Installation of 4W0643 Water Temperature Regulator Group{1355} Caterpillar

Introduction

The 4W0643 Water Temperature Regulator Group has two new 7C3472 Water Temperature Regulators that are higher temperature [88°C (190°F)] regulators than the former lower temperature [82°C (180°F)] regulators.

If the truck is equipped with radiator shutters, it will be necessary to install a higher temperature sensor for shutter operation, because of the higher operating temperature of the engine cooling system.

Installation of Water Temperature Regulators

NOTE: For engines equipped with a change 5 and up 9N5796 Front Housing [see photo for location (A) of part number and change number]; follow only steps 1, 3 and 4 for installation of the regulator group. The two 2W0947 Plugs are not needed because the bypass passage of the change 5 and up 9N5796 Front Housing has a smaller area. The modification of the shunt line is not needed since an internal casting change to the front housing prevents reverse flow through the shunt line to the radiator when the thermostats are closed.

1. Remove four bolts (1). Remove elbow connector (2). Remove the gasket. Remove the two water temperature regulators (3).

2. Inspect the engine front housing for the diameter of the bypass holes behind holes (4). If the diameter is 32 mm (1.25") install two 2W0947 Orifice Plugs and 7C3472 Regulators.

3. If the diameter of the bypass holes is 19 mm (.75") install two 7C3472 Water Temperature Regulators (5) only.

4. On all engines, put 1W9698 Gasket (6) in position and install the elbow or connector with the former bolts.

5. Remove two bolts (7). Remove shunt connector (8) and the gasket.

6. Install a 3B0551 Plug in the threads of hole (9) and install the former bolts.

7. Locate port (B) on the right hand side of the front housing. Remove the plug and replace it with a 322154 Elbow or similar fitting. If port (B) is being used, an appropriate tee may be used.

NOTE: If port (B) can not be used, do steps 8 through 11 to modify 9N5770 Elbow (11), (Ford Motor Co. part D5HA-8K528-AA Connector), otherwise go to step 12.

8. Install a piece of 5P0765 Hose, cut to correct length, between the radiator shunt connection and the fitting in port (B) or the tube in the elbow or connector. Fasten the hose in place with 5D1026 Hose Clamps.

9. Drill a 20 mm (.787") diameter hole through the side, in a location away from flanges or edges, to give clearance for hoses and clamps.

A. For the 9N5770 Elbow (11) measure 54 mm (2.16"), dimension (C), from the end of the inlet.

B. For the Ford D5HA-8K528-AA Connector (12), measure 90 mm (3.54"), dimension (D), from the center of the inlet.

10. Install a thin wall tube (13), that has a 19.05 mm (.75") outside diameter, 15.75 mm (.62") inside diameter and is 50.8 mm (2.0") long. Put the tube in position so that 38 mm (1.50") of its length is outside the elbow or connector. Use AWS Class ENi-Cl weld rod and arc weld the tube in place with a 3.0 mm (.12") fillet weld, all around. Be sure all foreign material is removed from the elbow and connector.

11. Put 9L6467 Gasket in position and install the elbow or connector with the former bolts.

12. Install a piece of 5P0765 Hose, cut to correct length, between the radiator shunt connection and the tube in the elbow or connector. Fasten the hose in place with 5D1026 Hose Clamps.

13. Install all other hoses that were removed.