Install Crankshaft
Carefully slide fl ywheel end of crankshaft through main
bearing in crankcase.
Install Connecting Rods with Pistons and Rings
Piston and Connecting Rod Details
A
B
A Cylinder 1 B Cylinder 2
Connecting Rod Bolt Details
A
B
C
Type Torque
A 8 mm Straight Shank 22.7 N·m (200 in. lb.)
B 8 mm Step-Down 14.7 N·m (130 in. lb.)
C 6 mm Straight Shank 11.3 N·m (100 in. lb.)
NOTE: Cylinders are numbered on crankcase. Make
sure to install piston, connecting rod and end
cap into its 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.
NOTE: 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.
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 piston 1 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 towards
fl ywheel side of engine. Use a hammer with a rubber
grip and gently tap piston into cylinder as shown. 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 screws.
Three different types of connecting rod bolts have
been used and each has a different torque value. If 8
mm straight shank type bolts are used, torque in
increments to 22.7 N·m (200 in. lb.). If 8 mm step-
down bolts are used, torque in increments to
14.7 N·m (130 in. lb.). If 6 mm straight shank bolts
are used, torque in increments to 11.3 N·m (100 in.
lb.). Illustrated instructions are provided in service
rod package.
6. Repeat above procedure for other connecting rod
and piston assembly.
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. Turn governor cross shaft clockwise until lower end
of shaft contacts cylinder. Make sure cross shaft
remains in this position while installing camshaft.
4. 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. Install shim removed during disassembly onto
camshaft.
2. Position camshaft end play checking tool on
camshaft.
3. Apply pressure on camshaft end play checking tool
(pushing camshaft toward crankshaft). Use a feeler
gauge to measure camshaft end play between shim
spacer and checking tool. Camshaft end play should
be 0.076/0.127 mm (0.003/0.005 in.).
4. If camshaft end play is not within specifi ed range,
remove checking tool and replace 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.)
Reassembly
7324 690 06 Rev. C KohlerEngines.com
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