Reassembly Install Flywheel End Oil Seal and Camshaft Oil Seal 1. Check to make sure that there are no nicks or burrs in crankshaft and camshaft seal bores of crankcase. 2. Apply a light coat of engine oil to outside diameter of fl ywheel end oil seal. 3. Install oil seal into crankcase using a seal driver. Make sure oil seal is installed straight and true in bore, until tool bottoms against crankcase. 4. Apply a light coat of engine oil to outside diameter of camshaft oil seal. 5. Install camshaft oil seal to a depth of 1.0-1.5 mm (0.039-0.059 in.) below top of seal bore. Do not bottom seal in bore or oil passage may be obstructed. NOTE: Cylinders are numbered on crankcase.
Make sure to install piston, connecting rod and end cap into its appropriate cylinder bore, as previously marked at time of disassembly. Do not mix end caps and connecting rods. NOTE: Proper orientation of piston/connecting rod assemblies inside engine is extremely important. Improper orientation can cause extensive wear or damage. NOTE: Make sure to align chamfer of connecting rod with chamfer of its mating end cap. When installed, fl at faces of connecting rods should face each other. Faces with raised rib should be toward outside. 1. Stagger piston rings in grooves until end gaps are 120° apart. Oil ring rails should also be staggered. 2.
Lubricate cylinder bore, piston, and piston rings with engine oil. Compress rings of cylinder 1 piston using a piston ring compressor. 3. Lubricate crankshaft journals and connecting rod bearing surfaces with engine oil. 4. Make sure FLY stamping on pistons is facing towards fl ywheel side of engine. Use a hammer with rubber grip and gently tap piston down into cylinder. Be careful that oil ring rails do not spring free, between bottom of ring compressor and top of cylinder. 5. Guide lower end of connecting rod and rotate crankshaft to join two. Install rod cap to connecting rod using screws and torque in increments to 11.3 N·m (100 in. lb.). 6.
Repeat above procedure for other connecting rod and piston assembly. Install Governor Cross Shaft 1. Lubricate governor cross shaft bearing surfaces in crankcase with engine oil. Apply a small amount of grease to lips of oil seal. 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 governor shaft up in position, then place a 0.25 mm (0.010 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. 4.
Pivot governor cross shaft so bottom end faces cylinder 1 side. Install Crankshaft NOTE: Apply cellophane tape over crankshaft keyway to prevent cutting oil seal during installation. 1. Lightly lubricate lips of crankshaft seal with grease. 2. Carefully slide fl ywheel end of crankshaft into crankcase through oil seal. Install Camshaft 1. Inspect edges of camshaft keyway, make sure they are not nicked or burred. Use a seal protector (11/16") to prevent damaging seal lips, or dislodging inner spring when camshaft is installed. Cellophane tape over keyway is also recommended. 2. Lubricate camshaft bearing surfaces of crankcase and camshaft with engine oil.
Apply a small amount of grease to lips of oil seal. 3. Rotate crankshaft and position timing mark of crankshaft gear at 12 o'clock position. 4. Turn governor cross shaft clockwise until lower end of shaft contacts crankcase (cylinder 1 side). Make sure cross shaft remains in this position while installing camshaft. 5. Slide camshaft into bearing surface of crankcase, positioning timing mark of camshaft gear at 6 o'clock position. Make sure that camshaft gear and crankshaft gear mesh, and timing marks are aligned. Install Connecting Rods with Pistons and Rings Piston/Connecting Rod Details 60 KohlerEngines.com 66 690 01 Rev. C B A A Cylinder 1 B Cylinder 2