Install Spark Plugs
1. Check gap using wire feeler gauge. Adjust gap to
0.76 mm (0.03 in.).
2. Install plug into cylinder head.
3. Torque plug to 27 N·m (20 ft. lb.).
Install Ignition Modules
1. Rotate ywheel to position magnet away from
ignition module bosses.
2. On engines equipped with SMART-SPARK
™
both
modules are installed with tabs out.
On engines not equipped with SMART-SPARK
™
modules are installed with spark plug lead wire from
module always away from cylinder. On cylinder 1,
single kill tab should be towards you. On cylinder 2,
single kill tab should be away from you (in).
3. Install each ignition module to crankcase bosses
with screws (hex ange or allen head, based on
model). Slide modules up as far away from ywheel
as possible and snug screws to hold them in
position.
4. Rotate ywheel to position magnet directly under
one ignition module.
5. Insert a 0.30 mm (0.012 in.) at feeler gauge
between magnet and ignition module. Loosen
screws enough to allow magnet to pull module down
against feeler gauge.
6. Torque screws to 4.0-6.2 N·m (35-55 in. lb.).
7. Repeat steps 4 through 6 for other ignition module.
8. Rotate ywheel back and forth checking for
clearance between magnet and ignition modules.
Make sure magnet does not strike modules. Check
gap with a feeler gauge and readjust if necessary.
Final air gap: 0.280/0.330 mm (0.011/0.013 in.).
Install Intake Manifold
Torque Sequence
1
2
3
4
NOTE: If wires were disconnected from ignition modules
on engines with SMART- SPARK
™
, reattach
leads and seal base of terminal connectors with
GE/Novaguard G661 or equivalent dielectric
compound. Beads should overlap between
terminals to form a solid bridge of compound. Do
not put any compound inside terminals. 24 584
15-S ignition modules have a separator barrier
between terminals. On these modules, seal base
of terminals, but it is not necessary to have
overlapping beads of sealant between
connections.
1. Install intake manifold and new gaskets or O-rings
(plastic manifold), with wiring harness attached, to
cylinder heads. Slide any wiring harness clips onto
appropriate bolts before installing. Make sure
gaskets are in proper orientation. Torque screws in
two stages, rst to 7.4 N·m (66 in. lb.), then to
9.9 N·m (88 in. lb.), using sequence shown.
2. Two-barrel manifold (carburetor) models: Route
wiring harness through mounting clip on underside
of debris shield if separated earlier. Carefully
position debris shield as rearward as possible.
3. Connect kill lead to tab terminal on standard ignition
modules.
Reassembly
82
24 690 06 Rev. JKohlerEngines.com
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