Kohler 24-841-01-S Cylinder Head Gasket Kit Instruction Manual

Introduction

This manual provides essential information for the proper installation and maintenance of the Kohler 24-841-01-S Cylinder Head Gasket Kit. This kit is designed for specific Kohler Command CH18-CH22, CH620-CH641, CV18-CV22 & CV620-CV640 Model Engines. Adherence to these instructions, along with your engine's service manual, is crucial for optimal performance and longevity.

Safety Precautions

• Always disconnect the battery before performing any engine maintenance or repairs to prevent accidental starting.
• Allow the engine to cool completely before working on it to avoid burns from hot components or fluids.
• Wear appropriate personal protective equipment (PPE), including safety glasses and gloves.
• Ensure proper ventilation when working with engine fluids or cleaning agents.
• Refer to your engine's specific service manual for detailed safety warnings and procedures.

Kit Contents

The Kohler 24-841-01-S Cylinder Head Gasket Kit typically includes the following components:

• Cylinder Head Gasket
• Exhaust Gaskets
• Intake Gaskets
• O-rings
• Mounting Nuts (quantity may vary)

This image displays the complete Kohler 24-841-01-S Cylinder Head Gasket Kit. It includes the primary cylinder head gasket, smaller gaskets for exhaust and intake manifolds, rubber O-rings, and mounting nuts. These components are essential for sealing the cylinder head to the engine block and other associated parts.

Setup and Installation

Replacing a cylinder head gasket requires mechanical aptitude and specific tools. If you are not confident in your abilities, it is recommended to seek professional assistance. Always consult your engine's official service manual for precise torque specifications and step-by-step procedures.

Required Tools (General)

• Socket set and wrenches
• Torque wrench
• Scraper or gasket removal tool
• Surface cleaner/degreaser
• Straight edge and feeler gauge (for checking head flatness)

Installation Steps (Overview)

1. Preparation: Ensure the engine is cool. Disconnect the battery. Drain engine oil and coolant (if applicable). Remove any components obstructing access to the cylinder head (e.g., air cleaner, carburetor, exhaust manifold, valve cover).
2. Cylinder Head Removal: Loosen cylinder head bolts in the reverse order of the tightening sequence specified in your engine manual. Carefully remove the cylinder head.
3. Gasket Removal and Surface Cleaning: Remove the old head gasket and thoroughly clean both the cylinder head and engine block mating surfaces. Ensure all old gasket material, carbon deposits, and debris are removed. Inspect surfaces for damage or warpage using a straight edge.
4. New Gasket Placement: Carefully position the new Kohler cylinder head gasket onto the engine block, ensuring it aligns correctly with all bolt holes and passages. Do not use sealants unless explicitly instructed by the engine manufacturer.
5. Cylinder Head Reinstallation: Carefully place the cylinder head back onto the engine block, aligning it with the gasket and dowel pins.
6. Bolt Tightening: Install the cylinder head bolts. Tighten them in the sequence and to the torque specifications provided in your engine's service manual. This is critical for proper sealing and to prevent head warpage. Often, a multi-stage tightening process is required.
7. Reassembly: Reinstall all removed components, ensuring all connections are secure and hoses/wires are routed correctly. Refill engine oil and coolant to appropriate levels.

Operating (Post-Installation)

After completing the installation:

• Initial Startup: Start the engine and allow it to run at idle. Carefully check for any leaks around the cylinder head, exhaust, and intake manifolds.
• Monitor: Observe engine temperature and oil pressure. Listen for any unusual noises.
• Break-in: Follow any specific break-in procedures recommended by Kohler for newly installed gaskets or engine components.

Maintenance

Proper engine maintenance contributes to the longevity of your cylinder head gasket:

• Regularly check and maintain proper engine coolant levels (if applicable) to prevent overheating, which can damage head gaskets.
• Ensure the engine's cooling system is clean and functioning efficiently.
• Perform oil changes at recommended intervals using the correct type of engine oil.
• Address any engine performance issues promptly to prevent secondary damage.

Troubleshooting

If issues arise after head gasket replacement, consider the following:

• Oil or Coolant Leaks: Recheck bolt torque, inspect gasket seating, and ensure mating surfaces were clean and flat.
• Overheating: Could indicate improper gasket installation, air in the cooling system, or other cooling system issues.
• Loss of Compression: May point to an improperly sealed gasket or other internal engine damage.
• White Smoke from Exhaust: Often indicates coolant burning in the combustion chamber due to a gasket leak.
• Blue Smoke from Exhaust: Could indicate oil burning, potentially from a gasket issue or other engine wear.

For persistent issues, consult a qualified engine technician or Kohler customer support.

Specifications

Warranty Information

For specific warranty details regarding the Kohler 24-841-01-S Cylinder Head Gasket Kit, please refer to the official Kohler warranty policy or contact Kohler customer support directly. Warranty terms may vary based on purchase location and product registration.

Customer Support

If you require further assistance, have questions about installation, or need to locate correct parts for your specific engine model, please contact Kohler customer support. You may need to provide your engine's model, spec, and serial numbers for accurate assistance.

Visit the official Kohler website for contact information and support resources.