYPERFORMED IF YOUR ENGINE IS EQUIPPED WITH
A V-BELT DRIVEN RAW WATER PUMP.
11. Disconnect water hose connected to the input ofthe pump. Remove the (2) bolts and (2) lockwashers securing the r/w pump to the r/w pumpadjustment bracket. Rotate the pump 180° (camretaining screw is up) and reinstall the pumponto the adjustment bracket.

b. Disconnect and remove the transmission oil
hoses from the oil cooler and the transmission
and discard hoses. Have materials available
to absorb transmission fluid that will spill fromthe lines, cooler, and transmission.

NOTE: The following procedure involves the relocationof the Transmission Oil Cooler and oil hoses. Havematerials in place to absorb any transmission fluid
spilled.

c. Remove the oil cooler, with mounting clamp
attached, from the engine. The cooler clamp
will be secured to the engine either by aground stud bolt on the bell housing or a bolt,
lock washer, and nut through a mounting holeon the bell housing. If it was secured by theground stud, replace the ground stud and all
grounds after removal of the cooler; if it was
secured by a bolt, lock washer, and nut, those
items may be discarded.

NOTE: It is recommended that the transmission fluid
be removed from the transmission at this time. This
will help minimize the amount of fluid spilled during thecooler relocation process.
IMPORTANT: In most cases, engines equipped withthe v-belt driven r/w pump will have the oil cooler
located on the starboard rear of the engine. If yourengine has the oil cooler located on the starboard
rear of the engine, you must perform step 12.

NOTE: To minimize transmission fluid spillage in theboat, once the cooler has been removed from its
mounting point, perform step e on a work bench.

L591003
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9FWC KIT INSTALLATION INSTRUCTIONS - DIRECT DRIVE
d. The transmission oil line fittings need to be
re-indexed. Remove the top fitting on thetransmission, clean the threads, coat threads
with PST, and reinstall the fitting so it is facing
the front of the engine at an approximate 45°
angle to port. Remove the lower port oil line
fitting on the transmission, clean the threads,
coat the threads with PST, and reinstall thefitting so it is facing down with a slight angle
toward the engine.

g. Mount the assembled cooler to the engine port
front motor mount trunnion bolt. Remove thenut and lock washer from the trunnion bolt,
slide the oil cooler bracket onto the trunnion
bolt and secure with the nut and lock washer.

e. The transmission oil line fittings will need to be
re-indexed. Remove the oil line fittings fromthe oil cooler. Clean the threads thoroughly,
apply PST to the fitting threads, and reinstall
the fittings into the oil cooler so the rear fitting
is parallel with the cooler facing the rear of
the engine, and the forward fitting is facing therear at a slight up angle to allow for oil hose
attachment. See Figure 1-5.

h. Route the transmission oil line hoses under
the remote oil filter lines. Attach the shortertransmission oil line hose to the bottom fitting
on the transmission, and the longer hose to
the upper fitting on the transmission. Make
sure all oil line hose connections are secure.

LARGE HOLE
MOUNTS TO
TRUNNION
BOLTTOWARD
ENGINEFRONTCOOLER
BRACKET

Once installed the cooler may need to be rotatedup or down slightly for best fit. Make sure all
mounting hardware is secure if loosened for fit
adjustment.

IMPORTANT: CHECK TRANSMISSION FLUID LEVEL.
IF IT IS NOT TO THE “FULL” MARK OF THE
DIPSTICK, ADD FLUID AT THIS TIME UNTIL FLUIDLEVEL INDICATES FULL.

TOTOP
TRANSMISSIONFITTING

COOLER
CLAMP
ORIENTATECOOLER SO
DRAIN FITTING
IS DOWNTO
BOTTOM
TRANSMISSIONFITTING

Figure 1-5 Transmission Oil Cooler, Reconfigured
f. From the kit, locate the Oil Cooler Bracket,(1) bolt, (1) lock washer, (1) nut, and (2)Transmission Oil Hoses (Figure 1-2, items 28- 33). If necessary, loosen the cooler clamp
and orientate the cooler to the position shownin Figure 1-5. Tighten the clamp. Attach thecooler bracket to the cooler clamp as shownin Figure 1-5. Attach the shorter of the twotransmission oil line hose to the rear oil fittingof the cooler. Attach the longer transmission
oil line hose to the forward fitting on the oilcooler.

10

L591003
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FWC KIT INSTALLATION INSTRUCTIONS - DIRECT DRIVE
13. 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 24-26).
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

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

IN

15. Remove the (3) oil header mounting bolts,
lock washers, and nuts. Relocate the oil header
to the new Oil Header Bracket (step 13). 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 27-28),
mount the oil header to the new bracket.

OIL
HEADER

BRACKET
MOUNTING
BOLTS

Figure 1-6 Oil Header and Bracket - New Location

16. Remove the oil lines from the Oil Bypass
Adapter and discard.
17. Remove the outboard oil adapter fitting.
18. 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 the oil fittingfrom the oil adapter housing attaching fitting.
Discard both old oil fittings. Figure 1-7.
19. 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 30) 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 1-7 Oil Adapter and Fittings

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

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11FWC KIT INSTALLATION INSTRUCTIONS - DIRECT DRIVE
20. Install the second new oil fitting(Figure 1-2, item 30) into the outboard port of theoil bypass adapter, orientating the oil connection
forward.
21. Route the new oil lines (Figure 1-2, item 29)
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 1-8 for proper
routing; Figure 1-6 and 1-9 for proper
connections at the oil header and oil adapter.

OIL LINESROUTED UNDER
AND BEHIND MOUNTCAUTION
Severe engine damage can occur if the oil lines are
not connected properly.
22. Remove the old remote oil header bracket.
Discard the bracket, (3) bracket mounting bolts,(3) lock washers, and (1) plug wire retaining clip
bracket.

Figure 1-8 Oil Line Routing

24. Remove the existing shift cable bracket andinstall the new shift cable bracket, from the kit.
(Figure 1-2, item 23) Be sure to reconnect theshift cable onto the new bracket.
25. Remove the starboard plug wire retaining
bracket, located on the rear of the starboard
head. Retain bolt and lock washer for use instep 26.

OUTPUTFROMHEADER

INPUT
TO
HEADER

Figure 1-9 Oil Line Connections at Adapter
Housing

12

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FWC KIT INSTALLATION INSTRUCTIONS - DIRECT DRIVE
NOTE: For steps 26 -28 of this procedure parts added
and relocated will vary according to the Bell Housing
installed on your engine. Refer to Figure 1-10 for Bell
Housing differences. Figure 1-10A is distinguished byhaving ‘PCM’ cast into the upper center surface and is abottom mount starter only housing. Figure 1-10B is thecurrent style Bell Housing and is distinguished by being
able to accept either top mount or bottom mount starters
dependent upon application.
26. Relocate the 10-Pin Bracket to the lower top
mount starter block-off plate bolt, or to the upper
starboard transmission mounting bolt. Refer toFigure 1-10. If a ground wire was secured at
the 10-Pin Bracket mounting point, relocate thisground wire to the lower mounting hole on therear of the starboard head using (1) bolt and (1)lock washer, from step 25. If the 10-Pin bracket
was originally secured with a ground stud bolt
(typical of Figure 1-10B) return the bolt to its
original location and tighten. If the 10-Pin was
secured by a bolt and lock washer (typical of
Figure 1-10A) you may discard the bolt and lockwasher.

HEAT EXCHANGERBRACKETLOCATIONHEAT EXCHANGERGROUND WIRELOCATION

10-PIN BRACKETNEW LOCATIONAHEAT EXCHANGERGROUND WIRELOCATION

27. From the kit, install the Heat Exchanger Ground
Wire (Figure 1-2, item 37) at the upper port bell
housing mounting bolt. Refer to Figure 1-10 forexact location.

10-PIN BRACKET
OLD LOCATIONHEAT EXCHANGERBRACKETLOCATION

28. From the kit, install the Heat Exchanger Bracket(Figure 1-2, items 31 - 36) to the bell housing.
For the bell housing pictured in Figure 1-10A
use items 31-33 from the kit, for the bell housing
pictured in Figure 1-10B use items 34-36 fromthe kit.
29. From the kit, cut the rubber isolator withadhesive into thirds (Figure 1-2, item 38). Affix
the isolator onto the Heat Exchanger Bracket in
the center and inboard of each of the mounting
clamp holes.

10-PIN BRACKET
OLD LOCATION

10-PIN BRACKETNEW LOCATION

B

Figure 1-10 Bell Housing Configurations andAccessory Mounting Locations

30. From the kit, obtain the Heat Exchanger (Figure
1-2, item 39). Mount the Heat Exchanger
assembly to the H.E. Bracket using (2) 4” Hose
Clamps (Figure 1-2, item 41). Do not fullytighten the clamps, at this time.
31. From the kit, use the Nut w/lock washer (Figure
1-2, item 42) to secure the ground wire to the
H.E. ground stud.

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13

FWC KIT INSTALLATION INSTRUCTIONS - DIRECT DRIVE
32. From the kit, install the (2) Raw Water Dump
Hoses, using (4) 1” Hose Clamps, (Figure 1-2,
items 43 - 44) to the H.E. 1” outboard fittings andto the 90° fittings installed in rear ports of theexhaust manifolds.

39. From the kit, locate the Coolant Overflow
Bottle w/Cap, Coolant Overflow Hose, 1/4”
Hose Clamps, and Overflow Bottle mounting
hardware, (2) bolts, (2) flat washers, (2) lockwashers, and (2) nuts (Figure 1-2, items 58-64).
Attach the coolant overflow hose to the overflow
bottle using 1/4” hose clamp. Mount theOverflow Bottle to the Heat Exchanger Bracket
using the (2) bolts, flat washers, lock washers
and nuts. Bolt with flat washer on the bottle side
and lock washer and nut on bracket side. Routethe overflow hose under the H.E. then up andforward to the engine rear fitting on the coolant
fill riser and secure with 1/4” hose clamp.

NOTE: The r/w dump hoses may need to be trimmed
slightly, at the H.E. side, to prevent them from rubbing on
the corner of the engine heads.
33. If you performed steps 11-12 of this procedure,from the kit, install the Cooler to R/W Pump
Hose (Figure 1-2, item 45) using hose clamps
provided (Figure 1-2, item 46). The hose mayneed to be trimmed at the cooler side to provide
a smooth fit.
34. From the kit, install the Circulating Pump to
Heat Exchanger Hose (Figure 1-2, item 47).
Use 1-3/4” hose clamp (Figure 1-2, item 48) at
the circulating pump and use 1-1/2” hose clamp(Figure 1-2, item 49) at the H.E. The hose mayneed to be trimmed at the heat exchanger end
to provide a smooth fit.
35. From the kit, install the R/W Pump to Heat
Exchanger Hose (Figure 1-2, item 50) using
1-1/4” hose clamps (Figure 1-2, item 51).
NOTE: The R045102A hose (Figure 1-2, item 50)
is moulded to fit the crank driven r/w pump. Wheninstalling this hose on a system using the belt driven r/w
pump you will have to cut the ‘U’ end of the hose off
and then trim it to fit.
36. From the kit, install the Coolant Fill Riser toHeat Exchanger Hose (Figure 1-2, item 52),
using 1” hose clamps (Figure 1-2, item 53). The
moulded end of the hose will connect to thefill riser and the end of the hose connecting to
the H.E. may need to be trimmed to provide asmooth fit.
37. From the kit, install the Thermostat Housing
to Heat Exchanger Hose (Figure 1-2, item 54),
using 1-1/4” hose clamps (Figure 1-2, item 55).

40. Ensure that the H.E. r/w and f/w drains arefacing straight down. From the kit, installa rubber isolator (Figure 1-2, item 40) undereach of the H.E. mounting clamps, then tighten
clamps securing the H.E. to the H.E. Mounting
Bracket.
IMPORTANT: If you performed step 12 of thisprocedure, relocation of the transmission oil cooler
will require a new water intake hose between thecooler and the sea cock (or sea strainer, depending
upon application). Hoses disconnected during thisprocedure may be of sufficient length to accomplish
this or you may need to order 1-1/4” i.d. water hoseof sufficient length from the O.E.M. or other source.
Ensure that this connection is made before you
operate the engine.
41. Remove the engine block drain plugs and drain
any remaining water from the engine block.
Reinstall block drain plugs.
42. Make sure that ALL drain plugs are properly
installed and all hose connections (fuel, oil, andwater) are secure.
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.

38. From the kit, install the Coolant Fill Riser tothermostat Housing Hose (Figure 1-2, item 56),
using 1/4” hose clamps (Figure 1-2, item 57).
This hose connects to the nipple fitting locatedon the engine front of the fill riser and routes
inside the oil fill tube to the thermostat housing
fitting.

14

L591003
RK147046

FWC KIT INSTALLATION INSTRUCTIONS - DIRECT DRIVEFILLING FRESH-WATER COOLING SYSTEMWARNINGA 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:

Visually inspect unit for fuel leaks before operating
the engine. If fuel leaks are present, DO NOT operate
the engine, repair immediately.
47. Start the engine and operate at idle speed(650-1000 RPM) to purge air from the system.
Continue to add coolant until the coolant levelremains constant, then add coolant to theOverflow Bottle to the “Full” mark on the bottle.
Install the pressure cap on the Coolant Fill Riser.

•

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

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

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

•

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

48. Continue to run the engine until it reaches
normal operating temperature. Check for fuelleaks, oil leaks, fresh water coolant leaks, andraw water leaks at all fittings and connections.
Correct all leaks, as required.
NOTICE: It is not necessary to remove pressure cap
to check coolant levels. Check Overflow Bottle daily
and keep filled to between the ‘ADD” and “FULL” levelindicated on the bottle.

TO FULLY REALIZE ITS MANY ADVANTAGES,
DEX-COOL™ MUST NEVER BE MIXED WITHCONVENTIONAL COOLANTS.

WARNING

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.

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.
49. Continue to run the engine at normal operating
temperature. Verify engine operating
temperature and thermostat operation. Check
the Overflow Bottle for the proper level and add
coolant if necessary.

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.

50. Tun engine off. Check transmission fluid level.
If the level is not to the ‘FULL’ mark on thedipstick add fluid until level reads ‘FULL’ . DO
NOT overfill.

IMPORTANT: More than 50% antifreeze solution cancontribute to an overheating condition.
43. Reconnect negative terminal of the battery.

Check engine oil level. Add oil until level reads“Full” on the dipstick. DO NOT overfill.

44. Remove the pressure cap from the Coolant Fill
Riser.

51. From the kit, affix decals to the new hood (Figure
1-2, items 65-69) and attach the hood to theengine with the retention nuts removed in step2.

45. Prepare 5 gallons of DEX-COOL™ 50/50
solution. Slowly fill the system with antifreeze
solution until the system is full. Coolant Fill Riser
will be full to the top.
46. Prime the fuel system. Turn the ignition key to
the ON position for 5 seconds, turn the key OFF
for 10 seconds, and repeat 1-3 times.

Installation of the Fresh Water Cooling Kit on a Direct
Drive application is complete.

L591003
RK147046

15

Figure 2-1 Fresh-Water Cooling System (5.7L Crank Driven R/W Pump)

16

L591003
RK147046= Drain Locations= FRESH WATER FLOW

= RAW WATER FLOWTo Cylinder
Block

To Cylinder
Block

From Intake
Manifold

FIGURE 2-1, FWC WATER FLOW DIAGRAM

= Drain Locations= FRESH WATER FLOW

= RAW WATER FLOWTo Cylinder
Block

To Cylinder
Block

From Intake
Manifold

FIGURE 2-2, FWC WATER FLOW DIAGRAM

Figure 2-1 Fresh-Water Cooling System (5.7L Belt Driven R/W Pump)

L591003
RK147046

17