Reassembly Install 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). Cylinder Head Torque Sequence 3 1 1 3 Install Valve Covers 1. Make sure sealing surfaces of cylinder heads and valve covers are clean and free of all old gasket material. 2. Install new valve cover gaskets onto valve covers. 3. Install valve covers with gaskets in their original locations. 4. Install lower mounting screws in each cover, and fi nger tighten only. Upper screws will be installed later. 4 2 #1 #2 2 4 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. Rotate crankshaft to position piston in cylinder 1 to top dead center (TDC) on compression stroke. 3. Install a new cylinder head gasket. 4. Install cylinder 1 head onto number 1 side mounting studs. 5. Install a plain washer onto each stud and secure with a nut. 6. Torque nuts in two steps, fi rst to 16.9 N·m (150 in. lb.) and then to 33.9 N·m (300 in. lb.), using torque sequence shown. 7. Repeat installation procedure for cylinder 2 side head. Install Water Pump, Drive Belt, and Transfer Tube Assembly Water Pump Components Install Push Rods and Rocker Arms NOTE:
Push rods must always be installed in same position as before disassembly. 1. Note mark or tag identifying push rod as either intake or exhaust for cylinder 1. Lightly apply engine oil or grease to ends of push rods and install. Make sure that each push rod ball seats in its respective hydraulic lifter socket. 2. Apply grease to contacting surfaces of rocker arms and rocker arm pivots. Install rocker arms and rocker arm pivots on cylinder head. 3. Install new rocker arm screws with Dri-Loc® thread locking compound on threads. Torque screws to 11.3 N·m (100 in. lb.). When tightening, use a steady motion, without interruption, until proper torque is achieved.
Frictional heat from engaging threads may otherwise cause locking compound to set prematurely. If new screws are not available, apply Loctite ® 242 ® to bottom 4 or 5 threads. Then install and torque screws to 11.3 N·m (100 in. lb.). 4. Use a spanner wrench or rocker arm lifting tool to lift rocker arms and position push rods underneath. 5. Rotate crankshaft so piston in cylinder 2 is at top dead center on compression stroke, and repeat steps for remaining cylinder. Do not interchange parts from one cylinder head with parts from other cylinder head. Water Pump Torque Sequence 5 3 1 2 6 4 NOTE:
A mark or dot of paint applied to top, of pulley, indicating keyway location, will make installation easier. 64 KohlerEngines.com 66 690 01 Rev. C A B C E D A O-ring B Water Pump C Water Pump Belt D Camshaft Pulley E Transfer Tube