5.7L CCV System Breather Retrofit Instructions
Contents
1. oil to be applied equally to both the inlet and outlet of the cooler preventing oil flow through the cooler As the oil temperature approaches 180 F the valve begins to close forcing all of the oil to flow through the cooler and return through the valve to the source This fail safe design insures full al flow to the source regardiess of whether the valve is open or closed The cooler remains full of of at all times BEFORE COOLER eliminating pressure variations aeration and aniona Diagram 2 TYPICAL INSTALLATION Fluid Control Th tat AFTER COOLER _ BEFORE COOLER Hose Barb Fittng Not nuded ELUID CONTROL THERMOSTAT INSTALLATION Install the 1 2 NPT x 1 2 Hose Barb Fittings Not Included into the four ports using Teflon tape or sealer on the threads 2 Choose where you want to interrupt both oil lines to instal the Fluid Control Thermostat Thermostat needs to be securely fastened to the vehicle frame fender wel or other stationary location Mounting Hardware Not Included Splice into the lines connecting the Engine Transmission to the Oil Cooler Following Diagram 1 connect the lines from the Engine Transmission and the Oil Cooler in the orientation shown above Be sure the Hot lines are connected to the hot side of the Fluid Control Thermostat and that the oil flows in the direction of the arrows Securely fasten al hoses before starting the vehice Start the engine and check for leaks Warn2. POWER SOLUTIONS INTERNATIONAL PRODUCT BULLETIN Product Affected 5 7L CAC CCV System Date of Bulletin 2 1 2015 Bulletin Number PSI012015 Category Breather Retrofit Instructions Part Number 38050376 w Oil Cooler 38050375 w o Oil Cooler Summary of product bulletin This bulletin is to inform technicians how to properly install the retrofit CCV kit on the GM 5 7L turbocharged engine This kit will help keep the CCV system from freezing in cold weather climates Below is a list of parts and quantities If your engine does not have an oil cooler you will not have 32502455 or 32500608 NPT x 3 8HB 5 71T CAC CCV hoses with Oil 33001562 Tie Zip High Temp High temperature zip tie Cooler 3100045 Thermostat 195 Degree Change engine thermostat Gasket Engine change Mount thermostat hoses 32500608 Hose Fuel 1 2 96 New oil cooler hose POWER SOLUTIONS INTERNATIONAL Step 1 Remove the CCV hose and brass breather adaptor from the inlet pipe Install the new composite fitting sealing with pipe threat sealant Do not re install breather hose yet Step 2 Slide the Pa insulating jacket IE aN N NNE iia over the hose a N Qe oo Install hose on the ima B ae f mo A composite fitting and secure clamp eZ age POWER SOLUTIONS INTERNATIONAL Step 3 Secure 5S ne SRN both sides of the S insulating jacket with provided Zip Ties vi Mi OHHH LL O
3. e Step 4 Install oil cooler thermostat Mount the thermostat in a location where it will not be damaged or come in contact with other parts Oil flow is shown below More information about the oil cooler thermostat can be found on the last page of these instructions Use the included 7 hose as needed to connect thermostat into the system FROM COOLER POWER SOLUTIONS INTERNATIONAL Step 5 If replacing engine coolant thermostat follow service manual procedure When reinstalling water outlet tighten studs to 18 lb ft Refill engine with Long Life coolant meeting engineering standard GM6277M typically a bright orange color Engine Oil Cooler Information POWER SOLUTIONS INTERNATIONAL IF YOU HAVE ANY QUESTIONS ABOUT THIS UPDATE PLEASE CONTACT THE PSI SERVICE DEPARTMENT AT 1 888 331 5764 or SERVICE POWERGREATLAKES COM FOR SERVICE PARTS ORDERING INFORMATION CONTACT THE PSI PARTS DEPARTMENT AT 1 888 331 5769 OR PARTS POWERGREATLAKES COM Please read these instructions completely before starting the installation KIT CONTENTS TOOLS NEEDED QTY DESCRIPTION Standard Screw Driver Open End Wrench s 1 Fluid Control Thermostat 1 2 NPT Ports Teflon Tape RECOMMENDED FOR IMPORTANT Transmissions Engines The Fluid Control Thermostat can be mounted in i positon Reference Diagram 1 amp 2 to insure the direction of oil flow is How It Works When the of is cool the valve is in the open position allowing
4. ing When routing hoses be sure to keep all hoses away from sharp edges moving parts and hot engine components Hoses should be routed carefully and should not be bent in less than a 5 radius important A kinked hase will restrict fow and could cause failure Warning instalation of accessories should only be undertaken by those with mechanical knowle and are familiar with working on vehicles ng p use eye protection es safety glasses or shield Park the vehicle in a wel It area on level ground and apply the rking brake Only work on a cold v that has sting gemat failure to Go so wil result in severe bums and nuy fore starting vehicle make Sure no tools or any other items are left under hood that could interfere with or be drawn into moving parts of the engine Failure to follow instructions can lead to severe damage and personal injury
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