Reassembly Checking/Setting Camshaft End Play 1. Install shim removed during disassembly onto camshaft. 2. Position end play tool on camshaft. 3. Apply pressure on end play checking tool (pushing camshaft toward crankshaft). Use a feeler gauge to measure end play between shim and end play tool. Camshaft end play should be 0.076/0.127 mm (0.003/0.005 in.). 4. If camshaft end play is not within specifi ed range, remove original shim and reinstall end play tool. Use a feeler gauge to determine clearance between camshaft and tool. Subtract 0.100 mm (0.004 in) from measured clearance to obtain required shim thickness. Refer to table below and install shim that matches calculated thickness.
Repeat steps 1-3 to verify that correct end play exists. Camshaft Shims White: 0.69215/0.73025 mm (0.02725/0.02875 in.) Blue: 0.74295/0.78105 mm (0.02925/0.03075 in.) Red: 0.79375/0.83185 mm (0.03125/0.03275 in.) Yellow: 0.84455/0.88265 mm (0.03325/0.03475 in.) Green: 0.89535/0.99345 mm (0.03525/0.03675 in.) Gray: 0.94615/0.98425 mm (0.03725/0.03875 in.) Black: 0.99695/1.03505 mm (0.03925/0.04075 in.) Crankshaft End Play Shims Remove closure plate. If end play requires adjustment, remove original shim and install appropriate size replacement.
BLUE 0.48-0.52 mm (0.050 mm Nominal) (0.019 in.) BLACK 0.667-0.705 mm (0.686 mm Nominal) (0.27 in.) GREEN 0.8366-0.9127 mm (0.8750 mm Nominal) (0.34 in.) YELLOW 1.9652-1.1414 mm (1.1033 mm Nominal) (0.043 in.) RED 1.2938-1.3700 mm (1.3319 mm Nominal) (0.052 in.) Install Closure Plate Oil Seal Cylinder Head Torque Sequence Oil Pump Assembly Oil pump is mounted to inside of closure plate. If service was required, and oil pump was removed, refer to assembly procedures under Oil Pump Assembly in Reassembly. Governor Assembly Governor assembly is located inside closure plate. If service was required, and governor was removed, refer to assembly procedures under Governor Assembly in Reassembly.
Thrust Bearing, Washer and Shim Some specifi cations use a thrust bearing, thrust washer, and shim to control end play of crankshaft. If these items were noted during disassembly, make sure they were reinstalled in proper sequence, as illustrated. A different procedure must be followed to check and adjust crankshaft end play on these models. Race for thrust bearing presses loosely into closure plate. If it is not already installed, push it into crankshaft bore inside closure plate. Pack thrust bearing with heavy grease and stick bearing into race. Wipe some grease on face of thrust washer and stick it onto thrust bearing.
Wipe some grease on face of original shim and stick it onto thrust washer. Install closure plate onto crankcase without applying RTV sealant and secure it with only two or three fasteners at this time. Use a dial indicator to check crankshaft end play. End play should be 0.070/0.590 mm (0.0027/0.0232 in.). Shims are available in fi ve color- coded thicknesses listed below if adjustment is needed. 1. Check to make sure that there are no nicks or burrs in crankshaft bore of closure plate. 2. Apply a light coat of engine oil to outside diameter of oil seal. 3. Drive oil seal into closure plate using a seal driver. Make sure oil seal is installed straight and true in bore to depth shown.
66 690 01 Rev. C KohlerEngines.com 61 A C B A Oil Seal B 8.0 mm (0.315 in.) C Closure Plate