Service Manual

48
Disassembly/Inspection and Service
KohlerEngines.com 66 690 01 Rev. C
Remove Intake Manifold, Thermostat Housing, By-
pass Hose and Wiring Harness
1. Disconnect by-pass hose from fi tting on water pump.
2. Remove six mounting screws and carefully separate
intake manifold from cylinder heads, with by-pass
hose and wiring harness attached.
3. Remove intake manifold gaskets.
4. Further disassembly of intake manifold components
may be performed as necessary. If thermostat is to
be removed, loosen and remove screws securing
thermostat housing to intake manifold. Separate
housing and remove thermostat, discard old gasket.
Water Pump Components
C
A
E
B
D
A O-ring B Water Pump
C Water Pump Belt D Camshaft Pulley
E Transfer Tube
Remove Camshaft Pulley and Water Pump Belt
1. Remove screw and fl at washer, securing cogged
drive pulley to camshaft.
2. Carefully lift pulley off camshaft and remove belt
from water pump pulley.
3. Remove camshaft key from keyway.
Remove Water Pump and Transfer Tube
1. Loosen and unscrew hex cap section securing
transfer tube to 90° fi tting in crankcase. Support
fi tting with a wrench, when loosening hex cap
section.
2. Remove screws securing water pump to crankcase.
3. Lift water pump up, and carefully work ferruled end
of transfer tube out of fi tting. Remove water pump
with transfer tube and hose section attached.
Remove and discard O-ring from within channel of
pump housing.
4. Inspect and, if necessary, separate transfer tube and
hose section from water pump. Remove hose
clamps, noting their size differences and position of
tangs.
IMPORTANT: 90° fi tting in crankcase, which transfer
tube is connected to, is sealed and installed at
factory in a specifi c position. Do not loosen, remove,
or alter mounted position of this fi tting at any time.
Contact factory service department for specifi c
instructions if fi tting is damaged, or its mounting is
affected in any way.
Inspection and Service
Water Pump Details
A
B
A Impeller B Drive Pulley
Water/coolant pump consists of a sealed impeller
assembly, which includes outer cover and a cogged
drive pulley. When pump is mounted to crankcase,
impeller fi ts into a cast recess, and cover seals against
an O-ring outside perimeter of recess.
Impeller assembly is not serviceable, but it should be
inspected for wear or damage.
1. Inspect impeller to make sure blades are in good
condition and free of any cracks, nicks, or damage.
2. Impeller shaft should rotate smoothly, without
binding or wobbling, and there should be no sign
that coolant has leaked past shaft to outer surface of
cover.
3. Check that drive pulley is not cracked or damaged in
any way.
If your inspection causes you to doubt its reliability, water
pump assembly should be replaced. Always use a new
O-ring whenever water pump is removed. Do not reuse
old O-ring or try to use RTV in its place.