Kohler Comand Pro CH1000 Service Manual page 115

Install Connecting Rods with Pistons and
Rings
NOTE: The cylinders are numbered on the crankcase.
Make sure to install the piston, connecting
rod and end cap into the appropriate cylinder
bore as previously marked at disassembly.
Do not mix the end caps and connecting
rods.
NOTE: Proper orientation of the piston/connecting
rod assemblies inside the engine is extremely
important. Improper orientation can cause
extensive wear or damage. Be certain the
pistons and connecting rods are assembled
exactly as shown in Figure 10-17.
No. 1 Side
Figure 10-17. Piston and Connecting Rod
Orientation.
1. Stagger the piston rings in the grooves until the
end gaps are 120° apart. The oil ring rails should
also be staggered.
2. Lubricate the cylinder bore, piston, and piston
rings with engine oil. Compress the rings of the
#1 piston using a piston ring compressor.
3. Lubricate the crankshaft journals and connecting
rod bearing surfaces with engine oil.
4. Make sure the FLY stamping on the piston is
facing toward the fl ywheel side of the engine.
See Figure 10-18. Use a hammer with a rubber
grip and gently tap the piston into the cylinder as
shown in Figure 10-19. Be careful that the oil ring
rails do not spring free between the bott om of the
ring compressor and top of the cylinder.
Figure 10-18. FLY Mark on Piston.
No. 2 Side
Figure 10-19. Installing Piston Assembly Using
Ring Compressor Tool.
5. Install the inner rod cap to the connecting rod
using the two hex fl ange screws. Torque the
screws in increments to 11.3 N·m (100 in. lb.).
Illustrated instructions are provided in the
service rod package. See Figure 10-20.
NOTE: Align the chamfer of the connecting rod with
Figure 10-20. Torquing Connecting Rod End Cap
Screws.
the chamfer of its mating end cap. When
installed, the fl at faces of the connecting rods
should face each other. The faces with the
raised rib should be toward the outside.
Section 10
Reassembly
10
10.5