FRESHWATER COOLING 2002, 2003 1 . Fit the circulation pump (complete with tensioner bracket and spacer sleeve, position 4) . Tighten the bolts (M8x75) to 20 Nm (2,0 kpm) (14 .7 ft .lbs), position 1 . 2 . Suspend the heat exchanger loosely by the rear bolt (M8x16 and spring washer .), position 5 . a) Fit the pipe (position 6) and the hose (position 3) between the heat exchanger and the sea-water pump, using double hose clamps (apply soapy water to the rubber rings, applies for all rubber rings) . c) Fit the pipe between the heat-exchanger and the circulation pump, position 8 . 3 .
Locate the pipes in the heat-exchanger and and draw it forward tightening it with the two bolts (M8x16 and spring washers), positions 5 and 9 . 4 . Fit the pipe between the heat-exchanger and the exhaust elbow, position 10 . NOTE! The holderforthe pipe, (position b) Fit the pipe between the heat-exchanger and thermostat housing, position 7 . 11) and the lock (position 11 a) . 5 . Fit the pipe between the circulation pump (lower outlet) and the cylinder head, position 12 . 6 . Fit the pipe between the circulation pump (upper outlet) and the cylinder head, position 13 . 7 . Fit the alternator, place the bolt for the tensioner bracket with the head forwards . Put on and tension the V-belt . 8 .
Fit the expansion tank to the exhaust elbow, position 15 . 9 . Fit the hose between the tank and the circulation pump (double pipe ) 2002 = 450 mm (17 .7 in), 2003 = 550 mm (21 .7 in) (only single hose clamps are used on the fresh-water system), position 16 . 10 . Fit the nipple, position 17 . 11 . Fitthe hose between the tank and the thermostat housing (nipple 17) : 2002 = 350 mm (13 .8 in), 2003 = 450 mm (17 .7 in), position 18 . 12 . Fit the plugs in the exhaust elbow and the cylinder head, positions 19 and 20 . 13 . Fill the system to the right level with a mixture of fresh water (50% ) and anti-freeze (50%), altematively rust-protection additive (VP accessory) .
The fresh-water system volumes : 2002 = 4.0 dm2 (litre) (0.88 Imp. gals) (1.1 US gals), 2003 = 5 .5 dm 3 (litre) (1 .2 Imp . gals) (1 .45 US gals) . Pos 21 and 23 are for hot water outlet .