Reassembly 8. Position thermostat housing on gasket and intake manifold. Notch in manifold, gasket and thermostat housing must all be aligned. Install and torque screws to 9.9 N·m (88 in. lb.). 9. Apply rubber lubricant to inside end of upper radiator hose, and install hose to thermostat housing, if separated for servicing. Secure with clamp. Make sure tangs of clamp point toward cylinder 1, away from fan. NOTE: Always use a fl ywheel strap wrench or holding tool to hold fl ywheel when tightening fl ywheel fastener. Do not use any type of bar or wedge to hold fl ywheel, as component damage and personal injury could result. NOTE: Make sure fl ywheel key is installed properly in keyway.
Flywheel can become cracked or damaged if key is improperly installed. 1. Install woodruff key into keyway of crankshaft. Make sure that key is properly seated and parallel with shaft. 2. Thread starter mounting bolts into hub of fl ywheel, or use fl ywheel puller to serve as a handle and set fl ywheel in place. 3. Install screw and washer. 4. Use a fl ywheel holding tool to hold fl ywheel and torque screw to 66.4 N·m (49 ft. lb.). 5. Using a light, visually check that suffi cient clearance exists between cooling system components and bottom of fl ywheel. ● If clearance is OK, continue with installation of ignition modules.
● If clearance is insuffi cient or contact is noted, remove fl ywheel and adjust as required. Reinstall fl ywheel and recheck for adequate clearance. Install Coolant By-pass Hose (If separated from intake manifold through individual component servicing) 1. If connector fi tting for by-pass hose was removed from manifold, reinstall it at this time. Apply pipe sealant with Tefl on ® (Loctite ® 592™ or equivalent) onto threads and tighten, so fi tting faces/points toward 2 side, long intake manifold screw. 2. Attach coolant by-pass hose to fi ttings in water pump and intake manifold. Secure with clamps. 3.
Connect wire leads to temperature warning switch, audible alarm, and/or Oil Sentry switch, as equipped. Install Stator Assembly 1. Place a small amount of pipe sealant with Tefl on ® (Loctite ® 592™ or equivalent) into holes for stator mounting screws. Position stator assembly onto mounting studs so leads are at bottom, and directed out toward cylinder 1 side, in 3 o'clock position. Align mounting holes and install screws. Torque each screw to 6.2 N·m (55 in. lb.). Install Ignition Modules 1. Rotate fl ywheel magnet away from ignition module mounting bosses. 2. Install ignition modules, with ground terminal out, onto crankcase mounting bosses, using screws.
Slide ignition modules away from fl ywheel as far as possible, and tighten four screws. 3. Rotate fl ywheel to position magnet directly under one of ignition modules. 4. Insert a 0.25 mm (0.010 in.) fl at feeler gauge or shim stock between magnet and ignition module. Loosen screws enough to allow magnet to pull module against feeler gauge. 5. Torque screws to 4.0 N·m (35 in. lb.). 6. Repeat steps 3 to 5 for other ignition module. 7. Rotate fl ywheel back and forth checking for clearance between magnet and ignition modules. Make sure magnet does not strike modules. Recheck gap with a feeler gauge and readjust if necessary. Final air gap: 0.203/0.305 mm (0.008/0.012 in.). 8.
Connect kill leads to ignition modules. Push (bend) loop portion of clamp on cylinder 1 side back, as far as possible, for maximum clearance from fan. Install Flywheel NOTE: Before installing fl ywheel make sure crankshaft taper and fl ywheel hub are clean, dry, and completely free of lubricants. Presence of lubricants can cause fl ywheel to be overstressed and damaged when screw is torqued to specifi cations. 66 690 01 Rev. C KohlerEngines.com 67 CAUTION Damaging Crankshaft and Flywheel can cause personal injury. Using improper procedures can lead to broken fragments. Broken fragments could be thrown from engine. Always observe and use precautions and procedures when installing fl ywheel.