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 in order listed
below using a valve spring compressor.
● Intake and exhaust valves.
● Valve spring caps.
● Valve springs.
● Valve spring retainers.
● Valve spring keepers.
Install Cylinder Heads
Torque Sequence
1 2
NOTE: Cylinder heads must be attached with original
type of mounting hardware, using either screws,
or mounting studs with nuts and washers. Heads
are machined differently for studs than for
screws, so fastening method cannot be altered
unless heads are being replaced. Do not
intermix components.
NOTE: Match numbers embossed on cylinder heads
and crankcase.
Heads Secured With Screws
1. Check to make sure there are no nicks or burrs on
sealing surfaces of cylinder head or crankcase.
2. Install a new cylinder head gasket (with printing up).
3. Install cylinder head and start four screws.
4. Torque screws in two stages; rst to 22.6 N·m (200
in. lb.), then nally to 41.8 N·m (370 in. lb.), following
sequence shown.
Heads Secured With Mounting Studs, Nuts, and
Washers
1. Check to make sure there are no nicks or burrs on
sealing surfaces of cylinder head or crankcase.
2. If all studs were left intact, go to Step 6. If any studs
were disturbed or removed, install new studs as
described in Step 3. Do not use/reinstall any
loosened or removed studs.
3. Install new mounting stud(s) into crankcase.
a. Thread and lock 2 mounting nuts together on
smaller diameter threads.
b. Thread opposite end of stud, with preapplied
locking compound, into crankcase, until specied
height from crankcase surface is achieved. When
threading in studs, use a steady tightening motion
without interruption until proper height is
obtained. Otherwise frictional heat from engaging
threads may cause locking compound to set up
prematurely.
Studs closest to lifters must have an exposed
height of 75 mm (2 15/16 in.).
Studs furthest from lifters must have an exposed
height of 68 mm (2 3/4 in.).
c. Remove nuts and repeat procedure as required.
4. Check that dowel pins are in place and install a new
cylinder head gasket (printing up).
5. Install cylinder head. Match numbers on cylinder
heads and crankcase. Make sure head is at on
gasket and dowel pins.
6. Lightly lubricate exposed (upper) threads of studs
with engine oil. Install a new at washer and nut onto
each mounting stud. Torque nuts in two stages; rst
to 16.9 N·m (150 in. lb.), then nally to 35.5 N·m
(315 in. lb.), following sequence shown.
Install Push Rods and Rocker Arms
NOTE: Push rods should always be installed in same
position as before disassembly.
1. Note mark or tag identifying push rod as either
intake or exhaust and cylinder 1 or 2. Dip ends of
push rods in engine oil and install, making sure that
each push rod ball seats in its hydraulic lifter socket.
2. Apply grease to contact surfaces of rocker arms and
rocker arm pivots. Install rocker arms and rocker arm
pivots on one cylinder head, and start screws.
3. Torque screws to 18.1 N·m (160 in. lb.).
4. Use a spanner wrench or rocker arm lifting tool, to lift
rocker arms and position push rods underneath.
5. Repeat above steps for remaining cylinder. Do not
interchange parts from cylinder heads.
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.).
Check Assembly
Rotate crankshaft a minimum of two revolutions to check
longblock assembly and overall proper operation.
Install Spark Plugs
1. Check gap using wire feeler gauge. Adjust gap to
0.76 mm (0.030 in.).
2. Install plug into cylinder head.
3. Torque plug to 27 N·m (20 ft. lb.).
Reassembly
8124 690 07 Rev. H KohlerEngines.com
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