Cooling Hose Fit Problems

[76SeaRay]

So, the engine stand mockup continues and of course issues continue as well. I bought new hoses and have fit problems with two of them. Essentially, this is a 1996 Mercruiser 5.7L engine.

First, the T Stat Housing to Exhaust Manifold on the Port side is too short (see pic below). I ordered what is called out by Mercruiser (32-806635) and supposedly the one I received is a replacement for the one called out on the parts diagram. The weird thing is that the 32-806635 shows as a 90 degree angle on the exhaust manifold end but this one is straight. Is there a longer version of this hose?

Second, the Power Steering Oil Cooler to T Stat Housing (32-806856) is too short to get to the top of the intake manifold. Is there a longer version of this hose?

 

[Bondo]

Ayuh,..... The hose looks right, the P/S cooler is usually right up under behind the motor mount, where it's tough to get too,......

 

[76SeaRay]

The PS oil cooler to T Stat Hsg reaches the PS oil cooler but it doesn't get above the level of the intake manifold so it is nowhere near reaching the T Stat Hsg. Not sure what I will do with this hose.

For the other hose, I ran across an old hose in my used pile that seems to work for the Port Exh manifold (lower fitting) to T Stat Hsg. It is 32-87116 but I don't see that anywhere on the parts diagrams for any year even under the new numbers that it says replaces it. It looks just like the 32-806635 1 but is longer where it attaches to the exh manifold. Now I have to find a new 32-87116 part and see if that works.

 

[achris]

Houston, we have a problem!

You call that engine out, in your forum signature, as a vortec engine, but it has vee belts. When Merc released the Vortec engines in mid 96, part of the update was going to serpentine belts.

If you ordered your hoses based on it being a vortec engine, and it's not, there's the problem.

In order to know for sure what it is, please post the engine serial number.

Chris.......

 

[76SeaRay]

I am custom building the engine from a bare block so no serial number. However, the location of all fittings and the T Stat Housing are the same as a 1996 Mercruiser 5.7L/5.7LX. The distance from the center line of the oil cooler to the center line of the T Stat Housing on my engine is the same as standard Mercruiser 5.7L engines. The cooling hose listed in the part diagrams is too short to get up over the top of the intake manifold and would have the same problem even if it wasn't a vortec. I chose to go with all the parts that match the V Belt engine including the closed cooling system. The closed cooling system does not affect these two hoses as you simply reuse the stock ones as part of the closed cooling installation.

Again, I think I have solved the problem with the Port side T Stat Hsg to Exhaust Manifold lower fitting by using the 32-87116 hose thanks to finding an old used hose in my pile of parts with the part number written on the side of it.` This is a molded hose so there is only one way to install it. The vortec intake heads do not affect the position of the hose as it is molded to specifically fit the v belt engine and routes through the PS pump bracket and in between the alternator and the front lower edge of the exhaust manifold. When you do that with the 806635 hose it is 3 inches too short to reach the lower fitting. The 32-87116 is identical to the 806635 hose in its molded shape and size except it is longer where it runs under the exhaust manifold. I got lucky that I had the old hose in my collection of used parts since the 32-87116 doesn't seem to appear anywhere on parts diagrams. I would probably have never found the correct part otherwise.

I think I can solve the PS Oil Cooler hose to T Stat Hsg by finding the right length of a standard 90 degree 1 1/4 inch id hose and cutting it to length.

 

[achris]

I am custom building the engine from a bare block so no serial number. However, the location of all fittings and the T Stat Housing are the same as a 1996 Mercruiser 5.7L/5.7LX. ...

Early 1996 (non-vortec) or late 1996 (vortec)?????

 

[76SeaRay]

It really doesn't matter since the hose barely reaches the top of the water pump and will not reach the T Stat housing on either the non-vortec or the vortec engine (I have both styles of engines and intake manifolds). The only thing I can conclude is that the hose is a bad hose if the part number is correct. I could try the hose for the 1997 to 2001 engines (808033) but since specs on these hoses are not listed anywhere, I don't know if it will reach either so it would be a shot in the dark to buy another Mercruiser hose. Maybe somebody can give me the measurements for the 808033 hose to see if it is tall enough to reach.

 

[76SeaRay]

So, I ordered and just received the new 32-87116 hose for the T Stat to PS Oil Cooler. The old one I have fits perfectly but I wanted to put on all new hoses as part of the restoration. Here is the frustration as "replaced by" does not really mean it will fit in place of the old one. The Sierra "replaced by" doesn't match the old hose that is marked with the original Mercruiser part number.

The pictures below show the old hose (straight end where it connects to the exhaust manifold) and the new Sierra with a 90 degree bend (where it connects to the exhaust manifold. At least the supplier is only 3 hours away so maybe I can just take the old hose to them to match it up or just use the old hose on my engine. This is what I mean its a shot in the dark on these hoses even if you have the correct old part in your hand.

 

[achris]

Sierra...

 

[76SeaRay]

Guess that says it all..........