M. I .

549
*Rev. A

ELECTRO-MOTIVE DIVISION " GENERAL MOTORS CORPORATION

SERVICE DEPARTMENT MAINTENANCE INSTRUCTION

WATER COOLING RADIATORS

INTRODUCTION CLEANING
Heat from the engine cooling system water is When it becomes necessary to clean the radiator,
dissipated through means of a radiator and fan use the following procedure :
arrangement .
1 . Mark any areas on the air sides of the core
Heat developed by the engine is transfered to the that show signs of water treatment color.
water. The water enters the radiator directly from Discolored areas indicate leaks that will have
the engine. Within the radiator the water enters a to be repaired .
series of tubes called the core, Fig. 1 . Using the
tube material as a conductor, a fan draws 2. Remove header, if used.
ambient air between the tubes thus cooling the
heated water. Fins attached to the tubes aid in 3. Straighten bent header flanges and comb bent
cooling by allowing more air to contact the fins to ensure that air flow is not reduced .
heated tube surfaces .

This maintenance instruction describes the pro- 4. Blow debris from fins with compressed air.
cedures necessary when cleaning and repairing the
radiator . 5 . Clean gasket surfaces.

Fig. 1 - Typical Radiators

*This bulletin is revised and supersedes previous issues of this number.

DE-L October 1975

M.I . 549

6. Fill a soak tank with an undiluted non-toxic

organic cleaner . See Service Data. Level
should be sufficient to allow for complete
submersion of the radiator .

CAUTION : Use of caustic cleaners is not rec-

ommended. Bonding solder will dete-
riorate with the use of caustic
cleaners, causing leaks and hindering
heat transfer. 14014

Fig. 2 - Checking Fin-To-Tube Bond

7. Soak radiator core for three hours in a still
tank, with tubes lying horizontally . If clean-
ing solution is agitated, cut soaking time in
half. NOTE : If loose fins leave more than 25.4 mm
(1") of a tube length unsupported, that
NOTE : Cleaning is more effective in an agitated tube should be removed from service, see
tank. Tube Repair .

8. Rinse core using a steam-water mixture .

LEAK TEST
NOTE : Rinse core as soon as possible to prevent
Tube leaks or tube-to-header bond leaks can be
residue from hardening .
accurately located using the following procedure :
RADIATOR CORE TESTING 1 . Install a sealing plate or tank on each header-
flange of the core.
Radiator core failures, other than damage, can be
categorized under three headings : fin-to-tube
2. Apply 345 kPa (50 psi) air pressure on the
bond failures, tube failures, or tube-to-header
tube side with the core immersed in clean
bond failures . Repair limits for fin-to-tube bond
water at room temperature .
and tube failures are specified under Service Data.
If the failure is within the repair limits the core
CAUTION : Avoid exceeding 345 kPa (50 psi) air
can be repaired, if not, repair is not feasible and
pressure, higher pressures may damage
the core should be scrapped .
core tubes.
FIN-TO-TUBE BOND CHECK 3 . Mark tubes and areas of the tube-to-header
bonds that are emitting bubbles .
Loose fins will hinder heat transfer and allow the
tube to expand with water pressure. This
4. Qualify the core by using the repair limit
expansion-contraction cycle will eventually result
information given under Service Data. The
in a tube fracturing . Use the following steps to
core should be scrapped if tube failure ex-
check fin-to-tube bond.
ceeds repair limits .

1 . Using a suitable tool or probe, check fin-to- 5 . For repair procedures, refer to either Tube
tube bond by gently pressing against the fin Repair or Tube-To-Header Bond Repair sec-
collar . A loose fin will move relative to the tions, depending on nature of leak.
tube it supports, Fig. 2.
TUBE REPAIR
2. Repeat Step 1 for each fin and measure loose
fin area. The radiator should be scrapped if Tube leaks are repaired by sealing each end of
loose fin area exceeds limits specified under the defective tube with solder, thus eliminating it
Service Data. from service . When loose fins leave more than
 M.1. 549

25 .4 mm (1 ") of a tube unsupported it also 8 . Clean and flush both headers with water.
should be sealed using this method . Experience
has shown that up to 2% of the total tubes can 9 . Repeat Leak Test to assure that all leaks have
be sealed by this method without adversely been eliminated .
affecting efficiency . Use the information given
under Service Data as a guideline in determining 10. Spray all external surfaces with one coat of
whether the core is scrapped or repaired . Use this black radiator paint. See Service Data. Avoid
procedure for both solder and mechanical tube- spraying gasket and water swept surfaces .
to-header type bonds . Solder tubes closed using
the following procedure :
NOTE : Mix equal parts of radiator paint and
U.P .M . naptha.
NOTE : The recommended heating tip for melting
out old solder and applying new solder is TUBE-TO-HEADER BOND REPAIR
listed under Service Data.
The majority of tube-to-header bond leaks occur
in the outer two tube rows along the long side of
1 . Thoroughly dry inside of tubes to be re- the header . Although less common, leaks at the
paired . middle tube rows are also possible.

2. Pinch one end of each tube to be repaired NOTE : These procedures are intended to be used
closed . only on solder bond type radiator cores.
Cores which have a mechanical
tube-to-header bond are not repairable
NOTE : Use brass plugs to close tubes on mechan-
using this method.
ical tube-to-header type bonded cores.
Repair procedures are similiar for both outer and
3 . Clean tube with zinc chloride flux. See middle tube rows. The primary difference being
Service Data. When applying flux, play a the area from which the old solder is melted out.
medium flame on the fluxed surfaces. The Repair of outer tube rows requires solder removal
heating will boil the flux thus improving its from only the two outer tube rows on each side
cleaning ability . Use a soft wire brush to of the core, a total of four tube rows. Middle
scrub and clean the areas which are being tube row failures require that the entire area of
prepared for soldering . solder in the header be melted out . The recom-
mended heating tip for melting out old solder
and applying new solder is listed under Service
4. When the tube is thoroughly cleaned, solder Data.
pinched (plugged) end with a 50% tin, 50%
lead soft solder, and a 243 ° C (470° F) flame . While repairing tube-to-header bond failures, it is
See Service Data. critical that the header be kept in a position
which is square with the tubes. A cocked header
will cause a load on the tube-to-header bond,
5. Flush each soldered tube to avoid trapping
causing premature failure .
unused flux inside.
When repairing an outer tube row failure, the
6. Thoroughly dry inside of tube. header is held square by the solder which has not
been removed from the middle tube rows. To
repair a middle tube row failure a clamping
7. Turn core and solder opposite end of tube as fixture, Fig. 3, should be constructed to hold the
described above. header square while repairs are made.
M .l. 549

Top And Bottom Angle

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7 Holes (Top And
Bottom Angle)
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(1 .125")
28 .58 mm

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_44 .5 mm x44 .5 mm x7 mm
(1 .75" x 1 .75" x .25") Angle

DIMENSION CHART

CORE I A I B I C I D I E I F I G I H

1162 mm ± .3 1149 .4 mm 990 .6 mm 965 .2 , mm 1136 .7 mm 482 .6 mm 154 .8 mm 154 .8 mm

8-Row (45 .75"± .0 1)1(45 .25")1( 39)1(38 ') (44 .75") 1 (119) 1 (6 .093") (6 .093")

6-Row 1400 .2 mm ± .3 1387 .5 mm 889 mm 863 .6 ,mm 1374 .8 mm 431 .8 , mm 103 .2 mm 154 .8 mm
(double length) (55 .125" ± .01) I (54 .625") I (35) (34 ') I (54 .125") I (17 ') (4 .062") (6 .093")

6-Row 697 .2 mm ± .3 684 .5 mm 889 mm 863 .6 mm 671 .8 mm 431 .8, mm 103 .2 mm 154 .8 mm
(single length) (27 .45" ± .01) I (26 .95") (35") I (34 1 ) (26 .45") (17 ') (4 .062") (6 .093")

20834
Fig. 3 - Header Clamping Fixture (2 Required)
 M .l . 549

OUTER TUBE ROW REPAIR NOTE: When applying flux, play a medium flame
on the fluxed surfaces . The heating will
A leak detected within the first two outer tube boil the flux thus improving its cleaning
rows may be repaired using the following ability . Use a soft wire brush to scrub and
procedure : clean the areas which are being prepared
for resoldering .
1 . With the core resting on both header flanges
and the tubes in the horizontal position :
d. Repeat Step c using clean flux. This will
remove any remaining dirty flux.
a. Melt the solder from the first two outer
tube rows nearest the surface the core is
2. With the core resting on one header and the
resting on. The cross hatching in Fig. 4
tubes in the vertical position :
indicates the area from which solder is to
be removed . Melt solder out by playing a
a. Run a length of No. 7, 3 .2 min (1/8")
327° C (620° F) flame over the area. The
diameter silver wire solder along each tube
melted solder will run out of the dish,
row . See Service Data. Use a 327° C (620°
over the header flange, and out .
F) flame to sweat this solder into the
tube-to-header joints. See Fig. 5 .
b. Turn core over so that the two unmelted
rows which were at the top are now Silver Solder,
Header Tube Tube-To-Header
nearest the surface that the core is resting Puddle Solder
Joint
on. Repeat Step a.

c. Clean all surfaces that are to be resoldered

with zinc chloride flux. See Service Data.
Use a syringe to ensure that all cracks,
tubes and header surfaces have been
cleaned with flux. Fig . 5 - Radiator Core Cross-Section

20835

Fig. 4 - Radiator Core Schematic

M .l. 549

b. When solder stops running, use a small 1 . Construct a clamping fixture using the dimen-
amount of flux and a wire brush to sions given in Fig. 3 .
reclean the area. Reapply solder for the
gap between the header and the first tube NOTE : The clamping fixture will keep the
row . headers square while the core is being
repaired.
c. Using 9 .5 mm (3/8") TRIBAR puddle
solder, see Service Data, and a 260° C 2. Bolt each half of the clamping fixture to the
(500° F) flame, build up a puddle with a core header flanges .
minimum depth of 4 mm (5/32") . Blend
it with increasing depth up to 6 .4 mm 3 . With the core resting on both header flanges
(1/4") at the edge of the header dish. and the tubes in the horizontal position :

d. Solder space between rows using a 3 .2 a. Melt out all solder from the tube-to-
mm (1/8") wire puddle solder, see Service header bond . Melt solder by playing a
Data, and a 260° C (500° Fj flame . 327° C (620° F) flame over the entire area
of solder. The melted solder will run out
e. Blend excess solder with a 260° C (500° of the dish over the header flange and
F) flame carefully so that it runs and out .
levels out . Make certain that the old and
new puddle solder is well blended . b. When all solder has been removed, clean
all surfaces that are to be resoldered with
f. Remove all traces of flux by immersing zinc chloride flux . See Service Data. Use a
core several times in cold water . syringe to ensure that all cracks, tubes,
and header surfaces have been cleaned
3 . Repeat Leak Test to assure that all leaks have with flux.
been eliminated .
NOTE : When applying flux, play a medium flame
4 . Spray all external surfaces with one coat of on the fluxed surfaces . The heating will
black radiator paint. See Service Data. Avoid boil the flux thus improving its cleaning
spraying gasket and water swept surfaces. ability . Use a soft wire brush to scrub and
clean the area which are being prepared
NOTE : Mix equal parts of radiator paint and for resoldering .
U.P.M . naptha .
c. Repeat Step b using clean flux. This will
MIDDLE TUBE ROW REPAIR remove any remaining dirty flux .

Use the following procedure to repair leaks in the 4. Perform Steps 2-4 under Outer Tube Row
middle tube rows: Repair .
 M.I . 549

SERVICE DATA
SPECIFICATIONS
FIN-TO-TUBE BOND
Loose Fin-To-Tube Bond - Total Area Not To Exceed . . . . . . . . . 9678 mm2 (15 sq. in.)

Loose Fin-To-Tube Bond - No Single Area To Exceed . . . . . . . . . 6452 mm2 (10 sq . in.)

TUBE REPAIR
Maximum Number Of Adjacent Tubes Required . . . . . . . . . . . . . . . . . . . . . . . . 4

Maximum Percentage Of Total Number Of Tubes Repaired . . . . . . . . . . . . . . . . . . 2%

EQUIPMENT PART NO.

Solder, Soft - 50% Tin, 50% Lead, 0 .68 kg (1 .5 lb .) Bar . . . . . . . . . . . . . . . . . 3225762

Paint, Black Radiator - Use One Part Paint With One Part U .P .M .
Naptha, 3 .78 litres (1 Gallon) Can . . . . . . . . . . . . . . . . . . . . . . . . . . . 8204764

Solder, TRIBAR - 4W Tin, 60% Lead, 11 .34 Kg (25 lb.) Bar . . . . . . . . . . . . . . 8478479

Solder, Silver Wire - 2 .5% Tin, 97% Lead, .5% Silver, 3 .2 mm

1/8") dia . No. 7, 11 .34 kg (25 lb.) Spool . . . . . . . . . . . . . . . . . . . . . . . 8478480

Solder, Puddle - 38% Tin, 62% Lead, 3 .2 mm (1/8") dia . 11 .34 kg

(25 lb.) Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8486859

Flux, Zinc Chloride - 3 .78 litres (1 Gallon) Can . . . . . . . . . . . . . . . . . . . . . . 500-FL-93

Cleaning Solutions - Quaker Solv Cleaner 76, Cecolene (trichlor

Ethylene), Or Oakite No. 31

Soldering Tip, Stainless Steel Tube - Available From National Cylinder

Gas and Blower Pipe Company, under PN 700-27-813N

7 Litho in U .S .A .