Disassembly/Inspection and Service 5. After torquing, rotate gear and check for freedom of movement. Make sure there is no binding. If binding occurs, loosen screws, reposition pump, retorque screws and recheck movement. 1. Remove screws securing closest connecting rod end cap. Remove end cap. 2. Carefully remove connecting rod and piston assembly from cylinder bore. 3. Repeat above procedure for other connecting rod and piston assembly. Remove Oil Pump (Style B) Oil pump is mounted inside closure plate. If service is required, continue with Disassembly, Inspection, and Reassembly. Disassembly 1. Remove screws. 2. Lift oil pump assembly from closure plate.
Remove outer gerotor gear from closure plate. 3. Ensure ball and spring remain installed in pressure relief hole of closure plate. If ball and spring fall out of pressure relief hole, see reassembly for correct installation. 4. Remove oil pump cover O-ring from groove in closure plate. Inspection Inspect oil pump housing, gear, and rotors for nicks, burrs, wear, or any visible damage. Inspect oil pump cover O-ring for cuts, nicks, or any visible damage. If any parts are worn or damaged, replace oil pump assembly and/or O-ring. Check oil pickup screen for damage or restriction, replace if necessary. Reassembly 1. Lubricate outer gerotor gear with oil.
Install outer gerotor gear through shaft of oil pump, around inner gerotor gear. Matching molding dots on inner and outer gerotor gears is not necessary and will not affect oil pump effi ciency. 2. Reinstall ball, then spring into pressure relief hole in closure plate. 3. Reinstall O-ring into groove in closure plate; make sure it is fully seated in groove. 4. Install oil pump inserting center shaft into corresponding recess in closure plate. Apply consistent downward pressure to oil pump cover, compressing oil pressure relief spring and start screws. Secure oil pump by torquing screws (in no specifi c sequence) to 7.9 N·m (70 in. lb.). 5.
After torquing, rotate gear and check for freedom of movement. Make sure there is no binding. If binding occurs, loosen screws, reposition pump, retorque screws and recheck movement. Connecting Rods Offset, stepped-cap connecting rods are used in all these engines. Inspection and Service Check bearing area (big end) for excessive wear, score marks, running and side clearances. Replace rod and cap if scored or excessively worn. Service replacement connecting rods are available in STD crankpin size and 0.25 mm (0.010 in.) undersize. An 0.25 mm (0.010 in.) undersized rod can be identifi ed by a drilled hole located in lower end of rod shank.
Always refer to appropriate parts information to ensure correct replacements are used. Inspection Piston and Rings Components and Details Remove Camshaft Remove camshaft and shims. Remove Connecting Rods with Pistons and Rings NOTE: If a carbon ridge is present at top of either cylinder bore, use a ridge reamer tool to remove it before attempting to remove piston. NOTE: Cylinders are numbered on crankcase. Use numbers to mark each end cap and connecting rod/piston assembly for reassembly later. Do not mix end caps and connecting rods. 54 KohlerEngines.com 66 690 01 Rev.
C A B J C D D E E F F G G H I Style A H Style B A Piston Ring B End Gap C Identifi cation Mark D Piston E Top Compression Ring F Middle Compression Ring G Rails H Expander I Oil Control Ring (3 Piece) J Dye Colored Stripe