SERVICE BULLETIN

TOPIC: Cooling System

IDENT NO: 4-2891
SUPERSEDES: NEW
DATE: May 15, 2002
SUBJECT: Wastegate And Intercooler Water Tubes Retrofit Instructions

MODELS AFFECTED: 12 Cylinder VHP And VHP Series Fourâ

INTRODUCTION RETROFIT INSTRUCTIONS

The purpose of this Service Bulletin is to provide the INTERCOOLER WATER TUBES
retrofit instructions for improvements to the 12 cylinder
1. Drain the coolant from the auxiliary cooling water
VHP and VHP Series Four engine wastegate inlet and
circuit.
outlet tubes. This improved tube routing reduces the
amount of stress that the tubes are subjected to and 2. Disconnect the turbocharger water outlet tubes
helps prevent wastegate tube failures. If you are from the intercooler water outlet pipe (see
experiencing cracking or other failures with the Figure 1).
wastegate water tubing, complete the retrofit procedure
explained in this bulletin.
INTERCOOLER WATER OUTLET PIPE
The new wastegate water inlet and outlet tubes are
connected to new intercooler water tubes instead of at
the rear of the intercooler. Figure 7 shows the location
and part numbers of the new tubes and fittings.
Table 1 lists the parts required to retrofit the engine.
All engines shipped after March 25, 2002, have the
reconfigured wastegate tubing installed.
Table 1. Parts Required For Retrofit
TURBOCHARGER WATER
P/N DESCRIPTION QTY. OUTLET TUBES
214067P Wastegate Water Inlet Tube, RB 1
214067M Wastegate Water Inlet Tube, LB 1
214067V Wastegate Water Outlet Tube, RB 1
214067R Wastegate Water Outlet Tube, LB 1 Figure 1. Turbocharger Water Outlet Tubes
26750 1/4" NPT Pipe Plug 2
3. Open the Flexmaster couplings and remove the
A214100L* Pump To Intercooler Tube, Rear 1
intercooler water inlet and outlet tubes from the
A214100M* Intercooler Water Outlet Tube, Rear 1
engine (see Figure 2 and Figure 3).
NOTE:* The engine’s existing intercooler water tubes may be
modified by drilling holes and welding 1/4" NPT connectors
(P/N 209242A) in the correct locations. See “Intercooler Water FLEXMASTER COUPLINGS
Tubes Modifications” in this bulletin for information.

Figure 2. Flexmaster Couplings On Intercooler Outlet

Water Tube

WAUKESHA ENGINE
DRESSER, INC. Page 1 of 5
WAUKESHA, WI 53188-4999
Service Bulletin No. 4-2891
FLEXMASTER COUPLINGS
Figure 3. Flexmaster Couplings On Intercooler Inlet
Water Tube
NOTE: The intercooler water inlet and outlet tubes
can be replaced with new tubing, or the existing tubes
can be modified by drilling holes and welding 1/4" NPT
couplings. See “Intercooler Water Tubes Modifications”
at the end of this bulletin for modification instructions.
4. Install the new (or modified – see NOTE above)
intercooler water tubes (P/N A214100L and
P/N A214100M) with the wastegate fittings on the
engine (see Figure 4 and Figure 7).
WASTEGATE FITTINGS
Figure 4. New Intercooler Water Tubes Installed
Page 2 of 5
WASTEGATE WATER TUBES
Removal Of Existing Wastegate Tubing
1. Verify coolant is drained from the auxiliary cooling
water circuit.
2. Remove the wastegate water tubes from the rear
of the intercooler tubing (see Figure 5).
3. Remove the pipe tees from the reducer bushings
and set aside (see Figure 5). The pipe tees will be
reused.
REMOVE TUBING AND
PIPE TEES
Figure 5. Intercooler Disconnections
4. Remove the right bank wastegate water inlet and
outlet tubes from the wastegate (see Figure 6). Set
aside flex elbow, pipe nipple, pipe tee, drain cock,
and flex connector. These parts will be reused.
5. Remove the flex elbow from the left bank
wastegate and set aside (see Figure 6). The flex
elbow will be reused.
6. Remove the flex connector from the left bank
wastegate and set aside (see Figure 6). The flex
connector will be reused.
7. Remove the left bank wastegate water inlet and
outlet tubes from the wastegate (see Figure 6).
Installation Of New Wastegate Tubing
1. Install 1/4" NPT pipe plugs into the reducer
bushings installed in the rear of the intercooler.
2. Install new water inlet and outlet tubing to
wastegates as shown in Figure 7. Reuse pipe
tees, drain cocks, flex elbows, pipe nipples, and
flex connectors as necessary. Apply pipe sealant
to threads during assembly.
3. Install new wastegate inlet and outlet tubing to
intercooler water tubes as shown in Figure 7.
WAUKESHA ENGINE
DRESSER, INC.
WAUKESHA, WI 53188-4999
 Service Bulletin No. 4-2891

RIGHT BANK
2 WASTEGATE

3
5

1 6
4

11

LEFT BANK
WASTEGATE
10

12

13
8
9

ITEM ITEM
DESCRIPTION P/N DESCRIPTION P/N
NO. NO.
1 Wastegate Water Inlet Tube, RB 211636L 8 Pipe Tee 199109B
2 Flex Elbow 199111C 9 Pipe Tee 199109B
3 Pipe Nipple 118566X 10 Wastegate Water Outlet Tube, LB 211636K
4 Pipe Tee 78208B 11 Flex Elbow 199111C
5 Drain Cock 73413A 12 Flex Connector 194769A
6 Flex Connector 194769A 13 Wastegate Water Inlet Tube, LB 211636J
7 Wastegate Water Outlet Tube, RB 211636H

Figure 6. Existing Wastegate Water Inlet And Outlet Tubes

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DRESSER, INC. Page 3 of 5
WAUKESHA, WI 53188-4999
Service Bulletin No. 4-2891

RIGHT BANK
13 WASTEGATE
15
2 4

3
5

7 6

14
12

11
9

LEFT BANK
WASTEGATE

10

ITEM ITEM
DESCRIPTION P/N DESCRIPTION P/N
NO. NO.
1 Wastegate Water Outlet Tube, RB 214067V 9 Wastegate Water Inlet Tube, LB 214067M
2 Flex Connector 194769A 10 Flex Elbow 199111C
3 Pipe Tee 78208B 11 Flex Connector 194769A
4 Drain Cock 73413A 12 Wastegate Water Outlet Tube, LB 214067R
5 Pipe Nipple 118566X 13 Pipe Tee 199109B
6 Flex Elbow 199111C 14 Pump To Intercooler Tube A214100L
7 Wastegate Water Inlet Tube, RB 214067P 15 Intercooler Water Outlet Tube A214100M
8 Pipe Tee 199109B

Figure 7. Retrofitted Wastegate Water Inlet And Outlet Tubes

Page 4 of 5 WAUKESHA ENGINE

DRESSER, INC.
WAUKESHA, WI 53188-4999
 Service Bulletin No. 4-2891
INTERCOOLER WATER TUBES
1/4" NPT COUPLING
MODIFICATIONS P/N 209242A 2.75" (69.85 mm)

Instead of replacing the intercooler water tubes, you

can modify the existing tubes by drilling holes and
welding 1/4" NPT pipe couplings in the correct loca-
tions. Complete the following steps to modify the inter- 1.47"
.12 (37.338 mm)
cooler water tubes.
1. Remove tubing by following the instructions
provided in the section, “Intercooler Water Tubes”.
2. Locate and drill 0.91" (23 mm) holes in the tubes
according to the dimensions shown in Figure 8
and Figure 9.
Figure 8. Tube P/N A211700L To P/N A214100L
Modification
WARNING
Comply with the welder manufacturer’s
recommendations for procedures concerning the
proper use of the welder. Improper welder use can
result in severe injury or death.

3. Weld 1/4" NPT couplings (P/N 209242A) as shown

in Figure 8 and Figure 9 with water tight welds. G .12

1/4" NPT COUPLING

P/N 209242A
5.375"
(136.525 mm)

Figure 9. Tube P/N A211761E To P/N A214100M

Modification

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DRESSER, INC. Page 5 of 5
WAUKESHA, WI 53188-4999