Installation Procedure for a 2012 Paccar Mx Heavy Duty Engine

Evans Cooling Systems, Inc. 255 Gay Street Sharon, CT 06069 860-364-5130

INSTALLATION PROCEDURE FOR A 2012 PACCAR MX HEAVY DUTY ENGINE

Procedure: Installing Evans waterless Heavy Duty Formula coolant and a ResistorPac into a Paccar MX engine VER 19Sep2011

CAUTIONARY NOTE: DO NOT FLUSH COOLING SYSTEM WITH WATER!

This procedure is modeled on Walpole Truck #485 VIN CJ296121

Coolant temperature sensor: Paccar P/N 1426321 Stock thermostat: Paccar P/N 1661375 Fan clutch: Stock is Borg Warner on-off No sleeper No APU No fuel or fuel tank heaters With DEF tank heater. With coolant through transmission cooler. The stock coolant filter is a non-chemical type. Paccar P/N 1843659

In this procedure a 55-Ohm ResistorPac is placed in series with the coolant temperature sensor, raising the fan-on, fan-off, and derating temperatures by making the ECM “think” the coolant temperature is cooler than it really is. The coolant temperature gauge is driven from the ECM and will read the temperature that the ECM thinks it sees. The actual coolant temperature will be approximately 20⁰ F warmer than the gauge reads.

A. Supplies, information, and special tools needed:

1. Purchase this item from a Paccar dealer: a. A non-chemical coolant filter. Paccar P/N 1843659 b. Note: No gaskets or o-rings need be purchased for the thermostat housing.

2. The following items are sourced from Evans Cooling Systems, Inc.: 888-990-2665 a. Enough Evans waterless Heavy Duty Formula coolant. (13 gallons should suffice, including 1 gallon for flushing.) [More will be needed if the system includes additional plumbing, such as an APU unit, a sleeper cab, etc.] b. Evans-provided labels to warn against the addition of water. c. One RP6-C55-PA2-0830 ResistorPac.

d. If the thermostat temperature is being elevated, purchase one E3032-205 thermostat. (In the case of the Walpole truck a higher temperature thermostat was not installed.) e. Refractometer for measuring water content – Evans Part No. E-2190. f. Water Chaser – Evans Part No. E-2195. 3. A high-volume air source (rather than high pressure) such as Makita blower Model UB 1101, widely available from the internet. A powerful (and clean) shop vac, used in the blower mode, is a very acceptable high-volume air source. 4. A small angled pick for removing the connector to the coolant temperature sensor. 5. A larger angled pick for difficult hoses. 6. Funnels.

B. The installation:

1. Inspect the cooling system for leaks. If there is a leak, do not proceed with the installation until the leak is repaired.

2. Place containers to catch drained coolant.

3. If the engine is hot, wait for it to cool to a safe temperature. Never open a cooling system pressure cap if the engine is hot.

4. Remove the pressure cap and drain coolant from the bottom of the radiator. Keep the drain open until advised otherwise.

5. When possible, disconnect the bottom radiator hose and leave it to drain.

6. Observe the coolant hose return manifold:

The coolant return hoses Top left: From cab heater Top Right: From transmission Bottom: From DEF tank thermostat

7. Disconnect all three hoses.

8. Blow out the heater circuit and chase with coolant: a. Turn the key on, set heat control to max, and turn on the heater blower to a low setting. b. Using the Water Chaser, blow air into the heater return hose. c. Fill the Water Chaser about ¾ with waterless coolant and blow the coolant through the heater circuit. d. Reattach the heater hose and turn the key off.

9. From beneath the truck, disconnect the coolant lines from the transmission and blow air through the transmission cooling circuit and into both coolant lines. Unless a small portable air blower is available, use shop air for this purpose. Reattach the transmission coolant lines.

10. From beneath the truck, pull the coolant lines off the thermostat for the DEF tank heater. Blow air through the hoses thus made available. Re-connect the hoses.

11. If there more ancillary coolant circuits (sleeper cab heater, APU unit, fuel tank heaters, etc.), use the same degree of care in removing old coolant from them.

12. Re-attach all coolant lines.

13. Remove the charge air duct from the turbo to the charge air cooler.

14. Remove the coolant filter, drain it, and discard.

15. Blowing air and waterless coolant through the head and block: a. Remove the modular thermostat housing. b. If the higher temperature thermostat is to be installed, install it now into the removed housing. c. Removal of the thermostat housing reveals two holes, a larger one that communicates through the EGR cooler to the engine coolant jacket and a smaller one that communicates with the inlet side of the pump. d. Block the smaller hole with a rag and blow air into the larger hole. Keep blowing air until old coolant STOPS coming out the bottom radiator hose. e. Pour the balance of the gallon jug of waterless coolant into the larger hole. f. Blow air into the larger hole (with the small hole blocked). Keep blowing air until nothing comes out of the bottom radiator hose. g. Re-connect the bottom radiator hose. h. Close the radiator drain.

15. Re-install the thermostat housing.

16. Install the new non-chemical coolant filter.

17. Installing the ResistorPac a. Make sure the ResistorPac says RP6-C55-PA2-0830.

Location of MX coolant temp sensor Use pick to lift connector tab

b. Un-plug the connector at the coolant temperature sensor using a small pick. c. Plug the ResistorPac ends between the sensor and the connector just removed. d. Mount the ResistorPac at a suitable location and tidy up the wires with zip-ties.

18. Police all hose connections one last time to assure that they are tight.

19. Fill the cooling system with Evans Waterless Heavy Duty Thermal Coolant (HDTC).Operate the engine to assure the opening of the thermostats and thorough circulation of the coolant. Add coolant as required to maintain the “hot” level. The system should take about 11 gallons (not counting the gallon used for flushing). [Expect that after operating and cool-down cycles additional topping may be required. Make sure that the truck is stocked with an extra gallon and that the driver is advised.]

20. Apply labels warning against the addition of water or water-based coolant to the cooling system in the vicinity of the expansion tank and on the dashboard.

21. This procedure is designed for the installed coolant to have 3.0 percent or less water content. Test the water content of the coolant with the Evans refractometer after several operation and cool-down cycles of the engine according to the following procedure: Calibrate the refractometer by placing a drop or two of new HDTC on the refractometer glass and setting the reading to 55.70. After cleaning the glass, place a drop or two of coolant, obtained from the expansion tank, on the glass. The reading must be 54.40 or higher to verify that the water content is 3 percent or less.

The procedures contained herein are subject to revision as techniques evolve that speed up the work and that conserve materials. The latest revision can be found on www.evanscooling.com. Evans Cooling Systems solicits suggestions from installers to help improve the procedures. If you have a suggestion, please call Tom Light 860-435-2418.

Bar’s Leaks Liquid Aluminum Stop Leak is compatible with Evans HDTC and is effective in stopping small leaks.