Kohler 5ECD Coolant Filler Neck Installation

Tacoma290

Tacoma290

Active Member
Oct 5, 2006
498
Tacoma, WA
Boat Info
340 Sundancer 2007
Engines
Twin 8.1 V-drives
I am replacing the manifold on my Kohler 5ECD, and want to be sure I am on the right track to properly install the coolant filler neck, which is threaded and made of thin brass. See photo below of the new manifold and new filler neck with the cap.
The original manifold suffered some corrosion, and the original filler neck would not come out without destroying itself. So I am going with all new.
My question is how to install this threaded fitting without deforming (destroying) this delicate little threaded brass fitting. My plan is to use a strap wrench after removing the paint over-spray on the manifold. I will tighten with the cap on (to prevent bending the brass fitting; I will use the old cap during tightening).
Any other ways to thread the fitting in, or am I on the right track?
Generator-Coolant-fill-and-Cap.jpg
 
Tacoma290 said:
I am replacing the manifold on my Kohler 5ECD, and want to be sure I am on the right track to properly install the coolant filler neck, which is threaded and made of thin brass. See photo below of the new manifold and new filler neck with the cap.
The original manifold suffered some corrosion, and the original filler neck would not come out without destroying itself. So I am going with all new.
My question is how to install this threaded fitting without deforming (destroying) this delicate little threaded brass fitting. My plan is to use a strap wrench after removing the paint over-spray on the manifold. I will tighten with the cap on (to prevent bending the brass fitting; I will use the old cap during tightening).
Any other ways to thread the fitting in, or am I on the right track?
Generator-Coolant-fill-and-Cap.jpg
Click to expand...

You should be good with your method of install. The only thing I would add is to use some Teflon tape on the threads.
 
The Teflon tape worked well. I added wraps to arrive so the the overflow fitting wound up at the right position. About one wrap was good for about 1/4 less turns.

Also solved a different challenge. One of the brass plugs with an Allen head stripped. Needed to get it out to install a sensor. The thread was fine but the 8mm hex Allen turned into a circle. The fix was was to drill the plug out a little, heat the plug, then pound in a T55 Torx socket into the plug. Came right out! Just touched up the paint afterwards.
 
Tacoma290 said:
The Teflon tape worked well. I added wraps to arrive so the the overflow fitting wound up at the right position. About one wrap was good for about 1/4 less turns.

Also solved a different challenge. One of the brass plugs with an Allen head stripped. Needed to get it out to install a sensor. The thread was fine but the 8mm hex Allen turned into a circle. The fix was was to drill the plug out a little, heat the plug, then pound in a T55 Torx socket into the plug. Came right out! Just touched up the paint afterwards.
Click to expand...
Glad that worked out for you. Next time, put a little grease on the drill bit first so it will pick up the shards that might go in the hole. Instead of using a torx bit, an easy out is cheap and much easier on anything you're working on.
 
Great advice on the drill bit. Will file that one away.
Funny that I have never gotten an easy out to work. I have about 4 sets in little plastic boxes, and none has ever worked for me. I guess we all have our kryptonite...
Is there a brand that’s worked for you?
 
Tacoma290 said:
Great advice on the drill bit. Will file that one away.
Funny that I have never gotten an easy out to work. I have about 4 sets in little plastic boxes, and none has ever worked for me. I guess we all have our kryptonite...
Is there a brand that’s worked for you?
Click to expand...
You do have to tap them in to get the initial grip some times. I don't have a particular brand, but fair warning, if you break one off in the bolt hole you won't like it. They aren't easy to drill. Be careful and don't crank it too hard. Always use a left hand drill bit to drill the pilot hole. A lot of times the bolt will come out as you're drilling.
 
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