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Reassembly
Install Water Pump, Drive Belt, and Transfer Tube
Assembly
Water Pump Components
C
A
O-ring
C
Water Pump Belt
E
Transfer Tube
Water Pump Torque Sequence
3
1
6
NOTE: A mark or dot of paint applied to top, of pulley,
indicating keyway location, will make installation
easier.
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
PST
592™ Thread Sealant or equivalent) on
®
threads and tighten it into pump. Orient fi tting so
outlet points in 11 o'clock position.
92
A
B
E
D
B
Water Pump
D
Camshaft Pulley
5
2
4
(Loctite
®
KohlerEngines.com
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 off set 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 14 Rev. A
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