NOTE: Make sure engine is assembled using all
specified torque values, tightening sequences,
and clearances. Failure to observe specifications
could cause severe engine wear or damage.
Always use new gaskets. Apply a small amount
of oil to threads of critical fasteners before
assembly, unless a sealant or Loctite
®
is
specified or preapplied.
Make sure all traces of any cleaner are removed before
engine is assembled and placed into operation. Even
small amounts of these cleaners can quickly break down
lubricating properties of engine oil.
Check oil pan, crankcase, cylinder heads, and valve
covers to be certain that all old sealing material has
been removed. Use gasket remover, lacquer thinner, or
paint remover to remove any remaining traces. Clean
surfaces with isopropyl alcohol, acetone, lacquer thinner,
or electrical contact cleaner.
Install Flywheel End Oil Seal
1. Make sure seal bore of crankcase is clean and free
of any nicks or burrs.
2. Apply a light coat of engine oil to outside diameter of
oil seal.
3. Drive oil seal into crankcase using a seal driver.
Make sure oil seal is installed straight and true in
bore and tool bottoms against crankcase.
Install Governor Cross Shaft
1. Lubricate governor cross shaft bearing surfaces in
crankcase with engine oil.
2. Slide small lower washer onto governor cross shaft
and install cross shaft from inside of crankcase.
3. Install nylon washer onto governor cross shaft, then
start push-on retaining ring. Hold cross shaft up in
position, place a 0.50 mm (0.020 in.) feeler gauge on
top of nylon washer, and push retaining ring down
shaft to secure. Remove feeler gauge, which will
have established proper end play.
Install Crankshaft
Carefully slide flywheel end of crankshaft through main
bearing in crankcase.
Breather/Oil Pan/Oil Reservoir/Piston Components
R
W
C
A
Q
P
K
I
L
X
O
T
C
J
G
D
E
F
U
B
Y
H
V
N
M
Z
S
A
Oil Fill/Dipstick
B
Dipstick Tube
C
Oil Seal
D
Breather Gasket
E
Breather Cover
F
Flat Washer
G
Breather Reed
H
Governor Cross Shaft
I
Oil Pan Gasket
J
Piston Ring Retainer
K
Piston Pin
L
Piston
M
Piston Ring Set
N
Connecting Rod
O
Connecting Rod End
Cap
P
Camshaft
Q
Governor Gear
R
Locking Tab Thrust
Washer
S
Oil Pan
T
Oil Screen
U
Ball
V
Spring
W
Oil Pump Cover
O-ring
X
Outer Gerotor Gear
Y
Oil Pump Assembly
Z
Crankshaft
Reassembly
54
24 690 37 Rev. B
KohlerEngines.com
