Kohler KDI Series

8
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_07ED0053029590
INDEX
8.5 Connecting rod-piston 122
8.5.1 Connecting rod dimension check 122
8.5.2 Checking the gudgeon pin-pin axes are parallel 123
8.5.3 Piston rings check 123
8.5.4 Piston dimension check 123
8.6 Cylinder head 124
8.6.1 Flatness check 124
8.6.2 Valve seats check 125
8.6.3 Valve springs 125
8.6.4 Valve guides check 125
8.6.5 Valve guides replacement 126
8.6.6 Rocker arm check 126
8.7 Oil pump check 127
8.7.1 Dimensional and visual check 127
8.7.2 Rotors clearance check 127
8.7.3 Oil pressure valve check 128
9 ASSEMBLY INFORMATION 129
9.1 Information on engine conguration 129
9.2 Assembly recommendations 129
9.3 Short block assembly 130
9.3.1 Crankshaft bushings 130
9.3.2 Tappets 130
9.3.3 Camshaft 130
9.3.4 Oil spray nozzles 131
9.3.5 Crankshaft 131
9.3.6 Lower crankcases 131
9.3.7 Rings 133
9.3.8 Piston 133
9.3.9 Piston and connecting rod unit 134
9.3.10 Crankshaft oil seal ange 136
9.3.11 3rd PTO cover 136
9.4 Oil sump unit assembly 137
9.4.1 Oil vapour pipes 137
9.4.2 Oil suction pipe 137
9.4.3 Oil Sump 137
9.5 Flange unit assembly 138
9.5.1 Flange bell 138
9.5.2 Flywheel 138
9.6 Timing system gear assembly and injection pump assembly 139
9.6.1 Timing system gears 139
9.6.2 High-pressure fuel injection pump 140
9.7 Cylinder head unit assembly 141
9.7.1 Valve stem gasket 141
9.7.2 Electronic injector sleeves 141
9.7.3 Electronic injector projection
141
9.7.4 Valves 142
9.7.5 Cylinder head 142
9.7.6 Valve rods and bridges 144
9.7.7 Rocker arm 145
9.7.8 Rocker arm gudgeon unit 145
9.7.9 Rocker arm cover 146
9.8 Fuel system assembly 146
9.8.1 Fuel lter 146
9.8.2 Common Rail 147
9.8.3 Electronic injectors 147
9.8.4 High-pressure fuel lines 148
9.8.5 Fuel return tubes 148
9.9 Intake manifold assembly 149
9.9.1 Internal half-manifold 149
9.9.2 External half-manifold 150
9.10 Exhaust manifold assembly 150