Kohler KDW 2204 - Cylinder Head Tightening For Engines Without Hydraulic Tappets; Cylinder Head Tightening Steps; Assembling And Tightening The Cylinder Head On Engines With Hydraulic Tappets

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KDW 1603
KDW 2204
2204/T
Disassembly / Reassembly
Cylinder head tightening for engines without hydraulic
tappets
Useatorquewrench(ttedwithtoolforangulartightening).
Itisrecommendedtoreplacethescrewswhenever theheadis
disassembled.
 Important
The cylinder head must never be retightened.
It is advisable to lubricate the lower part of the screws with
anti-seize of the type MOLYSLIP AS COMPOUND 40.
Cylinder head tightening steps
Following the number sequence shown in the gure 57 bolts
should be tightened in four susequent steps with the following
torquevalues:
1ststep=40Nm
2ndstep=70Nm
3rdstep=100Nm
4thsteps= For bolts 10 R: Rotate wrench by 180° (in two
steps90°+90°)
 For bolts 12 R (present only in the TURBO
engines):performarotationofthekeyof270°(in
threesteps,90°+90°+90°).
Assembling and tightening the cylinder head on engines
with hydraulic tappets
Important
Before re-assembling the cylinder head the tappets must be
removed from their housing and released.
Thisoperationmustbecarriedoutusingapin1.
Insertpin1 insidethetappetandopenthenon-returnvalve.
Theexcessoilisreleasedbyturningthetappetupsidedown.
Rotatethecrankshaftsoastopositionthepistonsathalfstroke
forthree-cylinderengines.
Forfour-cylinderengines,placethepistonofcylindernumberone
at150°afterthetopdeadcentre(incrossoverstage).
Fitthehead,insertthefasteningscrewsandtightentheminthe
order shown in gure 57 and to their respective torques (see
“CylinderHeadTighteningStage).
Reassemblethecompletepininsertingtheseatsoftherocker-armsontheirrespectiverodsandscrewupthefasteningscrews
ofthesupportsbyhand.
Important
To avoid bending the push rods or damaging the tappets, the fastening screws of the rocker-arm pin supports must be
tightened gradually before reaching the nal torque.
Thisprocedurewillgivetimefortheexcessoilinthetappetstodrainaway.
Eachtimeyoustarttotightenupthefasteningscrewsofthesupports,youcanusetheupperspringsupportcupofthevalvespring
asanindicatortoknowhowfartoscrewthemup.
Thecupmustneverbecompressedsomuchthatittouchesthevalvestemoilsealingringttedontheguide.
Workshop Manual KDW 1603_2204_2204/T _ cod. ED0053029180 - 1° ed_rev. 00