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Service Manual K38, K50, QSK38 and QSK50 Volume 3

Service Manual K38, K50, QSK38 and QSK50 Volume 3

Service Manual K38, K50, QSK38 and QSK50 Volume 3
Service Manual K38, K50, QSK38 and QSK50 Volume 3 Copyright© 2008 Cummins Inc. All rights

Service Manual K38, K50, QSK38 and QSK50 Volume 3

Service Manual K38, K50, QSK38 and QSK50 Volume 3 Copyright© 2008 Cummins Inc. All rights reserved

Copyright© 2008 Cummins Inc. All rights reserved

Bulletin 4021528 Printed 27-MARCH-2008

Foreword

This manual contains instructions for troubleshooting and repairing this engine in the chassis, complete rebuild procedures and specifications. Disassembly, cleaning, inspection, and assembly instructions are included. A listing of accessory and component suppliers is located in Section M - Component Manufacturers. Suppliers can be contacted directly for any information not covered in this manual.

Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in Section i - Introduction.

The manual is organized to guide a service technician through the logical steps of identifying and correcting problems related to the engine. This manual does not cover vehicle or equipment problems. Consult the vehicle or equipment manufacturer for repair procedures.

The repair procedures in this manual are based on the engine or component removed from chassis. Some rebuild procedures require the use of special service tools. Make sure the correct tools are used as described in the procedures.

When a specific brand name, number, or special tool is referenced in this manual, an equivalent product can be used in place of the recommended item.

A series of specific service manuals (for example: Troubleshooting and Repair, Specifications, and Alternative Repair) are available and can be ordered by Contacting your local area Cummins Regional office. A Cummins Regional office listing is located in Service Literature (Section L).

Cummins Inc. encourages the user of this manual to report errors, omissions, and recommendations for improvement. Please use the postage paid, pre-addressed Literature Survey Form in the back of this manual for communicating your comments.

The specifications and rebuild information in this manual is based on the information in effect at the time of printing. Cummins Inc. reserves the right to make any changes at any time without obligation. If differences are found between your engine and the information in this manual, contact a Cummins Authorized Repair Location or call 1-800-DIESELS (1-800-343-7357) toll free in the U.S. and Canada.

The latest technology and the highest quality components are used to manufacture Cummins engines. When replacement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts.

Table of Contents

Section

Cooling System — Group 08

8

Drive Units — Group 09

9

Air Intake System — Group 10

10

Exhaust System — Group 11

11

Compressed Air System — Group 12

12

Electrical Equipment — Group 13

13

Engine Testing — Group 14

14

Mounting Adaptations — Group 16

16

Miscellaneous — Group 17

17

Main Power Generator — Group 21

21

Service Literature

L

Component Manufacturers

M

Specifications

V

Back

back

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Page 8-a

Section 8 — Cooling System — Group 08

Section Contents

 

Page

Belt Guard

8-3

Clean and Inspect for Reuse

8-4

Install

8-4

Remove

8-3

Coolant Bypass Tube

8-12

Clean and Inspect for Reuse

8-14

Industrial

8-14

Marine Applications

8-14

Finishing Steps

8-16

Install

8-15

Industrial

8-15

Marine Applications

8-15

Preparatory Steps

8-12

Remove

8-12

Industrial

8-12

Marine Applications

8-13

Coolant Filter

8-17

Install

8-17

Remove

8-17

Coolant Temperature Gauge

8-11

Inspect for Reuse

8-11

Coolant Thermostat

8-18

Finishing Steps

8-32

General Information

8-18

Inspect for Reuse

8-23

Install

8-27

Conventional Aftercooling

8-27

LTA

8-28

with Electronically Actuated Injector

8-29

Gas Compression

8-30

Leak Test

8-24

Conventional Aftercooling

8-25

LTA

8-26

Preparatory Steps

8-19

Remove

8-19

Conventional Aftercooling

8-19

LTA

8-20

with Electronically Actuated Injector

8-22

Test

8-23

Coolant Thermostat Housing Support

8-32

Clean and Inspect for Reuse

8-37

LTA

8-37

Finishing Steps

8-41

General Information

8-32

Install

8-37

LTA

8-37

Preparatory Steps

8-33

Remove

8-33

Cooling System

8-42

Drain

8-42

Fill

8-44

Flush

8-42

Cooling System Diagnostics

8-54

Inspect

8-54

Cooling System - Air or Combustion Gas Test

8-46

Test

8-46

Overflow Method

8-46

Page 8-b

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Sight Glass Method

8-47

Air Compressor

8-48

Combustion Gas Leak

8-49

Cylinder Head and Cylinder Liner

8-52

Drive Belt, Cooling Fan

8-5

Adjust

8-11

Inspect for Reuse

8-7

Install

8-8

Remove

8-5

ECM Cooling Plate

8-169

Assemble

8-173

Clean and Inspect for Reuse

8-170

Disassemble

8-169

Finishing Steps

8-174

Install

8-174

Preparatory Steps

8-169

Remove

8-169

ECM Cooling Plate Lines

8-175

Finishing Steps

8-178

Inspect for Reuse

8-176

Install

8-177

Preparatory Steps

8-175

Remove

8-175

Expansion Tank

8-75

Clean and Inspect for Reuse

8-77

Finishing Steps

8-80

Install

8-78

Preparatory Steps

8-75

Remove

8-75

Fan Clutch, Viscous

8-55

Measure

8-55

Fan, Cooling

8-70

Finishing Steps

8-71

Install

8-71

Preparatory Steps

8-70

Remove

8-70

Fan Drive Idler Arm Assembly

8-56

Assemble

8-60

Clean

8-59

Disassemble

8-58

Finishing Steps

8-62

Install

8-62

Preparatory Steps

8-56

Remove

8-57

Fan Hub Bracket

8-62

Clean and Inspect for Reuse

8-63

General Information

8-62

Install

8-64

Remove

8-63

Fan Hub, Belt Driven

8-64

Assemble

8-67

Clean and Inspect for Reuse

8-65

Disassemble

8-66

Finishing Steps

8-70

Install

8-69

Preparatory Steps

8-64

Remove

8-65

Fan Shroud Assembly

8-70

Inspect for Reuse

8-70

Heat Exchanger

8-81

Assemble

8-101

Tube Type

8-101

Plate Type

8-103

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Page 8-c

Box Type

8-106

Clean

8-92

 

Tube Type

8-92

Clean and Inspect for Reuse

8-97

Tube

Type

8-97

Plate

Type

8-98

Box Type

8-99

Disassemble

8-92

Tube

Type

8-92

Plate

Type

8-93

Box Type

8-95

 

Exploded View

8-81

Finishing Steps

8-121

Inspect

8-100

Tube Type

8-100

 

Plate Type

8-100

Box Type

8-101

Install

8-110

Tube Type

8-110

Plate Type

8-116

Box Type

8-119

Preparatory Steps

8-85

Pressure Test

8-108

Tube Type

8-108

Box Type

8-110

Remove

8-85

Tube

Type

8-85

Plate

Type

8-88

Box Type

8-90

Low-Temperature Aftercooler (LTA) Water Pump

8-168

Maintenance Check

8-168

with Mechanically Actuated Injector

8-168

Radiator

8-72

Test

8-72

Radiator Hoses

8-74

Inspect for Reuse

8-74

Radiator Pressure Cap

8-74

Inspect for Reuse

8-74

Pressure

Test

8-75

Sea Water Hoses

8-168

Inspect

8-168

Sea Water Pump

8-121

Assemble

8-128

Gear Driven

8-128

Spline Driven

8-132

Clean and Inspect for Reuse

8-127

Gear Driven

8-127

Spline Driven

8-128

Disassemble

8-122

Gear Driven

8-122

Spline Driven

8-125

Finishing Steps

8-136

Spline Drive

8-136

General Information

8-121

Gear Driven

8-121

Install

8-136

Spline Drive

8-136

Preparatory Steps

8-121

Spline Drive

8-121

Remove

8-122

Spline Drive

8-122

Sea Water Pump Support

8-136

Clean and Inspect for Reuse

8-138

Page 8-d

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

with Mechanically Actuated Injector

8-138

with Electronically Actuated Injector

8-138

Finishing Steps

8-140

Install

8-139

with Mechanically Actuated Injector

8-139

with Electronically Actuated Injector

8-140

Preparatory Steps

8-136

Remove

8-137

with Mechanically Actuated Injector

8-137

with Electronically Actuated Injector

8-137

Sea Water System Diagnostics

8-165

General Information

8-165

Inspect

8-165

Pressure Test

8-167

Test

8-166

Service Tools

8-1

Cooling System

8-1

Supplemental Coolant Additive (SCA)

8-140

Maintenance Check

8-140

Water Manifold

8-141

Clean and Inspect for Reuse

8-141

Water Pump

8-142

Assemble

8-154

with Mechanically Actuated Injector

8-154

Clean and Inspect for Reuse

8-148

with Mechanically Actuated Injector

8-148

with Electronically Actuated Injector

8-149

Disassemble

8-149

with Mechanically Actuated Injector

8-149

Finishing Steps

8-164

with Mechanically Actuated Injector

8-164

with Electronically Actuated Injector

8-165

General Information

8-142

with Mechanically Actuated Injector

8-142

Inspect

8-152

with Mechanically Actuated Injector

8-152

Install

8-160

with Mechanically Actuated Injector

8-160

with Electronically Actuated Injector

8-162

Preparatory Steps

8-144

with Mechanically Actuated Injector

8-144

with Electronically Actuated Injector

8-144

Remove

8-145

with Mechanically Actuated Injector

8-145

with Electronically Actuated Injector

8-145

K38, K50, QSK38, and QSK50

Service Tools

Section 8 — Cooling System — Group 08

Page 8-1

Service Tools

Cooling System

The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from a local Cummins® Authorized Repair Location.

Tool No.

Tool Description

Tool Illustration

 

Gear Puller

  Gear Puller

ST-647

Used to remove the water pump pulley and impeller.

 

Pulley Installation Tool

  Pulley Installation Tool

3376326

Used to install drive pulleys.

 

Water Pump Bearing Mandrel

  Water Pump Bearing Mandrel

3375318

Used to press the bearing and shaft into the water pump body.

 

Water Pump Bearing Mandrel

  Water Pump Bearing Mandrel

3375319

Used to install the front water pump oil seal into the water pump body.

 

Bearing Separator

  Bearing Separator

3375326

Used to hold the bearing when removing it from the shaft.

 

Thermostat Seal Driver

  Thermostat Seal Driver

3375411

Used to install thermostat seal.

Service Tools

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Page 8-2

Tool No.

Tool Description

Tool Illustration

 

Pipe Sealant

  Pipe Sealant

Used when installing pipe plugs or cup plugs on the engine in order

3375066

to prevent leaks.

 

Digital Optical Tachometer

  Digital Optical Tachometer

3377462

Used to measure the rpm of the fan.

 

Reflective Tape

  Reflective Tape

Used with optical tachometer, Part Number 3377462, to measure the

3377464

rpm of the fan.

 

Cooling System Test Kit - Fleetguard®

  Cooling System Test Kit - Fleetguard®

CC-2602

Used to measure supplemental cooling additive (SCA) concentration.

 

Snap-On Pry Bar

  Snap-On Pry Bar

1650

Used to remove thermostat seals.

 

Torque Wrench

  Torque Wrench

3164794

Used to tighten capscrews 13 to 136 N•m [10 to 100 ft-lb].

K38, K50, QSK38, and QSK50

Belt Guard

Section 8 — Cooling System — Group 08

Page 8-3

Belt Guard (008-001)

Belt Guard (008-001)

Remove

Remove the two capscrews and washers connecting the auxiliary drive guard from the vibration damper guard.

Loosen the two capscrews from the rear of the gear housing securing the auxiliary drive guard to the gear housing.

Remove the auxiliary drive guard.

Remove the four capscrews, washers, and isolators from the vibration damper guard.

Remove the four capscrews, washers, and isolators from the vibration damper guard.

Remove the vibration damper guard.

Remove the capscrews and washers from the alternator mounting bracket to the alternator belt guard.

Remove the capscrews and washers from the alternator mounting bracket to the alternator belt guard.

Remove the two mounting capscrews and washers from the front of the alternator belt guard to the front gear cover.

Remove the two mounting capscrews and washers from the front of the alternator belt guard to

Remove the alternator belt guard.

and washers from the front of the alternator belt guard to the front gear cover. Remove
and washers from the front of the alternator belt guard to the front gear cover. Remove
and washers from the front of the alternator belt guard to the front gear cover. Remove
and washers from the front of the alternator belt guard to the front gear cover. Remove

Belt Guard

K38, K50, QSK38, and QSK50

Page 8-4

Section 8 — Cooling System — Group 08

Pa g e 8-4 Section 8 — Cooling S y stem — Grou p 08 Clean
Pa g e 8-4 Section 8 — Cooling S y stem — Grou p 08 Clean
Pa g e 8-4 Section 8 — Cooling S y stem — Grou p 08 Clean
Pa g e 8-4 Section 8 — Cooling S y stem — Grou p 08 Clean

Clean and Inspect for ReusePa g e 8-4 Section 8 — Cooling S y stem — Grou p 08 WARNING

Cooling S y stem — Grou p 08 Clean and Inspect for Reuse WARNING When using
Cooling S y stem — Grou p 08 Clean and Inspect for Reuse WARNING When using

WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

clothing to reduce the possibility of personal injury. WARNING Wear appropriate eye and face protection when
clothing to reduce the possibility of personal injury. WARNING Wear appropriate eye and face protection when

WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Use solvent to clean the belt guards.

Dry with compressed air.

Inspect the belt guards and brackets for cracks or other damage. If damaged, they must be replaced. damage. If damaged, they must be replaced.

Inspect the isolators for damage. If the isolators are hard and brittle, they must be replaced.

Install the two mounting capscrews, washers, and alternator belt guard to the front gear cover. the front gear cover.

Install

Install the capscrews and washers to the alternator belt guard through the alternator mounting bracket. guard through the alternator mounting bracket.

Operate the engine and check for proper operation.

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Install the vibration damper guard, four capscrews, washers, and isolators to the front gear cover.

Install the vibration damper guard, four capscrews, washers, and isolators to the front gear cover.

Torque Value:

 
Torque Value:  

Vibration

Guard

25

N•m

[ 18 ft-lb ]

Capscrews

Install the auxiliary drive guard.

 

Install the two capscrews on the rear of the gear housing securing the auxiliary drive guard to the gear housing.

Torque Value:

the two capscrews on the rear of the gear housing securing the auxiliary drive guard to
the two capscrews on the rear of the gear housing securing the auxiliary drive guard to

Rear

Guard

40

N•m

[ 30 ft-lb ]

Housing

Capscrews

Install the two capscrews and washers connecting the auxiliary drive guard to the vibration damper guard.

 

Torque Value:

 

Auxiliary

Drive

15

N•m

[ 133 in-lb ]

Guard

Capscrews

Operate the engine and check for proper operation.

 

Drive Belt, Cooling Fan (008-002)

Drive Belt, Cooling Fan (008-002)

Remove

NOTE: The back side idler system uses one of two types of control rods (turnbuckles) or a shock absorber. Refer to the OEM service manual for the instructions that apply to the engine being serviced.

Remove the back side idler end of the shock absorber, solid control rod (turnbuckle), or control rod tensioner assembly.

Loosen the upper capscrew (31). Remove the lower capscrew (31).

NOTE: One of the jam nuts on the solid control rod (turnbuckle) has left hand threads.

Loosen the solid control rod (turnbuckle) jam nuts (11). Turn the adjusting screw (10) until the spacer (1) is not touching the end of the slot in the control rod (9).

Drive Belt, Cooling Fan Page 8-5

until the spacer (1) is not touching the end of the slot in the control rod
until the spacer (1) is not touching the end of the slot in the control rod
until the spacer (1) is not touching the end of the slot in the control rod
until the spacer (1) is not touching the end of the slot in the control rod

Drive Belt, Cooling Fan Page 8-6

Drive Belt, Cooling Fan Pa g e 8-6 K38, K50, QSK38, and QSK50 Section 8 —
Drive Belt, Cooling Fan Pa g e 8-6 K38, K50, QSK38, and QSK50 Section 8 —
Drive Belt, Cooling Fan Pa g e 8-6 K38, K50, QSK38, and QSK50 Section 8 —
Drive Belt, Cooling Fan Pa g e 8-6 K38, K50, QSK38, and QSK50 Section 8 —

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Remove the capscrew (7), washers (2)(3), and spacers (1).

Remove the control rod assembly from the idler assembly.08 Remove the capscrew (7), washers (2)(3), and spacers (1). To remove the control rod with

To remove the control rod with spring, remove the two jam nuts (26), washers (25)(24), and spring (23). nuts (26), washers (25)(24), and spring (23).

Remove the following parts:the two jam nuts (26), washers (25)(24), and spring (23). • Capscrew (20) • Lock washer

• Capscrew (20)

Lock washer (19)

• Washer (18)

• Spacer (17)

• Capscrew (14)

Lock washer (13)

• Washer (12)

• Control rod (15).

WARNING The fan belt idler is under tension. Do not allow hands to get between the The fan belt idler is under tension. Do not allow hands to get between the idler, fan, or the fan hub. Failure to do so can result in personal injury.

Use a 8-point socket and breaker bar or large wrench to hold the idler in position against the spring tension.

to hold the idler in position against the spring tension. Remove the capscrews from the spring
to hold the idler in position against the spring tension. Remove the capscrews from the spring

Remove the capscrews from the spring cap.

Slowly turn the wrench until the spring tension is relieved.

Remove the fan belt.

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

NOTE: The fan center distance is the distance between the crankshaft and fan center lines.

On systems that use a two pulley fan drive (without idler pulley) with a 508 mm [20 in], 559 mm [22 in], or 610 mm [24 in] fan center, loosen the bolts that pass through the slotted holes in the fan hub bracket.

Loosen the fan hub adjusting screw.

On engines that use a two pulley drive with a 711 mm [28 in] fan center distance, loosen the bolts that pass through the slotted holes and fan hub bracket of the 711 mm [28 in] fan center system. The adjusting screw (16) is below the fan hub. The locknut (17) must be loosened before loosening the fan hub adjusting screw.

Remove the fan belt.

Remove the fan belt.

Inspect for Reuse

Inspect for Reuse

Inspect the fan belt for the following:

• Cracks

Glazing

Tears or cuts.

Drive Belt, Cooling Fan Page 8-7

Inspect the fan belt for the following: • Cracks • Glazing • Tears or cuts. Drive
Inspect the fan belt for the following: • Cracks • Glazing • Tears or cuts. Drive
Inspect the fan belt for the following: • Cracks • Glazing • Tears or cuts. Drive
Inspect the fan belt for the following: • Cracks • Glazing • Tears or cuts. Drive

Drive Belt, Cooling Fan Page 8-8

Drive Belt, Cooling Fan Pa g e 8-8 K38, K50, QSK38, and QSK50 Section 8 —
Drive Belt, Cooling Fan Pa g e 8-8 K38, K50, QSK38, and QSK50 Section 8 —
Drive Belt, Cooling Fan Pa g e 8-8 K38, K50, QSK38, and QSK50 Section 8 —

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Installand QSK50 Section 8 — Cooling S y stem — Grou p 08 Install the belt

Install the belt on the crankshaft and fan hub pulley.

Align the grooves on the belt on the ribs of the pulley.

WARNING The fan belt idler is under tension. Do not allow hands to get between the The fan belt idler is under tension. Do not allow hands to get between the idler, fan, or the fan hub. Failure to do so can result in personal injury.

After installing the fan belt, install the back side fan idler system. stall the back side fan idler system.

Rotate the idler against the spring tension until the capscrew holes are aligned.

the spring tension until the capscrew holes are aligned. Install the lock washer and capscrew. Torque
the spring tension until the capscrew holes are aligned. Install the lock washer and capscrew. Torque

Install the lock washer and capscrew.

Torque Value: 45 N•m [ 35 ft-lb ]

Slowly turn the wrench until the idler is against the belt.

NOTE: The fan hub pulley and the fan belt are shown removed for clarity. The fan hub pulley and the fan belt are shown removed for clarity.

When installing the solid control rod (turnbuckle) on older engines, the capscrews (4)(7) are 64 mm [2-1/2 in] in length. On the newer engines, engines, the capscrews (4)(7) are 64 mm [2-1/2 in] in length. On the newer engines, the capscrew (4)(7) are 57 mm [2-1/4 in] in length. It is recommended that SAE Grade 8 capscrews that are 57 mm [2-1/4 in] be installed or the capscrews can break.

Install a spacer (1), a heavy flat washer (2), and lock washer (3).

Install a SAE Grade 8 capscrew (4), 57 mm [7/16-14 x 2-1/4 in] in the upper control rod end (5).

Hand tighten the capscrew.

Install the upper control rod end in the fan hub support (6).

Install a spacer (1), a lock washer (3), and heavy flat washer (2).

Install a SAE Grade 8 capscrew (7), 57 mm [7/16-14 x 2-1/4 in] in the lower control rod end (8).

Install the lower control rod end on the idler arm (9).

Tighten the capscrews (4)(7).

Torque Value: 90 N•m [ 65 ft-lb ]

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

NOTE: The fan belt must be installed and under the tension of the fan idler arm spring to adjust the control rod. The fan belt and a portion of the flat washer are not shown for clarity.

Turn the adjusting screw (10) until the end of the slot on the lower control rod end (9) is touching the spacer (1). One of the nuts has left handed threads.

Hold the adjusting screw and tighten the two jam nuts (11).

To install the control rod with spring, install the flat washer (12), lock washer (13), and capscrews (14) in the upper end of the control rod (15).

spring, install the flat washer (12), lock washer (13), and capscrews (14) in the upper end

Install the control rod in the fan support (16).

Install the control rod in the fan support (16).

Tighten the capscrew.

 

Torque Value: 60 N•m [ 45 ft-lb ]

 

Install the spacer bushing (17), flat washer (18), lock washer (19), and capscrew (20) in the lower end of the control rod (21).

 

Install the lower end of the control rod on the fan idler are

(22).

Tighten the capscrews.

 

Torque Value: 60 N•m [ 45 ft-lb ]

CAUTION Do not tighten the inner fan nut excessively. If the jam nut is to
CAUTION Do not tighten the inner fan nut excessively. If the jam nut is to

CAUTION Do not tighten the inner fan nut excessively. If the jam nut is to tight, the spring retainer will bend and the control rod will fail.

the inner fan nut excessively. If the jam nut is to tight, the spring retainer will

Install the following parts:

Spring (23)

• Spring retainer washer (24)

Flat washer (25)

Jam nuts (quantity 2)(26).

Turn the inner jam nut until the spring retainer washer (24) touches the cylinder on the lower control rod end (27).

Hold the inner jam nut and tighten the outer jam nut.

Drive Belt, Cooling Fan Page 8-9

the lower control rod end (27). Hold the inner jam nut and tighten the outer jam
the lower control rod end (27). Hold the inner jam nut and tighten the outer jam
the lower control rod end (27). Hold the inner jam nut and tighten the outer jam

Drive Belt, Cooling Fan Page 8-10

Drive Belt, Cooling Fan Pa g e 8-10 K38, K50, QSK38, and QSK50 Section 8 —
Drive Belt, Cooling Fan Pa g e 8-10 K38, K50, QSK38, and QSK50 Section 8 —
Drive Belt, Cooling Fan Pa g e 8-10 K38, K50, QSK38, and QSK50 Section 8 —

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

CAUTION The shock absorber must be installed with the larger outer tube of the shock absorber attached to the fan hub support. If the absorber is installed wrong, dirt can enter the tube and cause
larger outer tube of the shock absorber attached to the fan hub support. If the absorber hub support. If the absorber is installed wrong, dirt can enter the tube and cause the part to fail.

wrong, dirt can enter the tube and cause the part to fail. Install the following parts
wrong, dirt can enter the tube and cause the part to fail. Install the following parts

Install the following parts to install the shock absorber:

• Spacer (28)

Flat washer (29)

Lock washer (30)

• Capscrew (31)

Shock absorber (32).

Install the shock absorber (32) in the fan support (6).

Install the flat washer (29), lock washer (30), and capscrew (31) in the lower end of the shock absorber.

Install the shock absorber on the fan idler arm.

Tighten the two capscrews (31).

Torque Value: 60 N•m [ 45 ft-lb ]

The following step is for installing the two pulley fan drive belt center 711 mm [28 in]. alling the two pulley fan drive belt center 711 mm [28 in].

Install the poly vee 20 rib L-section fan belt (23) on the crankshaft pulley (22) and the fan hub pulley (7). Align the grooves in the belt on the ribs in the pulleys.

Make sure the heavy nut (17) is positioned to allow the adjusting capscrew (16) to turn freely.

Turn the adjusting capscrew (16) counterclockwise to remove the slack from the belt.

The following step is for installing the two pulley fan drive belt centers 508mm [20 in], 559mm [22 in], and alling the two pulley fan drive belt centers 508mm [20 in], 559mm [22 in], and 610 mm [24 in].

Install the poly vee 20 rib L-section fan belt (18) on the crankshaft pulley (17) and the fan hub pulley (7). Align the grooves in the belt on the ribs in the pulleys.

Turn the adjusting capscrew (10) clockwise to remove the slack from the belt.

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Adjust

Only one method is acceptable for setting the two pulley fan drive belt tension. The recommended method is to use a belt tensioner gauge.

The recommended method is to use a belt tensioner gauge. WARNING The fan belt idler is
The recommended method is to use a belt tensioner gauge. WARNING The fan belt idler is

WARNING The fan belt idler is under tension. Do not allow hands to get between the idler, fan, or the fan hub. Failure to do so can result in personal injury.

fan hub. Failure to do so can result in personal injury. CAUTION Incorrect belt tension can
fan hub. Failure to do so can result in personal injury. CAUTION Incorrect belt tension can

CAUTION Incorrect belt tension can cause component failure.

Install the belt tension gauge, Part Number 3823772, or equivalent, on the belt in the middle between the two pulleys. Continue tightening the adjusting capscrew to a belt tension of 2668.9 to 2891.3 N [600 to 650 lbf] The belt tension will increase when the capscrews tighten the fan hub assembly to the fan support.

Tighten the capscrews.

Torque Value: 285 N•m [ 210 ft-lb ]

Remove the tension gauge and position the gauge on the other side of the belt. Check to make sure the tension is correct 2891.3 to 3336.2 N [650 to 750 lbf]. If the belt tension is not correct, loosen the capscrews and adjust to the correct tension again.

Torque Value: 285 N•m [ 210 ft-lb ]

Coolant Temperature Gauge (008-004)

Inspect for Reuse

Check for a blown fuse.

Check the wiring from the gauge to the sending unit for broken connection(s).

Coolant Temperature Gauge Page 8-11

fuse. Check the wiring from the gauge to the sending unit for broken connection(s). Coolant Temperature
fuse. Check the wiring from the gauge to the sending unit for broken connection(s). Coolant Temperature

Coolant Bypass Tube Page 8-12

Coolant Bypass Tube Pa g e 8-12 K38, K50, QSK38, and QSK50 Section 8 — Cooling
Coolant Bypass Tube Pa g e 8-12 K38, K50, QSK38, and QSK50 Section 8 — Cooling
Coolant Bypass Tube Pa g e 8-12 K38, K50, QSK38, and QSK50 Section 8 — Cooling

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Use a temperature gauge of known accuracy to check the existing gauge.

Use a temperature gauge of known accuracy to check the existing gauge.

Replace the gauge or sending unit if faulty.

Coolant Bypass Tube (008-005)

Coolant Bypass Tube (008-005)

Preparatory Steps

WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant
WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant
WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant

WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120•F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of
WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of

WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

WARNING Batteries cam emit explosive gases. To reduce the possibility of personal injury, always ventilate
WARNING Batteries cam emit explosive gases. To reduce the possibility of personal injury, always ventilate

WARNING Batteries cam emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To avoid the possibility of arcing, remove the negative (-) battery first, and attach the negative (-) battery cable last. Disconnect the battery cables. Refer to Procedure 013-009 (Batteries and Cable connections) in Section 13. Drain the cooling system. Refer to Procedure 008-018 (Cooling System) in Section 8.

Remove

Remove

Industrial

Loosen the hose clamps (5).

Remove the four capscrews, the two tubes (2) and (6), and the gaskets (1).

Remove the hose (4).

Discard the hose (4) and gaskets (1).

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Marine Applications

Remove the Straub coupling from the bypass line.

Remove the Straub coupling from the bypass line.

Remove the U-bolts from the bypass tube.

Remove the U-bolts from the bypass tube.

Remove the capscrews and washers from the lower flange connecting the bypass tube to the water pump.

Remove the capscrews and wa shers from the lower flange connecting the bypass tube to the

Remove the lower section of the bypass tube.

Discard the gasket.

Remove the capscrews and washers from the upper flange connecting the bypass tube to the thermostat housing.

Remove the capscrews and washers from the upper flange connecting the bypass tube to the thermostat

Remove the upper section of the bypass tube.

Discard the gasket.

Coolant Bypass Tube Page 8-13

the thermostat housing. Remove the upper section of the bypass tube. Discard the gasket. Coolant Bypass
the thermostat housing. Remove the upper section of the bypass tube. Discard the gasket. Coolant Bypass
the thermostat housing. Remove the upper section of the bypass tube. Discard the gasket. Coolant Bypass
the thermostat housing. Remove the upper section of the bypass tube. Discard the gasket. Coolant Bypass

Coolant Bypass Tube Page 8-14

Coolant Bypass Tube Pa g e 8-14 K38, K50, QSK38, and QSK50 Section 8 — Cooling
Coolant Bypass Tube Pa g e 8-14 K38, K50, QSK38, and QSK50 Section 8 — Cooling
Coolant Bypass Tube Pa g e 8-14 K38, K50, QSK38, and QSK50 Section 8 — Cooling
Coolant Bypass Tube Pa g e 8-14 K38, K50, QSK38, and QSK50 Section 8 — Cooling

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Clean and Inspect for Reuseand QSK50 Section 8 — Cooling S y stem — Grou p 08 Industrial WARNING Wear

Industrial

WARNING Wear safety glasses or a face shield, as well as protective clothing, to pr event personal injury when using a steam cleaner or high-pressure water. protective clothing, to prevent personal injury when using a steam cleaner or high-pressure water.

Use a gasket scraper and wire brush to clean the gasket sealing surfaces.

scraper and wire brush to clean the gasket sealing surfaces. Use steam to clean the tubes.
scraper and wire brush to clean the gasket sealing surfaces. Use steam to clean the tubes.

Use steam to clean the tubes.

Check the tube gasket sealing face and tube for damage.the gasket sealing surfaces. Use steam to clean the tubes. Replace if it is cracked or

Replace if it is cracked or otherwise damaged.

Replace the hose and hose clamps.

WARNING Wear safety glasses or a face shield, as well or otherwise damaged. Replace the hose and hose clamps. Marine Applications as protective clothing. Hot stem
WARNING Wear safety glasses or a face shield, as well

Marine Applications

safety glasses or a face shield, as well Marine Applications as protective clothing. Hot stem can
safety glasses or a face shield, as well Marine Applications as protective clothing. Hot stem can

as

protective clothing. Hot stem can cause serious personal injury.

Use a gasket scraper and wire brush to clean the gasket sealing surfaces.

Use steam to clean the tubes and Straub coupling.

Check the tube gasket sealing face and tube for damage.surfaces. Use steam to clean the tubes and Straub coupling. Inspect the Straub coupling for wear

Inspect the Straub coupling for wear or other damage.

Replace if cracked or otherwise damaged.

Replace the hose clamps.

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Install

Install

Industrial

Install the gasket (1) and the lower end of the bypass tube (2) on the water pump inlet housing (3) with lock washers and capscrews.

 

Put the hose (4) and two clamps (5) on the tube (2).

Install the end of the tube (6) in the hose. Install the gasket (7), lock washer, and capscrews that hold the tube to the thermostat support.

Tighten the four capscrews

 

Torque Value: 40 N•m [ 30 ft-lb ]

 

Check to be sure the hose (4) is the same length on both tubes.

 

Tighten the two hose clamps (5).

 

Torque Value: 5 N•m [ 44 in-lb ]

Marine Applications

 
Marine Applications  

Install the upper section of the bypass tube.

Install the capscrews and washers to the upper flange connecting the bypass tube to the thermostat housing.

Install the capscrews and washers to the upper flange connecting the bypass tube to the thermostat

Torque Value:

 

Upper

Flange

38

N•m

[ 28 ft-lb ]

Capscrews

Install the lower section of the bypass tube.

 

Install the capscrews and washers to the lower flange connecting the bypass tube to the water pump.

Torque Value:

Install the capscrews and wa shers to the lower flange connecting the bypass tube to the
Install the capscrews and wa shers to the lower flange connecting the bypass tube to the

Lower

Flange

28

N•m

[ 20 ft-lb ]

Capscrews

Coolant Bypass Tube Page 8-15

pump. Torque Value: Lower Flange 28 N•m [ 20 ft-lb ] Capscrews Coolant Bypass Tube Pag
pump. Torque Value: Lower Flange 28 N•m [ 20 ft-lb ] Capscrews Coolant Bypass Tube Pag
pump. Torque Value: Lower Flange 28 N•m [ 20 ft-lb ] Capscrews Coolant Bypass Tube Pag

Coolant Bypass Tube Page 8-16

Coolant Bypass Tube Pa g e 8-16 K38, K50, QSK38, and QSK50 Section 8 — Cooling
Coolant Bypass Tube Pa g e 8-16 K38, K50, QSK38, and QSK50 Section 8 — Cooling
Coolant Bypass Tube Pa g e 8-16 K38, K50, QSK38, and QSK50 Section 8 — Cooling
Coolant Bypass Tube Pa g e 8-16 K38, K50, QSK38, and QSK50 Section 8 — Cooling

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Check the gap between the upper and lower bypass tubes. The gap must not exceed

Check the gap between the upper and lower bypass tubes. The gap must not exceed 17 mm [0.70 in].

Install the U-bolts for the bypass tube.

Torque Value:

Torque Value:

U-Bolts

21 N•m

[ 186 in-lb ]

Install the Straub coupling onto the bypass line.

Install the Straub coupling onto the bypass line.

Torque Value:

Torque Value:

Straub Coupling

30 N•m

[ 22 ft-lb ]

Finishing Steps  

Finishing Steps

 
WARNING Batteries cam emit explosive gases. To reduce the possibility of personal injury, always ventilate
WARNING Batteries cam emit explosive gases. To reduce the possibility of personal injury, always ventilate
WARNING Batteries cam emit explosive gases. To reduce the possibility of personal injury, always ventilate
WARNING Batteries cam emit explosive gases. To reduce the possibility of personal injury, always ventilate

WARNING Batteries cam emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To avoid the possibility of arcing, remove the negative (-) battery first, and attach the negative (-) battery cable last.

Fill the cooling system. Refer to Procedure 008-018 (Cooling System) in Section 8.

Connect the battery cables. Refer to Procedure 013-009 (Batteries and Cable connections) in Section 13.

Operate the engine to normal operating temperature and pressure, then check for leaks.

K38, K50, QSK38, and QSK50

Coolant Filter

Section 8 — Cooling System — Group 08

Page 8-17

Coolant Filter (008-006)

Coolant Filter (008-006)

Remove

WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant
WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant

WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

Remove the pressure cap from the radiator.

WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of
WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of

WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

toxic. Keep away from children and pets. If not reused, dispose of in accordance with local

Turn valve (1) on the coolant filter head to the OFF position to prevent water loss.

Remove the coolant filters.

Install

Clean the area around the coolant filter head. Clean the gasket surface of the coolant filter head.

The o-ring can stick on the coolant filter head. Make sure the o-ring is removed.

surface of the coolant filter head. The o-ring can stick on the coolant filter head. Make
surface of the coolant filter head. The o-ring can stick on the coolant filter head. Make

Discard the coolant filters.

CAUTION When lubricating the seal on the coolant filter do not allow oil to get
CAUTION When lubricating the seal on the coolant filter do not allow oil to get

CAUTION When lubricating the seal on the coolant filter do not allow oil to get into the coolant filter. It will adversely affect the SCA.

the seal on the coolant filter do not allow oil to get into the coolant filter.

Lubricate the seal on the coolant filter with clean engine oil.

the coolant filter. It will adversely affect the SCA. Lubricate the seal on the coolant filter
the coolant filter. It will adversely affect the SCA. Lubricate the seal on the coolant filter
the coolant filter. It will adversely affect the SCA. Lubricate the seal on the coolant filter
the coolant filter. It will adversely affect the SCA. Lubricate the seal on the coolant filter

Coolant Thermostat Page 8-18

Coolant Thermostat Pa g e 8-18 K38, K50, QSK38, and QSK50 Section 8 — Cooling S

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Install the coolant filter.

Turn the coolant filter clockwise until the seal touches the coolant filter head.

Turn the coolant filter an additional ½ to ¾ of a turn after contact.

Turn the valve (1) on the coolant filter head to the ON position.

Coolant Thermostat (008-013)

General Information

The K38 and K50 engines must have thermostats that do not have a vent.

The K50 thermostats contain a nitrile rubber seat vulcanized to the brass collar at the barrel seat. This seat prevents coolant leakage and wear. The thermostat with the rubber seat must be used on K50 engines. The thermostat with the rubber seat is not required for the K38 engine, but can be installed.

The Low Temperature Aftercooling (LTA) arrangement uses four coolant thermostats and one LTA thermostat, the LTA thermostat has a knurled flange and is located in the center position between the engine coolant thermostats.

Thermostat, Part Number 3046191, must be used in all K50 engines to prevent premature thermostat failures.

This thermostat is designed to withstand the higher flow of the K50 engine and incorporates a nitrile rubber seal for reduced leakage and improved seating. This thermostat was released in July, 1985, engine serial number first 33109759. The standard thermostat will fail at low hours if installed in the K50 engines.

This thermostat was fitted to all K38 engines from May, 1993, engine serial number first 33124382.

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Preparatory Steps

Preparatory Steps
WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant
WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant

WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of
WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of

WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate
WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate

WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

Disconnect the batteries. Refer to Procedure 013-009 (Batteries and cable connections) in Section

13.

• Remove the cooling fan (if installed). Refer to Procedure 008-040 (Fan Cooling) in Section 8.

• Remove the fan belt (if installed). Refer to Procedure

008-002 (Drive Belt, Cooling Fan) in Section 8.

Drain the cooling system. Refer to Procedure 008-018 (Cooling System) in Section 8.

Remove the fan hub (if installed). Refer to Procedure 008-036 (Fan Hub, Belt Driven) in Section 8.

Remove the fan hub bracket (if installed). Refer to Procedure 008-035 (Fan Hub Bracket) in Section 8.

• Remove the water filters (if installed). Refer to Procedure 008-006 (Coolant Filter) in Section 8.

• Remove the heat exchanger (if equipped). Refer to Procedure 008-053 (Heat Exchanger) in Section 8.

Remove

Remove

Conventional Aftercooling NOTE: Shown is the K38 and K50 thermostat housing. Although different in appearance, the procedure remains the same for the QSK series engines.

Remove both upper radiator hoses from the thermostat housing.

Coolant Thermostat Page 8-19

for the QSK series engines. Remove both upper radiator hoses from the thermostat housing. Coolant Thermostat
for the QSK series engines. Remove both upper radiator hoses from the thermostat housing. Coolant Thermostat

Coolant Thermostat Page 8-20

Coolant Thermostat Pa g e 8-20 K38, K50, QSK38, and QSK50 Section 8 — Cooling S
Coolant Thermostat Pa g e 8-20 K38, K50, QSK38, and QSK50 Section 8 — Cooling S
Coolant Thermostat Pa g e 8-20 K38, K50, QSK38, and QSK50 Section 8 — Cooling S
Coolant Thermostat Pa g e 8-20 K38, K50, QSK38, and QSK50 Section 8 — Cooling S

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Remove the thermostat housing and gasket.and QSK50 Section 8 — Cooling S y stem — Grou p 08 Remove the 12

Remove the 12 capscrews.

Discard the gasket.

Remove the thermostats and seals from the thermostat housing. seals from the thermostat housing.

Remove the pipe plug from the lower water transfer connection on aftercooler core on each bank to drain the aftercooler plumbing on engines equipped connection on aftercooler core on each bank to drain the aftercooler plumbing on engines equipped with LTA.

LTA

Remove the tube clamps (1) and the aftercooler plumbing on both banks.the aftercooler plumbing on engines equipped with LTA. LTA Loosen the capscrews (2) on the water

Loosen the capscrews (2) on the water transfer connection to allow flexibility.

Remove the water transfer tubes.

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Remove the radiator hoses from the thermostat housing.

Remove the radiator hoses from the thermostat housing.

Remove the vent lines from the thermostat housing (1).

Remove the four water bypass tube capscrews (2).

Remove the four water bypass tube capscrews (2).

Remove the 14 capscrews and the heat shield.

Remove the thermostat housing and gasket.

Remove the thermostat housing and gasket.

Remove the four main thermostats and the one knurled LTA thermostat in the center. The main and LTA thermostats are not interchangeable.

thermostats and the one knurled LTA thermostat in the center. The main and LTA thermostats are

Coolant Thermostat Page 8-21

LTA thermostat in the center. The main and LTA thermostats are not interchangeable. Coolant Thermostat Pag
LTA thermostat in the center. The main and LTA thermostats are not interchangeable. Coolant Thermostat Pag
LTA thermostat in the center. The main and LTA thermostats are not interchangeable. Coolant Thermostat Pag
LTA thermostat in the center. The main and LTA thermostats are not interchangeable. Coolant Thermostat Pag

Coolant Thermostat Page 8-22

Coolant Thermostat Pa g e 8-22 K38, K50, QSK38, and QSK50 Section 8 — Cooling S
Coolant Thermostat Pa g e 8-22 K38, K50, QSK38, and QSK50 Section 8 — Cooling S
Coolant Thermostat Pa g e 8-22 K38, K50, QSK38, and QSK50 Section 8 — Cooling S
Coolant Thermostat Pa g e 8-22 K38, K50, QSK38, and QSK50 Section 8 — Cooling S

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Remove the two Straub couplings on the thermostat outlet tube on marine engines.and QSK50 Section 8 — Cooling S y stem — Grou p 08 Remove the hose

Remove the hose clamps and hoses for the industrial engines (not shown).

with Electronically Actuated Injector

Disconnect the vent line from the thermostat outlet tube.

Remove the capscrews and washers from the thermostat outlet connections to the outlet tube tube.

Remove the outlet tube and discard the gaskets.

Remove the six capscrews, washers, cover plate, and gaskets from the LTA thermostat housing. gaskets from the LTA thermostat housing.

thermostat housing.washers, cover plate, and gaskets from the LTA thermostat housing. Remove the LTA thermostats and seals

Remove

the

LTA

thermostats

and

seals

from

the

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Inspect for Reuse

Inspect for Reuse

Check the thermostat for wear or damage. If the barrel of the thermostat is worn or fretted, it must be replaced.

Test

Check the thermostat marking to see when the thermostat is designed to open.

Check the thermostat marking to see when the thermostat is designed to open.

The rated nominal temperature is marked on the side of the thermostat.

The design temperature of the thermostat is 82°C [180° F].

Engine Thermostat Initial Opening Temperature

°C

°F

82.2

MIN

180

94.4

MAX

202

LTA Thermostat Initial Opening Temperature

 

°C

°F

73.8

MIN

165

86.1

MAX

187

Continue to apply heat until the water reaches the full open temperature for the specific thermostat being tested. The temperature is 12°C [22°F] above nominal opening temperature. At that temperature, measure the open distance of the thermostat.

is 12°C [22°F] above nominal opening temperature. At that temp erature, measure the open distance of

The minimum open distance at full open temperature is 9.52 mm [0.375 in].

Coolant Thermostat Page 8-23

the thermostat. The minimum open distance at full open temperature is 9.52 mm [0.375 in]. Coolant
the thermostat. The minimum open distance at full open temperature is 9.52 mm [0.375 in]. Coolant
the thermostat. The minimum open distance at full open temperature is 9.52 mm [0.375 in]. Coolant

Coolant Thermostat Page 8-24

Coolant Thermostat Pa g e 8-24 K38, K50, QSK38, and QSK50 Section 8 — Cooling S
Coolant Thermostat Pa g e 8-24 K38, K50, QSK38, and QSK50 Section 8 — Cooling S
Coolant Thermostat Pa g e 8-24 K38, K50, QSK38, and QSK50 Section 8 — Cooling S

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Remove the container from the heat.and QSK50 Section 8 — Cooling S y stem — Grou p 08 With the thermostat

With the thermostat open, check for wear or other damage. damage.

If the seat of the thermostat is worn or fretted, it must be replaced.

Check to see if the thermostat returns to the closed position.

If the barrel of the thermostat is worn or fretted, it must be replaced.

Leak Test

is worn or fretted, it must be replaced. Leak Test WARNING Complete this procedure with engine
is worn or fretted, it must be replaced. Leak Test WARNING Complete this procedure with engine

WARNING Complete this procedure with engine coolant temperatures below 50°C [120°F]. Hot coolant or steam can cause serious personal injury.

This procedure has been developed to troubleshoot a thermostat failed in the open position, or experiencing excessive leakage at the seat.

This problem is often verified by observing premature warming of the thermostat housing coolant outlet pipes to the radiators. These pipes must not warm previous to coolant temperatures reaching the designated thermostat opening temperature.

The following procedure outlines troubleshooting a thermostat stuck in the open position:

NOTE: All troubleshooting procedures dealing with thermostats stuck in the open position must take place with coolant temperatures below the nominal opening temperatures of the thermostats.

Two test procedures are included. One defines the procedure for the standard cooling system, the second describes engines equipped with LTA.

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Conventional Aftercooling

WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of
WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of

WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations. NOTE: Shown is the K38 and K50 thermostat housing. Although different in appearance, the procedure remains the same for the QSK series engines.

and K50 thermostat housing. Although different in appearance, the procedure remains the same for the QSK

Remove the upper radiator hoses from the thermostat housing.

Coolant flowing from the thermostat housing with the hoses removed signifies a thermostat stuck in the open position. Remove the thermostat and test the operation as described in the Test section.

Install two hoses of the same size on the thermostat housing outlets long enough to reach a remote dry container.

Install two hoses of the same size on the thermostat housing outlets long enough to reach

Install and tighten the hose clamps on the housing outlets.

Place the end of the hoses in two dry containers.

Operate the engine at rated rpm for 1 minute.

Shut the engine off, and measure the amount of coolant collected in each container.

Shut the engine off, and measure the amount of coolant collected in each container.

The amount of coolant collected in either container must not exceed 200 cc [7 fluid oz].

If more than 200 cc [7 fluid oz] of coolant is collected from either container, the thermostat or thermostat seal is leaking.

than 200 cc [7 fluid oz] of coolant is collected from either container, the thermostat or

Remove the thermostat and test operation as described in the Test section.

Coolant Thermostat Page 8-25

is leaking. Remove the thermostat and test operation as described in the Test section. Coolant Thermostat
is leaking. Remove the thermostat and test operation as described in the Test section. Coolant Thermostat
is leaking. Remove the thermostat and test operation as described in the Test section. Coolant Thermostat
is leaking. Remove the thermostat and test operation as described in the Test section. Coolant Thermostat

Coolant Thermostat Page 8-26

Coolant Thermostat Pa g e 8-26 K38, K50, QSK38, and QSK50 Section 8 — Cooling S
Coolant Thermostat Pa g e 8-26 K38, K50, QSK38, and QSK50 Section 8 — Cooling S
Coolant Thermostat Pa g e 8-26 K38, K50, QSK38, and QSK50 Section 8 — Cooling S
Coolant Thermostat Pa g e 8-26 K38, K50, QSK38, and QSK50 Section 8 — Cooling S

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Remove the LTA radiator inlet hose (1) and the two main engine coolant outlet ho ses (2) to the radiator. engine coolant outlet hoses (2) to the radiator.

LTA

Coolant flow from the thermostat housing indicates a thermostat is stuck in the open position. Replace the thermostats. thermostat is stuck in the open position. Replace the thermostats.

Install a hose from the LTA Thermostat housing to a remote container (1). Install a hose from each of the main engine thermostat coolant outlets remote container (1). Install a hose from each of the main engine thermostat coolant outlets to a common remote container (2).

Partially fill each hose with coolant. Place the end of each hose in their respective containers. Allow the hoses to drain in this position. Remove the coolant from the containers.

Turn off the engine and measure the amount of coolant in the container. the container.

The amount of coolant collected from the main engine thermostats must not exceed 400 cc [14 fluid oz].

Operate the engine at rated rpm for 1 minute.

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Remove the draincock (3). Use a gauge of 420 kPa [60 psi] minimum capacity.

Remove the draincock (3). Use a gauge of 420 kPa [60 psi] minimum capacity.

Remove any coolant from the container collecting the LTA thermostat leakage.

Start the engine. Note the block coolant pressure.

Increase the engine speed until the coolant pressure reaches 170 kPa [25 psi]. Maintain this engine speed for 1 minute. Shut the engine off and measure the amount of coolant collected in the container.

tain this engine speed for 1 minute. Shut the engine off and measure the amount of
tain this engine speed for 1 minute. Shut the engine off and measure the amount of

The amount of coolant collected from the LTA thermostat

must not exceed 100 cc [3.5 fluid oz]. If more is collected, the thermostat or thermostat seal is leaking. Remove the thermostat(s) and test.

[3.5 fluid oz]. If more is collected, the thermostat or thermostat seal is leaking. Remove the
[3.5 fluid oz]. If more is collected, the thermostat or thermostat seal is leaking. Remove the

Install

Conventional Aftercooling NOTE: Shown is the K38 and K50 thermostat housing. Although different in appearance, the procedure remains the same for the QSK series engines.

and K50 thermostat housing. Although different in appearance, the procedure remains the same for the QSK

The seal must be installed with the part number up.

Use a mallet and seal driver, Part Number 3375411. Install the seal.

Install the seal no more than 0.51 mm [0.020 in] below the top of the cast edge.

Coolant Thermostat Page 8-27

the seal. Install the seal no more than 0.51 mm [0.020 in] below the top of
the seal. Install the seal no more than 0.51 mm [0.020 in] below the top of
the seal. Install the seal no more than 0.51 mm [0.020 in] below the top of
the seal. Install the seal no more than 0.51 mm [0.020 in] below the top of

Coolant Thermostat Page 8-28

Coolant Thermostat Pa g e 8-28 K38, K50, QSK38, and QSK50 Section 8 — Cooling S
Coolant Thermostat Pa g e 8-28 K38, K50, QSK38, and QSK50 Section 8 — Cooling S
Coolant Thermostat Pa g e 8-28 K38, K50, QSK38, and QSK50 Section 8 — Cooling S
Coolant Thermostat Pa g e 8-28 K38, K50, QSK38, and QSK50 Section 8 — Cooling S

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Install the thermostat by pushing on the outer rim. NOTE: If the engine being serviced is a K50, be sure the thermostat is installed. NOTE: If the engine being serviced is a K50, be sure the thermostat is installed.

The K50 thermostats contain a nitrile rubber seat vulcanized to the brass collar at the barrel seat. This seat prevents coolant leakage and wear. The thermostat with the rubber seat must be on K50 engines. The thermostat with the rubber seat is not required for the K38 engine, but can be installed.

Install the thermostat housing.is not required for the K38 engine, but can be installed. Torque Value: Thermostat 45 N•m

Torque Value:

Thermostat

45 N•m

Housingthe thermostat housing. Torque Value: Thermostat 45 N•m [ 33 ft-lb ] On K38 and K50

[ 33 ft-lb ]

On K38 and K50 engines, install the two upper radiator hoses. hoses.

Tighten the hose clamps. K38 and K50 engines, install the two upper radiator hoses. Torque Value: 6 N•m [ 50

Torque Value: 6 N•m [ 50 in-lb ]

On the QSK38 and QSK50 engines, connect the water lines to the triangle, three bolt flanges, using new gaskets.

The seal must be installed with the part number up. must be installed with the part number up.

LTA

Use a mallet and seal driver Part Number, 3375411. Install the seal.

Install the seal no more than 0.51 mm [0.020 in] below the top of the cast edge.

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Install the thermostat by pushing on the outer rim.

Install the thermostat by pushing on the outer rim.

Install the four main engine thermostats and the one knurled LTA thermostat.

Install the four main engine thermostats and the one knurled LTA thermostat.

Install the thermostat housing.

Install the thermostat housing.

Torque Value: 45 N•m

[ 33 ft-lb ]

Install the radiator hoses at the thermostat housing.

 

Tighten the hose clamps.

Torque Value: 6 N•m

[ 50 in-lb ]

with Electronically Actuated Injector

 

Install the LTA thermostat seals and thermostats into the thermostat housings.

Install the LTA thermostat se als and thermostats into the thermostat housings.

Coolant Thermostat Page 8-29

  Install the LTA thermostat se als and thermostats into the thermostat housings. Coolant Thermostat Pag
  Install the LTA thermostat se als and thermostats into the thermostat housings. Coolant Thermostat Pag
  Install the LTA thermostat se als and thermostats into the thermostat housings. Coolant Thermostat Pag
  Install the LTA thermostat se als and thermostats into the thermostat housings. Coolant Thermostat Pag

Coolant Thermostat Page 8-30

Coolant Thermostat Pa g e 8-30 K38, K50, QSK38, and QSK50 Section 8 — Cooling S
Coolant Thermostat Pa g e 8-30 K38, K50, QSK38, and QSK50 Section 8 — Cooling S
Coolant Thermostat Pa g e 8-30 K38, K50, QSK38, and QSK50 Section 8 — Cooling S
Coolant Thermostat Pa g e 8-30 K38, K50, QSK38, and QSK50 Section 8 — Cooling S

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Install the new gasket, thermostat cover, washers, and capscrews into the LTA thermostat housing. stat cover, washers, and capscrews into the LTA thermostat housing.

Tighten the capscrews

Torque Value: 45 N•m [ 33 ft-lb ]

Install new gaskets and the thermostat outlet tube, washers, and capscrews to the outlet connection of the LTA thermostat housing. washers, and capscrews to the outlet connection of the LTA thermostat housing.

Tighten the capscrews

Torque Value: 45 N•m [ 33 ft-lb ]

Install the vent line to the thermostat outlet tube.

Install the two Straub couplings onto the thermostat outlet tube on marine engines. tube on marine engines.

Torque Value: 28 N•m [ 21 ft-lb ]

Install the hose and two hose clamps onto the thermostat outlet tubes on industrial engines (not shown).

Tighten the hose clamps.

Torque Value: 6 N•m [ 50 in-lb ]

Gas Compression NOTE: The seal must be installed with the part number up. NOTE: The seal must be installed with the part number up.

Use a mallet and seal driver, Part number 3375411, to install the seal.

Install the seal no more than 5.1 mm [0.02 in] below the top of the cast edge.

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Install the thermostat by pushing on the outer rim.

Install the thermostat by pushing on the outer rim.

The K50 thermostats contain a nitrile rubber seat vulcanized to the brass collar at the barrel seat. This seat prevents coolant leakage and wear. The thermostat with the rubber seat must be on K50 engines. The thermostat with the rubber seat is not required for the KTA38GC engine, but can be installed.

Install the thermostat housing.

Install the thermostat housing.

Torque Value: 40 N•m

[ 30 ft-lb ]

Coolant Thermostat Page 8-31

installed. Install the thermostat housing. Torque Value: 40 N•m [ 30 ft-lb ] Coolant Thermostat Pag
installed. Install the thermostat housing. Torque Value: 40 N•m [ 30 ft-lb ] Coolant Thermostat Pag

Coolant Thermostat Housing Support Page 8-32

Coolant Thermostat Housing Support Pa g e 8-32 K38, K50, QSK38, and QSK50 Section 8 —

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Finishing Steps

8 — Cooling S y stem — Grou p 08 Finishing Steps WARNING Coolant is toxic.
8 — Cooling S y stem — Grou p 08 Finishing Steps WARNING Coolant is toxic.

WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

of in accordance with local environmental regulations. WARNING Batteries can emit explosive gases. To reduce the
of in accordance with local environmental regulations. WARNING Batteries can emit explosive gases. To reduce the

WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

Install the fan hub bracket (if installed). Refer to Procedure 008-035 (Fan Hub Bracket) in Section 8.

Install the fan hub (if installed). Refer to Procedure 008-036 (Fan Hub, Belt Driven) in Section 8.

Install the fan belt (if installed). Refer to Procedure 008-002 (Drive Belt, Cooling Fan) in Section 8.

Install the cooling fan (if installed). Refer to Procedure 008-040 (Fan Cooling) in Section 8.

Install the heat exchanger (if equipped). Refer to Procedure 008-053 (Heat Exchanger) in Section 8.

• Install the water filters (if installed). Refer to Procedure 008-006 (Coolant Filter) in Section 8.

Fill the cooling system. Refer to Procedure 008-018 (Cooling System) in Section 8.

Connect the batteries. Refer to Procedure 013-009 (Batteries and cable connections) in Section 13.

Operate the engine until the coolant temperature reaches 70°C [158°F], and then check for leaks.

Coolant Thermostat Housing Support (008-015)

General Information

Thermostat Support

The thermostat support assembly contains a support and two thermostat housings. Each thermostat housing contains two thermostats. The support assembly also provides for connection of the water outlet tubing for the cylinder head, air compressor, aftercooler, and a mounting provision for coolant filters. The low temperature aftercooler thermostat housing does not include a mounting provision for coolant filters.

A revised thermostat housing support with 6.35 mm [0.25 inch] vent holes located higher in the support for improved venting replaced the previous housing in February of 1992, engine serial number first 33121370. The support housing with 19.05 mm [0.75 inch] holes remained in production.

Thermostat Seal

Each thermostat housing contains two thermostat seals.

The thermostat seal for K38 and K50 engines was changed. The revised seal has a sealing element that is thicker. This sealing element prevents fretting and leakage resulting from the higher coolant flow required in K38 and K50 engines. The thin seal is installed on other Cummins® engines. The thick seal must be used on K38 and K50 engines.

Heat Shield

All KT38, KTA38, and KTA50 engines with a center mount aftercooler or air transfer housing must have a heat shield installed on the right bank thermostat housing. This heat shield is required to prevent damage to the outlet hose from the heat of the exhaust outlet of the turbocharger. KTA38 and KTA50 engines with outboard aftercoolers do not require the heat shield. The thermostat housing mounted design replaced the coolant outlet hose mounted design in February of 1983, engine serial number first 33107562, a revised thermostat housing was also released to accommodate the revised heat shield. The older heat shield must not be installed again or failure of the right bank coolant outlet hose will result.

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Preparatory Steps

Preparatory Steps
WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant
WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant

WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause
WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of
WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of

WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

WARNING Batteries cam emit explosive gases. To reduce the possibility of personal injury, always ventilate
WARNING Batteries cam emit explosive gases. To reduce the possibility of personal injury, always ventilate

WARNING Batteries cam emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To avoid the possibility of arcing, remove the negative (-) battery first, and attach the negative (-) battery cable last.

Disconnect the battery cables. Refer to Procedure 013-009 (Batteries and Cable connections) in Section 13.

Drain the cooling system. Refer to Procedure Refer to Procedure 008-018 (Cooling System) in Section 8

Remove the air cleaner assemblies. Refer to Procedure 010-013 (Air Cleaner Assembly (Engine- Mounted) in Section 10.

• Remove the cooling fan (if installed). Refer to Procedure 008-040 (Fan, Cooling) in Section 8.

• Remove the fan belt (if installed). Refer to Procedure 008-002 (Drive Belt, Cooling Fan) in Section 8.

Remove the fan hub (if installed). Refer to Procedure 008-036 (Fan Hub, Belt Driven) in Section 8.

Remove the fan hub bracket (if installed). Refer to Procedure 008-035 (Fan Hub Bracket) in Section 8.

• Remove the water filters (if installed). Refer to Procedure 008-006 (Coolant Filter) in Section 8.

• Remove the heat exchanger (if equipped). Refer to Procedure 008-053 (Heat Exchanger) in Section 8.

Remove

Remove
WARNING This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious
WARNING This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious

WARNING This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure

WARNING This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal

to have assistance or use appropriate lifting equipment to lift this component or assembly. NOTE: Shown is the K38 and K50 thermostat housing and support bracket. Although different in appearance, the procedure remains the same for the QSK engines.

housing and support bracket. Although different in appearance, the procedure remains the same for the QSK

Remove the six support assembly to the cylinder block mounting capscrews.

Remove the thermostat support assembly (5).

Coolant Thermostat Housing Support Page 8-33

block mounting capscrews. Remove the thermostat support assembly (5). Coolant Thermostat Housing Support Pag e 8-33
block mounting capscrews. Remove the thermostat support assembly (5). Coolant Thermostat Housing Support Pag e 8-33

Coolant Thermostat Housing Support Page 8-34

Coolant Thermostat Housing Support Pa g e 8-34 K38, K50, QSK38, and QSK50 Section 8 —
Coolant Thermostat Housing Support Pa g e 8-34 K38, K50, QSK38, and QSK50 Section 8 —
Coolant Thermostat Housing Support Pa g e 8-34 K38, K50, QSK38, and QSK50 Section 8 —
Coolant Thermostat Housing Support Pa g e 8-34 K38, K50, QSK38, and QSK50 Section 8 —

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Remove the water transfer tubes (2) and (3). Remove the o-rings. o-rings.

Discard the o-rings.

Low Temperature Aftercooling Thermostat Support. ing Thermostat Support.

Remove the Straub coupling from the bypass line.

Remove the U-bolts from the bypass tube.Support. Remove the Straub coupling from the bypass line. Remove the capscrews and washers from the

Remove the capscrews and washers from the upper flange connecting the bypass tube to the thermostat housing. flange connecting the bypass tube to the thermostat housing.

Remove the upper section of the bypass tube.

Discard the gasket.

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

NOTE: The following step must be carried out on both engine banks.

NOTE: The following step must be carried out on both engine banks.

Remove the capscrews and retaining clamps from the water tubes to the aftercoolers.

NOTE: The following step must be carried out on both engine banks.

NOTE: The following step must be carried out on both engine banks.

Loosen the hose clamps connecting the transfer tubes to the rubber tee between the aftercoolers.

Separate the transfer tubes from the rubber tees.

Remove the capscrew and clamp from the right bank upper transfer tube on the LTA thermostat housing.

Remove the capscrew and clamp from the right bank upper transfer tube on the LTA thermostat

Remove the transfer tube and discard the o-rings.

Remove the two capscrews and upper half of the transfer tube isolator.

Remove the two capscrews and upper half of the transfer tube isolator.

Coolant Thermostat Housing Support Page 8-35

Remove the two capscrews and upper half of the transfer tube isolator. Coolant Thermostat Housing Support
Remove the two capscrews and upper half of the transfer tube isolator. Coolant Thermostat Housing Support
Remove the two capscrews and upper half of the transfer tube isolator. Coolant Thermostat Housing Support
Remove the two capscrews and upper half of the transfer tube isolator. Coolant Thermostat Housing Support

Coolant Thermostat Housing Support Page 8-36

Coolant Thermostat Housing Support Pa g e 8-36 K38, K50, QSK38, and QSK50 Section 8 —
Coolant Thermostat Housing Support Pa g e 8-36 K38, K50, QSK38, and QSK50 Section 8 —
Coolant Thermostat Housing Support Pa g e 8-36 K38, K50, QSK38, and QSK50 Section 8 —
Coolant Thermostat Housing Support Pa g e 8-36 K38, K50, QSK38, and QSK50 Section 8 —

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Remove the one capscrew, washer, and clamp from the left bank transfer tube. left bank transfer tube.

Remove the transfer tube and discard the o-rings.

Remove the six capscrews, gasket, and thermostat cover. sket, and thermostat cover.

Remove the LTA thermostats and seals.

Discard the cover gaskets and thermostat seals.

Remove the four mounting capscrews, washers, and LTA thermostat housing. thermostat housing.

Remove the transfer tube isolation bracket and water outlets from the thermostat housing. outlets from the thermostat housing.

Discard the o-ring and gaskets.

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Clean and Inspect for Reuse

Clean and Inspect for Reuse

LTA

WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations
WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations

WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt
WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt

WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Use a suitable scraper to clean all gasket surfaces.

Use a wire brush to clean the LTA thermostat support housing.

Thoroughly clean the o-ring bores.

Dry with compressed air.

Check for cracks or corrosion damage around the o-ring seal bores.

Check for cracks or corrosion damage around the o-ring seal bores.

Check for damaged threads and gasket surfaces.

Install

LTA

LTA

Use new gaskets and o-rings and install the water outlets and transfer tube isolation bracket onto the thermostat housing.

new gaskets and o-rings and install the water outlets and transfer tube isolation bracket onto the

Torque Value:

Water

Outlet

38

N•m

[ 28 ft-lb ]

Capscrews

Torque Value:

 

Transfer

Tube

11

N•m

[ 97 in-lb ]

Capscrews

Coolant Thermostat Housing Support Page 8-37

  Transfer Tube 11 N•m [ 97 in-lb ] Capscrews Coolant Thermostat Housing Support Pag e
  Transfer Tube 11 N•m [ 97 in-lb ] Capscrews Coolant Thermostat Housing Support Pag e
  Transfer Tube 11 N•m [ 97 in-lb ] Capscrews Coolant Thermostat Housing Support Pag e

Coolant Thermostat Housing Support Page 8-38

Coolant Thermostat Housing Support Pa g e 8-38 K38, K50, QSK38, and QSK50 Section 8 —
Coolant Thermostat Housing Support Pa g e 8-38 K38, K50, QSK38, and QSK50 Section 8 —
Coolant Thermostat Housing Support Pa g e 8-38 K38, K50, QSK38, and QSK50 Section 8 —
Coolant Thermostat Housing Support Pa g e 8-38 K38, K50, QSK38, and QSK50 Section 8 —

K38, K50, QSK38, and QSK50 Section 8 — Cooling System — Group 08

Torque Value:and QSK50 Section 8 — Cooling S y stem — Grou p 08 Install the thermostat

Install the thermostat housing, washers, and capscrews.

LTA

Thermostat

Capscrewsthermostat housing, washers, and capscrews. LTA Thermostat Housing 38 N•m [ 28 ft-lb ] Install new

Housing

38 N•m

[ 28 ft-lb ]

Install new thermostat seals, thermostats, new cover gasket, and cover. Install th e six washers and capscrews. s, thermostats, new cover gasket, and cover. Install the six washers and capscrews.

Torque Value: gasket, and cover. Install th e six washers and capscrews. LTA Thermostat Cover Capscrews 60 N•m

LTA

Thermostat

Cover Capscrews

60 N•m

[ 44 ft-lb ]

Install two new o-rings on the left bank transfer tube and lubricate them with vegetable oil. left bank transfer tube and lubricate them with vegetable oil.

Install the transfer tube, clamp, and one washer and capscrew.

Torque Value:the transfer tube, clamp, and one washer and capscrew. Left Transfer Capscrews Bank Tube 22 N•m

tube, clamp, and one washer and capscrew. Torque Value: Left Transfer Capscrews Bank Tube 22 N•m

Left

Transfer

Capscrews

Bank

Tube

22 N•m

[ 16 ft-lb ]

Install two new o-rings on the right bank transfer tube and lubricate them with vegetable oil. lubricate them with vegetable oil.

Install the transfer tube, clamp, and one washer and capscrew.

Torque Value:Install the transfer tube, clamp, and one washer and capscrew. Right Transfer Capscrews Bank Tube 22

transfer tube, clamp, and one washer and capscrew. Torque Value: Right Transfer Capscrews Bank Tube 22

Right

Transfer

Capscrews

Bank

Tube

22 N•m

[ 16 ft-lb ]

K38, K50, QSK38, and QSK50 Section 8 — Cooling Sy