Cooling Mod Installation How-To

[Zack]

Fast forward to the wiper cowl, upper and lower intake removed and coolant drained.
Use a 1/4" punch (or similar) and hammer down closest to the front of the engine. It will start angling itself out. Use a channel locks as pictured to remove it from the bore

http://i.imgur.com/9AQ0Zg6.jpg
http://i.imgur.com/rsJmbW2.jpg
http://i.imgur.com/w6A3m0r.jpg

Shove a small piece of towel down the bore, then remove the factory sealant lingering. Then clean the bore with a scotch brite pad and brake clean (be sure to remove the towel after cleaning)

http://i.imgur.com/c3l4K6j.jpg
http://i.imgur.com/DbUH5qc.jpg

Dry fit everything first (pretty much as pictured) then mark the fittings to the block as shown

http://i.imgur.com/Sx2fq1V.jpg

Coat the fitting lightly with silicone

http://i.imgur.com/2x5YquQ.jpg

Continued.....

[Zack]

Line the fittings up then drive them into the head, flush with the block.
Use a 3/8" flat punch. You will booger up the solder and brass installing them, but it will seal just fine

http://i.imgur.com/sD3ygMX.jpg
http://i.imgur.com/3pVa7N0.jpg

cQICG_zpPOw


Connect the fittings and clamp them:

http://i.imgur.com/qBay1B7.jpg

You will need to trim the lower intake if you installed the passenger fitting as shown. Eaton manifolds will need no trimming

http://i.imgur.com/bFerADR.jpg

Purchase hose number 80404 from Advance to connect the drivers fitting to the rest of the system, shown later
The right angle portion of the hose will need to be trimmed down

http://i.imgur.com/YRPtKrf.jpg

Use a piece of hose to make a heat shield from the egr tube

http://i.imgur.com/cRzglXA.jpg

[Zack]

Install the wiper cowl assembly before splicing the T fitting in.

http://i.imgur.com/zg0Ta0U.jpg

Using the provided Tee, splice into the pictured hose. You will have to remove about 1/2 to 3/4" of hose for the Tee to fit perfectly.
Clamp it up and you're done

http://i.imgur.com/IHUj83I.jpg

[03Merc]

Thanks a lot!


#1618 of 3214

[Zack]

I'm not answering dumb questions sorry

[guspech750]

I'm not answering dumb questions sorry


I know DTR's are slow and probably the engine barely gets above room temp. Do I need this too?






PS. Nice write up bubs.

Sent from The White House on taxpayers dimes.

[03Merc]

Haha, it's ok!


#1618 of 3214

[Zack]

Thanks knine for the donor car

[Sactown]

Awesome thanks!!

[fordnut02]

Great Write up and Pictures Zack Thanks
I'm NA STOCK , so I do need all 3 fittings ?
paypal to order Kit ?

[justbob]

I liked your old video of how to remove the freeze plugs better than these pics.

It made me whaf.

On a side note, looking at the heater hoses I see now I reversed them the last time at the heater core. Not like it matters anyhow. Oops..


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[Sactown]

Great Write up and Pictures Zack Thanks
I'm NA STOCK , so I do need all 3 fittings ?
paypal to order Kit ?

Yes...post 118 in the for sale thread http://www.mercurymarauder.net/forums/showpost.php?p=1488671&postcount=118

Paypal info is in that thread also

[8UWITH6]

I did not know you still worked on BLUE cars. ;) Nice write up. Gotta do the wife's car soon............ because lazy.

[ledzilla]

Two questions...

1) What kind of silicone was used to seal the new plugs?
2) What was used to trim the manifold?

[Bruce Wayne]

I was wondering about the silicone too, also what size and type of hose, Thanks Zack, great pictures, I'm going to do this mod this weekend

[Zack]

I gave the part number of the hose

If you have to ask what type of silicone, stick to sewing

[8UWITH6]

What he meant to say is Permatex "The Right Stuff" in a thin coat. ;)

[BeeDamn]

Thank you for the great write up this should get sticky.

[justbob]

I gave the part number of the hose

If you have to ask what type of silicone, stick to sewing


You must drink a lot. I would be.


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[MMBLUE]

Thanks knine for the donor car

Knine is back Maraudering eh?:beer:

[ledzilla]

What he meant to say is Permatex "The Right Stuff" in a thin coat. ;)

Thanks! I've seen so many silicone options out there, until I've done a particular job at least once I never know which one to use.

[Zack]

Thanks! I've seen so many silicone options out there, until I've done a particular job at least once I never know which one to use.

Anything 300+ degree rated is fine

[GetMeMyStogie]

I remember some discussion of an alternate routing of the hoses, which might have eliminated the long pipe on the pass. side of the engine and blocked off one of the ports on crossover tube. Did anything ever come of that?

[Zack]

I remember some discussion of an alternate routing of the hoses, which might have eliminated the long pipe on the pass. side of the engine and blocked off one of the ports on crossover tube. Did anything ever come of that?

You just answered your own question
Just hook the cooing mod to the heater core directly

[ledzilla]

What kind of hose was used to connect the fittings together? Is that just a piece of bulk heater hose? About how long is it?

[510paesan]

http://www.svtperformance.com/forums/showthread.php?1023525-HCM-(head-Cooling-Mod)-for-all-4-6-5-4-DOHC-Cobra
what about this ? this looks like it accomplishes the same thing just more labor intensive

[RubberCtyRauder]

You want to give MMR $199 for something you can't see?

[parker]

Totally looks cool with a spotter mirror

[knine]

Thanks knine for the donor car

Anytime. Literally.

[crownvic97]

Old thread bump.


What size hose for the heater core? Both 5/8?

[fastblackmerc]

Old thread bump.


What size hose for the heater core? Both 5/8?

Yes... 5/8 for both.

[crownvic97]

Yes... 5/8 for both.

Thank you sir!

[Invective]

Interesting - thanks for this. Surprised this isn't 'stickied'. For whatever reason I thought this could be done without removing the intake manifold - apparently not.

[03Merc]

Interesting - thanks for this. Surprised this isn't 'stickied'. For whatever reason I thought this could be done without removing the intake manifold - apparently not.



You have to modify the lower intake manifold.


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[Invective]

You have to modify the lower intake manifold.


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Correct. Are those brass fittings commonly available?

[RubberCtyRauder]

those brass fittings are custom made by Zack in this instance. There are vafious kits available. it is not a marauder only thing, mustangs with 4.6 dohc as well

[03Merc]

Correct. Are those brass fittings commonly available?



Contact MartyO.


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[crownvic97]

You have to modify the lower intake manifold.


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To do a fitting on the rear of the P/S Head you gotta do a little trimming.

http://i668.photobucket.com/albums/vv45/Markd20000/2003%20Mercury%20Marauder/CDEEC050-CAE1-40FC-93DE-4F1C057B7AB2_zpsooghdwl0.jpg (http://s668.photobucket.com/user/Markd20000/media/2003%20Mercury%20Marauder/CDEEC050-CAE1-40FC-93DE-4F1C057B7AB2_zpsooghdwl0.jpg.h tml)

[crownvic97]

Yes... 5/8 for both.

FWIW, the heater core inlet/outlet are actually 3/4, the hoses do reduce in size to 5/8 on the ends however.