Service Manual

66
Reassembly
KohlerEngines.com 66 690 01 Rev. C
Install Intake Manifold
1. Check that gasket surfaces of intake manifold and
cylinder heads are clean and free of any nicks or
damage.
2. Install new intake manifold gaskets onto port
surfaces of cylinder heads.
3. Set intake manifold, with by-pass hose and wiring
harness attached, down into position onto gaskets
and cylinder heads. Install and fi nger tighten screws
in their appropriate locations. Make sure clamps for
wiring harness are positioned on long screw on each
side. Torque six intake manifold mounting screws in
two steps: fi rst to 7.4 N·m (66 in. lb.), fi nally to
9.9 N·m (88 in. lb.) in sequence shown.
4. Install and tighten pipe plug or temperature warning
switch, if removed previously from threaded port of
intake manifold. Use pipe sealant with Tefl on
®
(Loctite
®
592™ or equivalent) on threads. Torque to
22.6 N·m (200 in. lb.).
5. Connect wire leads to temperature warning switch,
audible alarm, and/or Oil Sentry
™
switch as
equipped.
If thermostat and thermostat housing were removed from
intake manifold, reassemble them at this time.
6. Make sure sealing surfaces of housing and manifold
are clean and free of nicks or damage.
7. Install thermostat into recess in intake manifold, so
larger spring end is down. Place a new thermostat
housing gasket onto manifold surface, aligning
screw holes. Make sure that one of notches in
gasket is aligned with by-pass slot in manifold and
thermostat housing. Do not use a substitute gasket.
Flywheel/ignition/Intake Manifold Components
A
G
B
D
F
C
E
1
2
3
4
5
6
A Thermostat Housing B Intake Manifold C Thermostat D Ignition Module
E Flywheel F Stator G Torque Sequence