REPAIR INSTRUCTIONS, PART 1
Page 235
1. Insert the 90-degree elbow fitting in the
cooling duct cover oriented toward the rear
of the engine as shown.
The jam nut must be threaded all the way to the
elbow to permit maximum fitting thread
engagement.
2. Using a torque wrench, tighten the fitting
according to specification.
3. Using a torque wrench, tighten the coolant
hose jam nut according to specification.
4. Apply a 2 mm (5/16 inch) bead of 3M
Scotch-Grip™ 4799 Industrial Adhesive
inside the seal groove near the perimeter of
the cooling duct cover.
The surface inside the groove must be clean, dry
and free of oil, dust and dirt. The adhesive must
stay inside the groove. The adhesive cures
quickly. After the adhesive is applied, installation
of the cover must be completed as quickly as
possible.
5. Insert a new seal into the groove near the
perimeter of the cooling duct cover and
press into place.
336
Figure 336 — Installing Cooling Duct Cover Seal
6. Apply a generous coating of Dow Molykote
®
55 O-ring lubricant to the cooling duct
cover-to-pump outlet seal and then insert
the formed rubber seal into the coolant
pump base plate outlet.
337
Figure 337 — Installing Cooling Duct Cover-to-Pump
Outlet Seal
7. Make sure the cooling duct cover mounting
surface on the cylinder block is clean and
dry.
8. Apply a generous coating of Dow Molykote
®
55 O-ring lubricant to the duct cover seal.
The cooling duct cover is installed by positioning
the cover against the cylinder block and sliding
the cover forward until the cover inlet engages the
coolant pump outlet. If the cover seal is not
lubricated, the seal can roll out of the duct cover
groove as it is being slid forward.
The cooling duct cover engages a formed rubber
seal in the coolant pump outlet port. Installation of
the cooling duct cover without damaging the
cover seal or coolant pump outlet seal can be
difficult. A tool (88800022) is designed to help
install the cover on US07 emission MP7 and MP8
engines and is shipped as an essential tool. For
the US04 emission MP7 engine, the tool must
have a minor modification so that it can be used
to help install the cooling duct cover on this
engine. To modify this tool, drill two 9/32 inch
diameter holes at the locations shown in the
illustration. After the modification, the tool can be
secured to the cylinder block heater mounting
holes at the rear of the cooling duct cover.
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