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Install Hydraulic Lifters
NOTE: Hydraulic lifters should always be installed in
same position as before disassembly.
1. Refer to Disassembly/Inspection and Service for
lifter preparation (bleed down) procedures.
2. Apply camshaft lubricant (see Tools and Aids) to
bottom surface of each lifter. Lubricate hydraulic
lifters and lifter bores in crankcase with engine oil.
3. Install lifters into their respective lifter bores
according to location and cylinder number marked
during disassembly. Do not use a magnet.
Valve Stem Seals
These engines use valve stem seals on intake and
exhaust valves. Always use new seals whenever valves
are removed from cylinder head. Seals should also be
replaced if worn or damaged. Never reuse an old seal.
Assemble Cylinder Heads
Prior to installation, lubricate all components with engine
oil, paying particular attention to lip of valve stem seal,
valve stems and valve guides. Install following items in
order listed below using a valve spring compressor.
● Valve stem seals
● Intake and exhaust valves
● Valve spring caps
● Valve springs
● Valve spring retainers
● Valve spring keepers
Install Cylinder Heads
Cylinder Head Torque Sequence
3
1
A
2
A
Cylinder Head 1
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.
66 690 14 Rev. A
3
1
4
4
2
B
Cylinder Head 2
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
®
and torque screws to 11.3 N·m (100 in. lb.).
4. Use a spanner wrench or rocker arm lifting tool (see
Tools and Aids) 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.
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).
Install Valve Covers
1. Make sure sealing surfaces of cylinder heads and
valve covers are clean and free of all old gasket
material.
B
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 #2 cover, and fi nger
tighten only. Upper screws will be installed with air
cleaner bracket.
KohlerEngines.com
Reassembly
to bottom 4 or 5 threads. Then install
®
91
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