Disassembly/Inspection and Service 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. 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 Water Pump Components 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. 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. 48 KohlerEngines.com 66 690 01 Rev. C B A A Impeller B Drive Pulley A B C E D A O-ring B Water Pump C Water Pump Belt D Camshaft Pulley E Transfer Tube