Service manual

65
Reassembly
62 690 01 Rev. C KohlerEngines.com
Install Cylinder Heads
Torque Sequence
22
4
4
5
5
3
3
1
1
NOTE: Match numbers embossed on cylinder heads
and crankcase.
1. Check to make sure there are no nicks or burrs on
sealing surfaces of cylinder head or crankcase.
2. Check dowel pins are in place in 2 lower locations,
and install a new cylinder head gasket, (printed side
up).
3. Install cylinder head. Make sure head is fl at on
gasket and dowel pins. Install a fl at washer on
screws in locations 1 and 3. Install spacer followed
by a fl at washer on screw in location 5. Start 5
screws.
4. Torque screws in 2 stages, fi rst to 22.6 N·m
(200 in. lb.), fi nally to 45.2 N·m (400 in. lb.) following
sequence shown.
5. Repeat procedure for opposite cylinder.
6. Make sure threads of pipe plugs for cylinder heads
are clean and dry. Install a plug into each cylinder
head above screw on location 2 and torque to 28.25
N·m (250 in. lb.).
Install Push Rods and Rocker Arms
NOTE: Push rods should always be installed in same
position as before disassembly.
1. Note mark or tag identifying push rod as either
intake or exhaust and cylinder 1 or 2. Dip ends of
push rods in engine oil and install, making sure each
push rod ball seats in its hydraulic lifter socket.
2. Apply grease to contact surfaces of rocker arms and
rocker arm pivots. Install rocker arms and rocker arm
pivots on cylinder head 1, and start 2 screws.
3. Rotate crankshaft to establish TDC on compression
stroke. Keyway should be aligned with cylinder 1.
4. Torque screws to 14.6 N·m (130 in. lb.).
5. If push rods were not already seated, use a spanner
wrench or rocker arm lifting tool, to lift rocker arms
and position push rods underneath.
6. From PTO end, rotate crankshaft 270° (3/4 turn)
counterclockwise and align crankshaft keyway with
cylinder 2. This now puts cylinder 2 at TDC on
compression stroke.
7. Repeat steps 1-5 for remaining cylinder. Do not
interchange parts from cylinder heads.
8. Rotate crankshaft to check for free operation of
valve train. Check clearance between valve spring
coils at full lift. Minimum allowable clearance is 0.25
mm (0.010 in.).
Install Valve Covers
1. Make sure sealing surfaces are clean and free of
any nicks or burrs.
2. Install and properly seat seal onto each valve cover.
3. Install valve covers on same side as they were
originally installed.
4. Install a new grommet on each valve cover mounting
screw. Start each screw into hole.
5. Check position of each cover and seal, then torque
screws to 13.6 N·m (120 in. lb.).
6. Install oil fi ll cap onto valve cover (if equipped).
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.).
12