KOHLER KDI Measuring Injector Projection

Injector Projection is what's listed in the Workshop Manual...I call this injector protrusion for better understanding.

I plan to make a Tech Talk video explaining the procedure. Until then, this video may help with understanding operation and reading a dial indicator    • How to Read Dial Indicators - Quick M...  

When should this measurement be performed? That's a great question!
Obviously, the head needs to be removed in order to make the measurement. In my opinion, there's no reason to take it apart just to measure injector protrusion...that makes no sense. But if it's apart anyway, and it has a questionable service history where it may have been reassembled with the wrong "gaskets" (shims/spacers). Or you dropped the gaskets during injector removal and aren't sure which ones went where...then you need to perform this procedure.

The head shown in this video is from a KOHLER KDI engine that has been taken apart countless times for training purposes and other demonstrations; this is why it's out of spec.

A keen observer will also notice the measurement was performed multiple times before and after adjusting gasket thickness. Measure twice, cut once or something like that. Critical measurements should always be double or tripple checked.

I'm told that whatever thickness of gasket is needed for the correct protrusion on one cylinder should be the same for the remaining cylinders. And I'll believe this is true as soon as I have enough experience measuring numerous examples...I don't have that experience yet. I'll be measuring each one until then and I suggest you do the same.

Thanks for watching! More KDI content coming soon.