Kohler KDI 2504TM

INDEX
4.4 Engine starting after storage ....................................................................................................... 59
5 Information regarding discharge of liquids ....................................................................... 60
5.1 Coolant ........................................................................................................................................... 60
5.2 Engine oil ........................................................................................................................................ 61
6 Information for replacing the functional units ................................................................... 62
6.1 Injectors and injection pump replacement ................................................................................. 62
6.2 Coolant pump replacement .......................................................................................................... 70
6.3 Replace the crankshaft pulley ...................................................................................................... 71
6.4 Oil pump replacement ................................................................................................................... 72
6.5 Oil pressure valve replacement .................................................................................................... 75
6.6 Oil cooler unit and oil filter replacement ..................................................................................... 76
6.7 Fuel filter replacement .................................................................................................................. 78
6.8 Oil vapour separator replacement ............................................................................................... 79
7 Information for disassembly ............................................................................................... 81
7.1 Recommendations for disassembly ............................................................................................ 81
7.2 Electric components disassembly ............................................................................................... 81
7.3 Turbocharger disassembly ........................................................................................................... 83
7.4 Exhaust manifold disassembly ..................................................................................................... 83
7.5 Coolant recirculation components disassembly ........................................................................ 83
7.6 Crankshaft pulley disassembly .................................................................................................... 84
7.7 Lubrication circuit disassembly ................................................................................................... 85
7.8 Intake manifold disassembly ........................................................................................................ 86
7.9 Fuel system disassembly .............................................................................................................. 87
7.10 Timing system gear disassembly ................................................................................................. 89
7.11 Flange unit disassembly ............................................................................................................... 90
7.12 Cylinder head unit disassembly ................................................................................................... 90
7.13 Oil sump unit disassembly ............................................................................................................ 93
7.14 Engine block disassembly ............................................................................................................ 94
8 Information about overhauling ........................................................................................... 99
8.1 Recommendations for overhauls and tuning ............................................................................. 99
8.2 Crankcase ..................................................................................................................................... 100
8.3 Tappets and tappet housings..................................................................................................... 103
8.4 Crankshaft .................................................................................................................................... 103
8.5 Connecting rod - piston assembly ............................................................................................. 105
8.6 Cylinder head ............................................................................................................................... 108
8.7 Oil pump check ............................................................................................................................ 111
9 Assembly information ....................................................................................................... 113
9.1 Information on engine configuration ......................................................................................... 113
9.2 Assembly recommendations ...................................................................................................... 113