Chapter 7 - Kohler Engine Service Access and Fuel System
202
Cylinder head removal
NOTE: The Cylinder head can be removed from
the #1 cylinder without removing the engine from
the vehicle. The head on #2 cylinder is too close
to the frame to allow removal of the valve cover,
so the head cannot be removed with the engine
in-place. See Figure 7.23.
NOTE: It is generally accepted practice to ser-
vice cylinder heads as a pair. If either cylinder
head or head gasket needs repair, engine
removal is recommended. The engine should
be serviced on the bench, using procedures
described in the applicable Kohler’s Service
Manual.
Engine removal
1. Remove the cargo box from the vehicle:
See Figure 7.24.
• Lift and support the cargo box.
• Pry-off the retainer that holds the lift assist cylin-
der to the cargo box.
• Carefully lower the cargo box. Use a length of
2X4 dimensional lumber to block the latch that
normally secures the cargo box in the down
position.
• Remove the nuts and bolts that secure the cargo
box to the frame using a pair of 9/16” wrenches.
• With the help of an assistant or a mechanical lift-
ing device, slide the cargo box off the back of the
frame and remove it from the vehicle.
2. Release the Camloc® fasteners that secure the
engine cover and remove the engine cover.
3. Lift and safely support the vehicle.
4. Disconnect the black cable from the negative
terminal on the battery using a 10mm wrench.
Figure 7.23
#2 valve cover trapped
in-place by upper frame channel
Figure 7.24
Remove clip
to disconnect
lift cylinder
Hinge bolt
(1 per side)
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