91
Reassembly
24 690 31 Rev. D
KohlerEngines.com
Assemble Top Mount Control Panel
1. Install lower support control bracket with throttle
control shaft.
2. Install top mount control panel over throttle control
shaft. Secure control panel to blower housing with
screws.
3. Assemble throttle control lever and applicable
hardware to throttle control shaft.
4. Attach governor spring to previously marked hole on
governor lever.
Install Air Cleaner Assembly
Refer to Air Cleaner/Intake for air cleaner reassembly
procedure.
Heavy-Duty Air Cleaner
1. Install air cleaner assembly onto throttle body
mounting studs. Secure and torque nuts to 7.4-9.0
N·m (65.5-80 in. lb.).
2. Install and tighten two upper mounting screws
securing air cleaner to mounting bracket. Torque
screws to 9.9 N·m (88 in. lb.).
Low-Profi le Air Cleaner
1. Verify O-ring is present around machined O.D. of
throttle body and place air cleaner base onto throttle
body studs. Secure air cleaner base using three
nuts. Attach air cleaner base bracket to cylinder
heads with screws behind any control panel or
bracket. Attach air cleaner base to lower bracket with
M5 screws through lower section of base. Torque
nuts to 7.4-9.0 N·m (65.5-80 in. lb.), and lower M5
mounting screws to 2.3 N·m (20 in. lb.).
2. Install air cleaner components as described in Air
Cleaner/Intake.
Setting Initial Governor Adjustment
1. Move governor lever toward throttle body as far as it
will go (wide-open throttle) and hold in position.
2. Insert a nail into hole on cross shaft and rotate shaft
counterclockwise as far as it will turn, then torque
nut to 7.1 N·m (63 in. lb.).
Install Muffl
er
1. Install port liners (if equipped). Install exhaust
gaskets and muffl er. Install oxygen sensor, torque to
50.1 N·m (37 ft. lb.), and connect to wire harness.
2. Install remaining muffl er support hardware (screws
and nuts) and torque to 9.9 N·m (88 in. lb.).
3. Install nuts to exhaust studs. Torque nuts to 27.8
N·m (246 in. lb.).
Install Oil Cooler
1. Secure adapter to oil pan with oil fi lter nipple. Torque
oil fi lter nipple to 28.5 N·m (21 ft. lb.).
2. Verify all fuel and vent hoses are routed properly and
not pinched. Install screws to secure oil cooler to
blower housing. Torque top screw to 2.8 N·m (25 in.
lb.) and lower screw to 2.3 N·m (20 in. lb.).
Install Oil Filter and Fill Crankcase with Oil
NOTE: If testing oil pressure after completing
reassembly, install oil pressure adapter instead
of oil fi lter.
1. Prefi ll a new oil fi lter following instructions.
2. Place new fi lter in shallow pan with open end up. Fill
with new oil until oil reaches bottom of threads. Allow
2 minutes for oil to be absorbed by fi lter material.
3. Apply a thin fi lm of clean oil to rubber gasket on oil
fi lter.
4. Refer to instructions on oil fi lter for proper
installation.
5. Fill crankcase with new oil. Level should be at top of
indicator on dipstick.
6. Reinstall oil fi ll cap/dipstick and tighten securely.
Connect Spark Plug Leads
1. Connect leads to spark plugs.
Prepare Engine for Operation
NOTE: If ECU or TPS/throttle body were replaced, an
ECU Reset and TPS Learn is required. Refer to
ECU Reset and TPS Learn procedures in Fuel
System.
Engine is now completely reassembled. Before starting
or operating engine, be sure to follow steps below.
1. Make sure all hardware is tightened securely.
2. Make sure oil drain plugs, Oil Sentry
™
pressure
switch, and a new oil fi lter are installed.
3. Fill crankcase with correct amount, weight, and type
of oil. Refer to oil recommendations and procedures
in Maintenance, Specifi cations, and Lubrication
System.
4. Adjust idle speed adjusting screw as necessary.
Refer to Fuel System.
5. Turn on fuel supply.
