v - Boxxer 423S Owner’s ManualBoxxer 423S Owner’s Manual - iv
List of Figures
Figure 1-1. Hard Water Map of Mainland United States ............................................ 1-15
Figure 2-1. Location of Roof Vents in Vehicle ..............................................................2-1
Figure 2-2. Recommended Location of Boxxer 423s in Van ........................................2-3
Figure 2-3. Install Fuel Pump, Outlet Side Up ..............................................................2-6
Figure 2-4. Fuel Pump Must Be in Vertical Position .....................................................2-6
Figure 4-1. Boxxer 423s Upper Dash Assembly...........................................................4-1
Figure 4-2. Boxxer 423s Lower Dash Assembly...........................................................4-2
Figure 4-3. Boxxer 423s Chemical System Control and Metering................................4-4
Figure 5-1. Remove Valve Cap and Valve Assembly ...................................................5-8
Figure 5-2. Inspect Manifold and Old Valves ................................................................5-8
Figure 5-3. Replace Center Inlet Check Valve With Modied Check Valve ..................5-9
Figure 5-4. Apply Grease and Install Valves .................................................................5-9
Figure 5-5. Replace Valve Capand Torque to 95 ft lbs .................................................5-9
Figure 5-6. Separate Manifold from Crankcase......................................................... 5-10
Figure 5-7. Seal Assemblies May Come Off with Manifold ........................................ 5-10
Figure 5-8. Examine Ceramic Plungers..................................................................... 5-10
Figure 5-9. Remove Stainless Steel Plunger Bolt and Ceramic Plunger ...................5-11
Figure 5-10. Install O-ring, Apply Sealant and Slide Plunger over Plunger Guide .....5-11
Figure 5-11. Extract Retainers and Seals .................................................................. 5-12
Figure 5-12. Seal Kit and Insertion Tool for Seal Installation ..................................... 5-13
Figure 5-13. Install Seal Assembly Using O-Ring Grease ......................................... 5-13
Figure 5-14. Install Retainers into Cavities ................................................................ 5-14
Figure 5-15. Press Low Pressure Seal Assembly into Cavity.................................... 5-14
Figure 5-16. Re-install Manifold and Torque Fasteners ............................................. 5-15
Figure 5-17. Torque Sequence in “X” Pattern ............................................................ 5-15
Figure 5-18. Torque Bolts to 22 ft. lbs ........................................................................ 5-15
Figure 5-19. Recirculation Fitting............................................................................... 5-17
Figure 6-1. Flow Diagram - View 1 of 3 ........................................................................6-3
Figure 6-2. Flow Diagram - View 2 of 3 ........................................................................6-4
Figure 6-3. Flow Diagram - View 3 of 3 ........................................................................6-5
Figure 7-1. Electrical Schematic ...................................................................................7-2
Figure 7-2. Wiring Diagram - View 1 of 3 .....................................................................7-3
Figure 7-3. Wiring Diagram - View 2 of 3 .....................................................................7-4
Figure 7-4. Wiring Diagram - View 3 of 3 .....................................................................7-5
Figure 9-1. Adhesive/Sealant Material Reference ........................................................9-2
Figure 9-2. Console Assembly - View 1 of 6 .................................................................9-3
Figure 9-3. Console Assembly - View 2 of 6 .................................................................9-4
Figure 9-4. Console Assembly - View 3 of 6 .................................................................9-5
Figure 9-5. Console Assembly - View 4 of 6 .................................................................9-6
Figure 9-6. Console Assembly - View 5 of 6 .................................................................9-7
Figure 9-7. Console Assembly - View 6 of 6 .................................................................9-8
Figure 9-8. Frame Assembly - View 1 of 2 ................................................................9-11
Figure 9-9. Frame Assembly - View 2 of 2 ............................................................... 9-12
Figure 9-10. Blower Assembly - View 1 of 2 .............................................................. 9-13
Figure 9-11. Blower Assembly - View 2 of 2 .............................................................. 9-14
Figure 9-12. Pump Assembly .................................................................................... 9-16
Figure 9-13. Dash Assembly - View 1 of 2 ................................................................ 9-18
Figure 9-14. Dash Assembly - View 2 of 2 ................................................................ 9-19
Figure 9-15. Differential Check Valve Assembly ........................................................ 9-21
Figure 9-16. By-Pass Valve Assembly ....................................................................... 9-22
Figure 9-17. Hi-PSI Manifold Assembly ..................................................................... 9-24
Figure 9-18. Electrical Panel Assembly - View 1 of 2 ................................................ 9-26
Figure 9-19. Electrical Panel Assembly - View 2 of 2 ................................................ 9-27
Figure 9-20. Engine Assembly - View 1 of 2 ............................................................. 9-28
Figure 9-21. Engine Assembly - View 2 of 2 ............................................................. 9-29
Figure 9-22. Blower Heat Exchanger Assembly ....................................................... 9-30
Figure 9-23. Idler Pulley Assembly ........................................................................... 9-32
Figure 9-24. Silencer Assembly ................................................................................ 9-33
Figure 9-25. Water Box Assembly ............................................................................ 9-34
Figure 9-26. Exhaust Assembly ................................................................................ 9-36
Figure 9-27. Exhaust Manifold Assembly ................................................................. 9-37
Figure 9-28. Exhaust Diverted Assembly ................................................................. 9-38
Figure 9-29. Diverter Valve Actuator Assembly ........................................................ 9-40
Figure 9-30. Exhaust Diverter Valve Assembly ........................................................ 9-41
Figure 9-31. 70 Gallon Universal Recovery Tank (URT) Assembly .......................... 9-43
Figure 9-32. 70 Gallon Universal Recovery Tank (URT) Cover Assembly ............... 9-45
Figure 9-33. 100 Gallon Universal Recovery Tank (URT) Assembly ........................ 9-47
Figure 9-34. 100 Gallon Universal Recovery Tank (URT) Cover Assembly ............. 9-49
Figure 9-35. Vacuum Relief Valve Assembly ............................................................ 9-51
Figure 9-36. Dura-Flow APO Assembly .................................................................... 9-52
Figure 9-37. APO Pump Assembly ........................................................................... 9-54
To Next Page
Loading...