Usage:
Introduction
This Special Instruction contains the necessary procedures and information to install 6N9739 Jacket Water Heater Group. The 6N9739 Jacket Water Heater Group can be installed on all 3204 engines. The heater group has a 750 Watt, 120V heater element, to heat the coolant in the cylinder block.
NOTE: In the procedure that follows, all reference to left side or right side is made as viewed from the flywheel end of the engine.
1. Drain the coolant from the cylinder block. Remove the rear core plug from the right side of the engine. Remove any paint, sealant or rough edges in or around the area of the bore where the core plug was removed. Use a file or sand paper to put an approximate 0.8 mm (0.03 in) chamfer in bore for the element assembly.
2. Apply a thin coat of 8T9015 Form-A-Gasket Sealant on the gasket surfaces of 7N7957 Element Assembly (1) and 6N9119 Adapter (3).
3. Install 7N7957 Element Assembly (1), 6N9121 Gasket (2), 6N9119 Adapter (3), 4F7952 Seal (4), 6N9122 Ring (5), 6N9123 Plate (6), 2H3924 Lockwasher (7) and 2R1980 Nut (8). Make sure the element assembly (1) is not in contact with the inside of the cylinder block and tighten nut (8) to a torque of 45 ± N·m (35 ± 5 lb ft).
NOTE: Use all supplied parts such as lockwashers, seals, etc. Be sure all parts are installed in the core plug bore in the proper sequence before tightening.
NOTE: Use ONLY antifreeze as an installation lubricant. Do not use silicone, grease or liquid soap or other lubricating fluid (other than antifreeze) to facilitate assembly.
4. Install 6N1604 Cap (9).
NOTE: Cap (9) is used as a dust cover when cord assembly (10) has been removed. Align the terminals in cord assembly (10) with the terminals of element assembly (1), then tighten nut (11) to a torque of 10 ± 2 N·m (90 ± 20 lb in).
NOTE: For electrical supply to the heater, use electrical wire and connections that have a minimum capacity of 10 amps.