83
Reassembly
24 690 31 Rev. D
KohlerEngines.com
2. Apply camshaft lubricant to bottom surface of each
lifter. Lubricate hydraulic lifters and lifter bores in
crankcase with engine oil.
3. Note mark or tag identifying hydraulic lifters as either
intake or exhaust and cylinder 1 or 2. Install
hydraulic lifters into their appropriate locations in
crankcase. Do not use a magnet.
4. If breather reeds and stops were removed from
crankcase, reinstall them at this time and secure
with screw. Torque screw to 4.0 N·m (35 in. lb.).
Valve Stem Seals
These engines use valve stem seals on intake valves
and on exhaust valves. Use a new seal whenever valve
is removed or if seal is deteriorated or damaged in any
way. Never reuse an old seal.
Assemble Cylinder Heads
Prior to installation, lubricate all components with engine
oil, paying particular attention to lip of valve stem seal,
valve stems, and valve guides. Install following items in
order listed below using a valve spring compressor.
• Intake and exhaust valves.
• Valve spring retainers.
• Valve springs.
• Valve spring caps.
• Valve spring keepers.
Install Cylinder Heads
Torque Sequence
#1
#2
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. If all of studs were left intact, go to Step 6. If any
studs were disturbed or removed, install new studs
as described in Step 3. Do not use/reinstall any
loosened or removed studs.
3. Install new mounting stud(s) into crankcase.
a. Thread and lock mounting nuts together on
smaller diameter threads.
b. Thread opposite end of stud, with preapplied
locking compound, into crankcase, until specifi ed
height from crankcase surface is achieved. When
threading in studs, use a steady tightening motion
without interruption until proper height is
obtained. Otherwise frictional heat from engaging
threads may cause locking compound to set up
prematurely.
Studs closest to lifters must have an exposed height of
75 mm (2 15/16 in.).
Studs furthest from lifters must have an exposed height
of 69 mm (2 3/4 in.).
c. Remove nuts and repeat procedure as required.
4. Check that dowel pins are in place and install a new
cylinder head gasket (part number facing up).
5. Install cylinder head. Match numbers on cylinder
heads and crankcase. Make sure head is fl at on
gasket and dowel pins.
6. Lightly lubricate exposed (upper) threads of studs
with engine oil. Install a fl at washer and nut onto
each of mounting studs. Torque nuts in 2 stages; fi rst
to 16.9 N·m (150 in. lb.), then fi nally to 33.9 N·m
(300 in. lb.), following sequence.
Install Push Rods and Rocker Arms
NOTE: Push rods should always be installed in same
position as before disassembly.
NOTE: Two diff erent screws have been used to secure
rocker arms/pivots. Black screws are used with
heads that have a rocker pivot hole depth of
approximately 21 mm (0.83 in.). Silver screws
are used with heads that have a rocker pivot
hole depth of approximately 35 mm (1.38 in.).
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 that
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 one cylinder head, and start screws.
3. Torque black screws to 18.1 N·m (160 in. lb.).
Torque silver screws to 13.6 N·m (120 in. lb.).
4. Use a spanner wrench or rocker arm lifting tool to lift
rocker arms and position push rods underneath.
5. Repeat above steps for remaining cylinder. Do not
interchange parts from cylinder heads.
6. 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.).
Check Assembly
Important: Rotate crankshaft a minimum of 2 revolutions
to check longblock assembly and overall proper
operation.
Install Spark Plugs
1. Check gap using wire feeler gauge. Adjust gap to
0.76 mm (0.030 in.).
2. Install plug into cylinder head.
3. Torque plug to 27 N·m (20 ft. lb.).
