Install Air Cleaner Assembly
Torque Sequence
1, 5
4, 8
3, 7
2, 6
1. Connect breather hose to breather cover and fi tting
on adapter elbow. Route fuel line adjacent to fuel
solenoid, and secure to carburetor inlet with a clamp.
2. Install a new air cleaner gasket. Make sure all holes
align and are open.
3. Align air cleaner mounting bracket (if equipped) with
valve cover mounting holes and start screws.
4. Install air cleaner assembly onto mounting studs.
Secure with hex fl ange nuts. Torque nuts in 2
stages: fi rst to 7.3 N·m (65 in. lb.), then fi nally to
8.2 N·m (73 in. lb.), using sequence shown. Start
two mounting screws into top of intake manifold.
5. Check alignment of bracket and torque valve cover
screws as prescribed in Install Valve Covers. Torque
upper mounting screws into manifold to 9.9 N·m
(88 in. lb.).
6. Connect air cleaner hose to elbow or adapter on
carburetor and secure with a clamp.
Install Muffl er
1. Install port liners (if equipped). Install muffl er and
attaching hardware to muffl er bracket. Torque
screws to 9.9 N·m (88 in. lb.).
2. Install nuts to exhaust studs. Torque nuts to
24.4 N·m (216 in. lb.).
Install Oil Cooler (if equipped)
1. Secure adapter to closure plate with oil fi lter nipple.
Torque oil fi lter nipple to 27 N·m (20 ft. lb.).
2. Install screws and secure oil cooler to blower
housing.
Install Oil Filter and Fill Crankcase with Oil
NOTE: Make sure both oil drain plugs are installed and
torqued to specifi cations to prevent oil leakage.
1. Install oil drain plug(s). Torque plug(s) to 13.6 N·m
(10 ft. lb.). If oil drain valve is used, make sure valve
body is closed and cap is on.
2. Place new fi lter in shallow pan with open end up. Fill
with new oil until oil reaches bottom of threads. Allow
2 minutes for oil to be absorbed by fi lter material.
3. Apply a thin fi lm of clean oil to rubber gasket on oil
fi lter.
4. Refer to instructions on oil fi lter for proper
installation.
5. Fill crankcase with new oil. Level should be at top of
indicator on dipstick.
6. Reinstall oil fi ll cap/dipstick and tighten securely.
Connect Spark Plug Leads
Connect leads to spark plugs.
Prepare Engine for Operation
Engine is now completely reassembled. Before starting
or operating engine, be sure to follow these steps.
1. Make sure all hardware is tightened securely.
2. Make sure oil drain plugs, Oil Sentry
™
pressure
switch, and a new oil fi lter are installed.
3. Adjust carburetor idle speed adjusting screw as
necessary.
Testing Engine
It is recommended engine be operated on a test stand or
bench prior to installation in piece of equipment.
1. Set engine up on a test stand. Install an oil pressure
gauge. Start engine and check to be certain oil
pressure (20 psi or more) is present. Run engine at
idle for 2-3 minutes, then 5-6 minutes more between
idle and midrange. Adjust carburetor mixture settings
as necessary (as available).
2. Adjust idle speed screw and high-speed stop as
necessary. Make sure maximum engine speed does
not exceed 3750 RPM (no load).
Reassembly
68 24 690 34 Rev. DKohlerEngines.com
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