Reassembly NOTE: When installation is complete, tangs of two hose clamps should face outward, away from fl ywheel and slightly down. 1. Remove seal protector and/or protective tape (if used) from over keyway and make sure end of camshaft is clean and free of any nicks or damage. Install and fully seat key, squarely into keyway. Be careful not to contact camshaft seal. Test fi t cam pulley onto shaft and key; it must slide on without force or restriction. Remove pulley. 2. If water pump by-pass hose fi tting was removed previously, apply pipe sealant with Tefl on ® (Loctite ® 592™ or equivalent) on threads and tighten it into pump. Orient fi tting so outlet points in 11 o'clock position as shown.
3. Check sealing surfaces of water pump and crankcase. They must be clean and free of any nicks or damage. 4. Apply a small amount of grease in several locations to hold new water pump O-ring in place. Install a new O-ring in groove of crankcase. Do not use RTV sealant in place of O-ring, or attempt to reinstall a used O-ring. 5. Apply rubber lubricant to inner surfaces of short hose section. Assemble hose to outlet of water pump and secure with larger diameter clamp. Orient clamp so tangs extend out in 3 to 4 o'clock position. 6. Slide smaller diameter clamp onto extruded end of formed metal tube and insert this end of tube into hose section.
Position tube so its formed offset leads down and away from outlet, perpendicular to pump. Install clamp onto hose and position tangs of clamp parallel to those of fi rst clamp. 7. Holding pump assembly elevated, assemble transfer tube to 90° fi tting in crankcase as follows: a. For new/fi rst time tube installation: 1. Place a new ferrule/compression ring in 90° fi tting of crankcase and loosely install hex cap onto threads of fi tting. 2. Insert plain end of transfer tube through hex and compression ring. b. For reinstallation of an existing tube: 1. Insert end of transfer tube, with compression ring, into 90° fi tting of crankcase. 2. Start hex cap onto threaded section of fi tting.
90° fi tting in crankcase is installed and sealed at factory, in a specifi c position. Special tools and procedures are involved. Do not loosen, remove, or alter mounting position of this fi tting at any time. 8. Carefully push water pump down from raised position, thereby rotating tube 90° within end connections. Guide pump into position over O-ring; aligning two mounting pins and fi ve screw hole locations. Start screws, with longer screw nearest pump outlet. Torque screws to 9.9 N·m (88 in. lb.) in sequence shown. 9. Push down on formed tube and hold in this position to prevent it from pivoting upward when tightening hex cap. Torque hex cap to 22.6 N·m (200 in.
lb.), to secure joint connection. Support fi tting with a wrench while torquing, if possible, to prevent applying unnecessary pressure on fi tting and joint. Check that formed tube and hose section have not been pulled up. 10. Install drive belt onto cogged pulley of water pump, then around cam pulley. Slide cam pulley, with belt attached, down onto keyway end of camshaft. Be careful not to push key out of keyway and/or into seal when installing pulley. 11. Check or use a feeler gauge to see that there is at least 3.17 mm (0.125 in.) clearance between underside of pulley, and hose, tube, and clamps. Remove pulley and reposition tube or clamps if required.
Install fl at washer and screw, to secure pulley in place. Torque screw to 9.9 N·m (88 in. lb.). 66 690 01 Rev. C KohlerEngines.com 65