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Intake Manifold Assembly Components
A
Fitting
E
Fuel Rail
I
By-Pass Hose
Install Fuel Injectors
NOTE: Ensure all parts are clean, undamaged and free
of debris and make sure electrical connectors
have seal in place.
NOTE: O-rings and retaining clips should be replaced
any time fuel injector is separated from its
normal mounting position.
1. Lightly lubricate fuel injector O-rings with clean
engine oil.
2. Push retaining clip onto fuel injector, aligning clip.
3. Press fuel injector into fuel injector cap until retaining
clip snaps into place.
4. Press fuel injector into bore in intake manifold and
rotate to original position, as noted in Disassembly/
Inspection and Service.
5. Install fuel injector bracket screw into intake manifold
and torque to 4.0 N·m (35 in. lb.).
6. Push electrical connector on fuel injector making
sure a good connection is made. Ensure injector
connector is in proper position based on
identifi cation steps made in Disassembly.
7. Repeat steps 1 through 6 for other fuel injector.
66 690 14 Rev. A
C
A
B
Intake Manifold
B
Assembly
Intake Manifold
F
Screw
D
G
I
Intake Manifold
C
Gasket
G
Fuel Injector Bracket
Install Intake Manifold Assembly
Torque Sequence
1
5
4
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 assembly down into position
onto gaskets and cylinder heads. Route wires as
noted in Disassembly. Install and fi nger tighten
screws in their appropriate locations. Make sure
clamp for wiring harness is positioned on long screw
on #2 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.
4. Install and tighten temperature warning switch, if
removed previously from threaded port of intake
manifold. Use pipe sealant with Tefl on® (Loctite
PST
592™ Thread Sealant or equivalent) on
®
threads. Torque to 22.6 N·m (200 in. lb.).
KohlerEngines.com
Reassembly
E
G
H
F
F
F
D
Wiring Harness
Fuel Injector Bracket
H
F
F
F
Screw
3
6
2
®
93
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