Reassembly Flywheel/ignition/Intake Manifold Components 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. 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. 66 KohlerEngines.com 66 690 01 Rev. C A B C D E G 1 3 5 6 F 4 2 A Thermostat Housing B Intake Manifold C Thermostat D Ignition Module E Flywheel F Stator G Torque Sequence