Engine Service Manual

81
Reassembly
32 690 03 Rev. I KohlerEngines.com
Install Connecting Rods with Pistons and Rings
Piston and Connecting Rod Details
A
B
A Side 1 B Side 2
Connecting Rod Screw Details
A
B
Type Torque
A Black Coating 11.3 N·m (100 in. lb.)
B
Gray Metallic
Coating
13.6 N·m (120 in. lb.)
NOTE: Cylinders are numbered on crankcase. Make
sure to install piston, connecting rod, and end
cap into its appropriate cylinder bore as
previously marked during disassembly. Do not
mix end caps and connecting rods.
NOTE: Proper orientation of piston/connecting rod
assemblies inside engine is extremely important.
Improper orientation can cause extensive wear
or damage. Be certain pistons and connecting
rods are assembled exactly as shown.
NOTE: Align chamfer of connecting rod with chamfer of
its mating end cap. When installed, fl at faces of
connecting rods should face each other. Faces
with raised rib should be toward outside.
1. Stagger piston rings in grooves until end gaps are
120° apart. Oil ring rails should also be staggered.
2. Lubricate cylinder bore, piston, and piston rings with
engine oil. Compress rings using a piston ring
compressor.
3. Lubricate crankshaft journals and connecting rod
bearing surfaces with engine oil.
4. Make sure FLY stamping on piston is facing toward
fl ywheel side of engine. Use a hammer with a rubber
or wood grip and gently tap piston into cylinder. Be
careful oil ring rails do not spring free between
bottom of ring compressor and top of cylinder.
5. Install inner rod cap to connecting rod using screws.
Two different types of coatings on connecting rod
screws have been used. If black coating, torque in
increments to 11.3 N·m (100 in. lb.). If gray metallic
coating, it is not necessary to lubricate this screw,
torque in increments to 13.6 N·m (120 in. lb.).
Illustrated instructions are provided in service rod
package.
6. Repeat above procedure for other connecting rod
and piston assembly.
Install Valve Tappets and Camshaft
NOTE: Exhaust valve tappets are located on output
shaft side of engine, while intake valve tappets
are located on fan side of engine. Cylinder
number is embossed on outside of each cylinder
on crankcase. Valve tappets should always be
installed in same position as before disassembly.
1. Apply camshaft lubricant to contact surface of valve
tappets. Note mark or tag identifying tappets and
install them in their appropriate crankcase locations.
A small amount of grease applied to stems will hold
valve tappets up until camshaft is installed.
2. Liberally apply camshaft lubricant to lobes of
camshaft. Lubricate camshaft bearing surfaces of
crankcase and camshaft with engine oil.
3. Position timing mark of crankshaft gear at 12 o’clock
position.
4. Turn governor cross shaft clockwise until lower end
(blade) is laying against bottom of cylinder. Make
sure cross shaft remains in this position while
installing camshaft.
5. Slide camshaft into bearing surface of crankcase,
positioning timing mark of camshaft gear at 6 o’clock
position. Make sure camshaft gear and crankshaft
gear mesh with both timing marks aligned.
Oil Pump Assembly
Oil pump is mounted inside oil pan. If service
was required and oil pump was removed, refer to
Disassembly/Inspection and Service procedure.
Governor Assembly
Governor assembly is located inside oil pan. If service
was required and governor was removed, refer to
Disassembly/Inspection and Service procedure.