Install Connecting Rods With Pistons And Rings; Install Camshaft; Determining Camshaft End Play; Install Closure Plate Main Bearing And Oil Seal - Kohler CH940-CH1000 Service Manual

Install Connecting Rods with Pistons and Rings

Top of Piston
No. 1
Side
NOTE: Cylinders are numbered on crankcase. Make
sure to install piston, connecting rod and end
cap into appropriate cylinder bore as previously
marked at 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. Be certain pistons and connecting
rods are assembled exactly as shown.
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 #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 piston is facing toward
fl ywheel side of engine. Use a hammer with a rubber
grip and gently tap piston into cylinder. Be careful oil
ring rails do not spring free between bottom of ring
compressor and top of cylinder.
5. Install inner rod cap to connecting rod using two hex
fl ange screws. Tighten screws in increments to
torque specifi cations. Illustrated instructions are
provided in service rod package.
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.
6. Repeat this procedure for other connecting rod and
piston assembly.
62 690 01 Rev. C

Install Camshaft

1. Liberally apply camshaft lubricant to each cam lobe.
Lubricate camshaft bearing surfaces of crankcase
and camshaft with engine oil.
2. Position timing mark of crankshaft gear at 12 o'clock
position.
3. Slide camshaft into bearing surface of crankcase,
positioning timing mark of camshaft gear at 6 o'clock
position. Make sure camshaft gear and crankshaft
gear mesh, with both timing marks aligned.

Determining Camshaft End Play

1. Place a new closure plate gasket into position on
crankcase.
No. 2
2. Position camshaft end play checking tool over
Side
camshaft. Use a feeler gauge to check end play
between camshaft and end play checking tool.
Camshaft endplay should match specifi cations.
3. No shim is typically used from factory. However, if
camshaft end play is not within specifi ed range,
remove checking tool and shim as necessary.
Several color coded shims are available:
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.)
4. Reinstall end play checking tool and recheck end
play.

Install Closure Plate Main Bearing and Oil Seal

Main Bearing
If closure plate main bearing was removed during
servicing, install a new bearing.
1. Make sure closure plate bore for main bearing is
clean, dry, and free of nicks or burrs.
2. Install a new bearing with notch in 12 o'clock
position, using a press and driver. Make sure
bearing is fully seated against fl ange.
3. Lightly oil inside diameter of bearing.
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Reassembly
57