Models with Seawater Cooling
Cooling System
Section 6B - Models with Seawater Cooling
Table of Contents
Specifications.....................................................................6B-2
Thermostat Assembly........................................................ 6B-2
Thermostat Assembly—Exploded View......................6B-2
Thermostat Removal.................................................. 6B-2
Thermostat Testing.....................................................6B-2
Thermostat Installation............................................... 6B-3
90-879288300 AUGUST 2012
Poppet Valve Replacement........................................ 6B-4
T‑Fitting for Water Hose Assembly.................................... 6B-5
Bypass T‑Fittings........................................................ 6B-5
Removal......................................................................6B-5
Cleaning and Inspection............................................. 6B-5
Assembly.................................................................... 6B-5
6
B
Page 6B-1
Models with Seawater Cooling

Lubricants, Sealants, Adhesives

Tube Ref No. Description Where Used Part No.
19 Perfect Seal Both sides of the poppet valve gasket 92-34227Q02

Specifications
Description Specification
Seawater‑cooling system capacity 20 L (21 US qt)
Thermostat operating temperature 71° C (160° F)

Thermostat Assembly
Thermostat Assembly—Exploded View
11
1- Thermostat housing gasket
10 2- Thermostat sleeve
3- Thermostat
9 4- Thermostat gasket
5- Temperature sensor
8 6- Pipe plug
7- Poppet
8- Spring
7 9- Poppet cover gasket
10 - Thermostat cap
6 11 - Screw (3)
12 12 - Blue drain plug
13 - O‑ring
13
14 - Thermostat housing
15 - Water temperature sender
16 - Pipe plug
5 14 17 - Pipe plug

4
15
3 16
17

1 50005

Thermostat Removal
1. Drain the seawater from the engine.
2. Remove the hoses from the thermostat housing.
3. Remove the thermostat housing assembly.
4. Remove the sleeve, thermostat, and gasket from the thermostat housing.

Thermostat Testing
1. Remove the thermostat.
2. Place the thermostat on blocks in a container.
3. Add water to the container until it covers the thermostat.

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 Models with Seawater Cooling
4. Heat the water.
5. Stir the water constantly to avoid applying direct heat to the thermostat.

c a- Wooden blocks
b- Stirring rod
c- Thermometer
d- Thermostat

b
d

a 50079
6. Observe the thermostat and check the temperature when the thermostat fully opens. If the temperature is not within
specifications, then replace the thermostat.

Thermostat Installation
NOTE: Refer to the exploded view for parts identification.
1. Clean the gasket surfaces inside the thermostat housing, on the thermostat housing, and on the intake manifold.
2. Place a new thermostat gasket in the thermostat housing. Ensure that it is positioned properly in the housing.
3. Place the thermostat in the thermostat housing with the thermostatic element end toward the housing bottom.
4. Align the sleeve with the groove in the thermostat housing bore, and install the sleeve into the housing.
5. Position a new thermostat housing gasket on the intake manifold.
6. Install the thermostat housing and tighten the screws to specification.

Description Nm lb‑in. lb‑ft

Thermostat housing screws 41 30
7. Connect the hoses to the thermostat housing. Securely tighten the hose clamps.

NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.
8. Supply cooling water to the engine.
9. Start the engine and inspect for leaks.

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Models with Seawater Cooling

Poppet Valve Replacement

2
Poppet valve assembly
1 - Drain plug
1 2 - Cap
3 - Gasket
4 - Spring
5 - Poppet
3
6 - Thermostat housing
7 - Temperature sensor

35118

Removal
1. Drain the water from the engine block cooling passages.
2. Remove the three screws that hold the poppet valve assembly's cap in place, and remove the cap.
3. Remove and discard the gasket.
4. Remove the spring.
5. Remove the poppet.

Installation
1. If reusing the poppet, gently clean the poppet and spring.
2. Remove any gasket material that remains on the mating surfaces.
3. Coat both sides of a new gasket with Perfect Seal.

Tube Ref No. Description Where Used Part No.

19 Perfect Seal Both sides of the poppet valve gasket 92-34227Q02
4. Place the gasket onto the thermostat housing.
5. Insert the poppet into the housing as shown above.
IMPORTANT: Poppet valve springs are available in two spring ratings. Be certain to order a spring with the correct rating.
6. Insert the spring onto the poppet.
7. Place the cap onto the housing and secure it with the three screws. Tighten the screws to specification.

Description Nm lb‑in. lb‑ft

Poppet valve cap screws 11 95
8. After repairs are complete, pressurize the system (such as by starting the engine) and check for leaks.

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 Models with Seawater Cooling

T‑Fitting for Water Hose Assembly

Bypass T‑Fittings
Bypass T‑fittings are used on engines with seawater cooling to allow excess water to bypass the engine block and exhaust
manifolds and exit the cooling circuit through the exhaust elbows. The size of the bypass orifice is dependent on the engine
model. The color of the T‑fitting indicates the orifice size, as listed in the chart below.

Model T‑fitting color Orifice size T‑fitting part number

Alpha Red 6.35 mm (0.250 in.) 8M2014002
Bravo Green 9.52 mm (0.375 in.) 8M2014001
MIE Blue 12.70 mm (0.500 in.) 8M2014000

The T‑fitting is located at the end of the engine closest to the exhaust elbows. On most models, this means the rear of the
engine. The one exception is on V‑drive models, where it is at the front of the engine. See the illustrations below.

51173 51174

T-fitting location on all models except V-drive (typical) T-fitting location on V-drive models

Removal
1. Remove the hose clamps.
2. Disconnect the water hoses from the T‑fitting.

Cleaning and Inspection

1. Clean the T‑fitting with soapy water.
2. Inspect the T‑fitting for damage.
3. Replace the fitting if it is damaged.

Assembly
IMPORTANT: Confirm that the T‑fitting is correct for the application. Refer to Bypass T‑Fittings for details.
1. Align the marks on the hose to the alignment feature on the top of the T‑fitting.
2. Install the T‑fitting into the hose. Tighten the hose clamp securely.

Rear view of hose assembly

a - Hose from seawater‑cooling circuit to T‑fitting
b - T‑fitting
c c - Alignment feature (molded onto top of T‑fitting)
b d - Alignment marks (on hose)

50875

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Models with Seawater Cooling
3. Align the marks on the hoses to the parting line on the T‑fitting. Install the T‑fitting to the port and starboard elbow hoses
onto the T‑fitting.
4. Tighten the hose clamps securely.

Typical T-fitting connections

b a - T‑fitting
b - Alignment marks (on hose)
c - T‑fitting to port elbow hose
d d - T‑fitting to starboard elbow hose
c e - From seawater‑cooling circuit

a
e
30956

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