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1. 3454 1 2X 89 41 wee Sta F 18 520 1 2X 72 854 77 90 CRANKSHAFT 2 868 3 067 50 00 M8 X 1 25 1 969 4 STUDS EXHAUST GENGINE OIL FILL amp PORT 2 DIPSTICK A o OIL FILTER Maus 30 30 REMOVAL IOUNTIN o 50 00 MOX FLYWHEEL EN ue N a SIDE PORT 1 aee ee Lo
2. 20 1 kW 27 HP e 21 6 kW 29 HP Bore ECV C168 ch Gh I CECY cle 0 C E ee ee ee 80 mm 3 15 in Fa ECY 7 ITEC VAO n 9 83 mm 3 27 in Stroke ECV6O30 EGVO3U ECV G8U ECV AO ECV ZAAO ECV ZAN iassa a 69 mm 2 72 in Displacement Ix die os TY NOR OBU cc anes raa rrer EURE EEE EE EE Ea reais Era 694 cc 42 4 cu in FEV A OEC o i ECY rren E R O E 747 cc 45 6 cu in Compression Ratio ECVBOUEC VOU EC VOU pererin E E 8 8 1 EOV OEGI ECV Di n 9 1 1 liis dT 46 kg 102 Ib Oil Capacity w filter approximate determined py oil filterand Ol Cooler i so M Pm 19 12 0 58 Angle of Operation Maximum At Full Oil Level All Directions esee 25 Blower Housing Screws into cored aluminum hole or weld nut IVI AS Te eS VOU ssa E OO 0 0 0 0 S 6 2 N m 55 in Ib into new holes 4 0 N m 35 in Ib into used holes ING FS Cs ONC sigs aay M E E E E 10 7 N m 95 in Ib into new holes 7 3 N m 65 in Ib into used holes Blower Housing Screws into extruded hole in sheet metal Mo AGG es Volgo o 2 8 N m 25 in Ib into new holes 2 3 N m 20 in Ib into used holes alle eke tele le aoe Vey 6 i 2 8 N m 25 in Ib into new holes 2 3 N m 20 in Ib into used holes Blower Hou
3. 7 3 N m 65 in Ib Bracket for Heavy Duty Air Cleaner to Intake Manifold 9 9 N m 88 in Ib Air Cleaner to Throttle Body Fastener Nut FORGIUG ispecssetaiiemecnstesentnaraniesensasininess 8 2 N m 73 in Ib Muffler M iler Ret aii INS forro pc P 27 8 N m 246 in Ib Sos 072 hela alo aed eine lament eran im erry T erry etre 50 1 N m 37 ft Ib Oil Filter laeso C R refer to filter for instructions Section 1 Safety and General Information Oil Cooler OCOT Cig let IN He POPE pecs E pH OU S toU E n RI INE 28 5 N m 21 ft Ib Oil Cooler Fastener Torque MOP FSI m 2 8 N m 25 in Ib DOLORE EOS TNE a epee cence tcc taco Eos oE m HIR DU IE erDN MENU NEN PEU ENS EDI DIES 2 3 N m 20 in Ib Piston Piston Rings and Piston Pin 35lons osPriston Pin R unnine C lt 2s02 14 Gener pen err ner anrere rer Sere ne ener ee Ther 0 006 0 017 mm 0 0002 0 0007 in Piston Pin Bore I D ur CO YO UU 17 006 17 012 mm 0 6695 0 6698 in IIa VV L e a cece dau sb aes eeee cate asea macnn E 17 025 mm 0 6703 in Piston Pin O D hc m 16 995 17 000 mm 0 6691 0 6693 in Mae EC d T 16 994 mm 0 6691 in Top Compression Ring to Groo
4. Element Cover Nut Figure 4 7 Low Profile Air Cleaner Exploded View Section 4 Air Cleaner and Air Intake System Element Mounting Nuts 3 Bracket Screws 2 Figure 4 9 Base Plate Removal on Low Profile Air Cleaner 1 Loosen the cover retaining knob and remove the cover 2 Remove the foam precleaner from the paper air cleaner element 3 Wash the precleaner in warm water with detergent Rinse the precleaner thoroughly until all traces of detergent are eliminated Squeeze out excess water do not wring Allow the precleaner to air dry 4 Saturate the precleaner with new engine oil Squeeze out all excess oil 5 Reinstall the precleaner over the paper air cleaner element 6 Reinstall the air cleaner cover Secure the cover with the retaining knob 4 3 Section 4 Air Cleaner and Air Intake System Paper Element Service Every 100 hours of operation more often under extremely dusty or dirty conditions replace the paper element See Figure 4 8 and follow these steps 1 Loosen the cover retaining knob and remove the covet 2 Remove the wing nut element cover and air cleaner element 3 Remove the precleaner from the paper element Service the precleaner a
5. 0 255 in i NI Al A Figure 10 12 Oil Seal Depth in Oil Pan Install Oil Pan Assembly Most engines use an oil pan gasket Optionally RTV sealant is used as a gasket between the oil pan and the crankcase When assembling the oil pan only use a gasket if a gasket was removed Likewise if RTV was used only replace with RTV Do Not use both Refer to Section 2 for a listing of approved sealants Always use fresh sealant Using outdated sealant can result in leakage 1 Besure the sealing surfaces have been cleaned and prepared as described at the beginning of Section 10 or in Service Bulletin 252 2 Check to make sure that there are no nicks or burrs on the sealing surfaces of the oil pan or crankcase 3 Useanew gasket or apply RTV a Foranoil pan with a gasket 1 Before installing the gasket check to make sure O ring is present in counter bore around the dowel pin b Foran oil pan with RTV 1 Apply a 1 5 mm 1 16 in bead of sealant to the sealing surface of the oil pan Verify O ring is present See Figure 10 13 for the sealant pattern Section 10 Reassembly Apply 1 5 mm 1 16 in bead of sealant Figure 10 15 Torquing Oil Pan Fasteners Install Stator and Backing Plate 1 Apply pipe sealant with Teflon Loctite 592 PST Thread Sealant or equivalent to the stator mounting holes Figure 10 13 Oil Pan Sealant Pattern 2 Position the stator aligning the mounting holes so
6. 1 This signal serves as a reference for the control of ignition timing by the ECU Synchronization of the inductive speed pickup and crankshaft position takes place during the first two revolutions each time the engine is started The sensor must be properly connected at all times If the sensor becomes disconnected for any reason the engine will quit running Service The crankshaft position sensor is a sealed non serviceable assembly If Fault Code diagnosis indicates a problem within this area test and correct as follows 1 Check the mounting and air gap of the sensor It must be 0 20 0 70 mm 0 008 0 027 in 2 Inspect the wiring and connections for damage or problems 3 Make sure the engine has resistor type spark plugs 5 8 4 Disconnect the Black connector from the ECU 5 Connect an ohmmeter between the 4 and 13 pin terminals A resistance value of 325 395 at room temperature 20 C 68 F should be obtained If resistance is correct check the mounting air gap flywheel teeth damage run out etc and fly wheel key 6 Disconnect the crankshaft position sensor connector from the wiring harness Test resistance between the terminals A reading of 325 395 O should again be obtained a If the resistance is incorrect remove the screws securing the sensor to the mounting bracket and replace the sensor b If the resistance in step 5 was incorrect but the resistance of the sensor alone w
7. 3 Lift the entire air cleaner assembly off the engine Disassemble or service as required 4 Reinstall the components in reverse order of removal 5 Reset the governor see Section 5 Low Profile Air Cleaner Optional General An optional air cleaner is the low profile air cleaner with an oiled foam precleaner which surrounds a paper element The low profile air cleaner is shown in Figure 4 6 Figure 4 6 Low Profile Air Cleaner Service Check the air cleaner daily or before starting the engine Check for and correct any buildup of dirt and debris along with loose or damaged components NOTE Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure Precleaner Service If so equipped wash and reoil the precleaner every 25 hours of operation more often under extremely dusty or dirty conditions To service the precleaner see Figures 4 7 4 8 and 4 9 and perform the following steps Air Cleaner Base Element Precleaner Air Cleaner Cover Element Cover Rubber Sleeve Seal
8. 4 Remove the intake manifold and the intake manifold gaskets See Figure 8 48 Figure 8 45 Remove Screw for Ground Terminal 1 2 Remove the four hex flange screws securing D 2 the intake manifold to the cylinder heads Note Figure 8 48 Removing Intake Manifold which screw location holds the wiring clamp See Figure 8 46 5 Leave the wiring harness attached to the manifold Remove Spark Plugs 1 Remove the spark plug from each cylinder head See Figure 8 49 T aiii v z 1 u Fs Pu Se um Figure 8 46 Remove Intake Manifold Screws 3 Unclasp the wiring harness from the clip using a screwdriver See Figure 8 47 Figure 8 49 Removing Spark Plugs Remove Cylinder Heads and Hydraulic Lifters NOTE Cylinder heads are retained using either hex flange screws or hex flange nuts and washers on studs Do not interchange or mix components 1 Remove the four hex flange screws or hex nuts and washers securing each cylinder head See Figure 8 50 Discard the screws or nuts and washers once removed Do not reuse Studs if present should only be removed if damaged or if cylinder reconditioning is necessary Once removed they must be replaced Figure 8 47 Wire Harness Clip 8 12 Figure 8 50 Removing Cylinder Head Fasteners 2 Mark the location of the push rods as either intake or exhaust and cylinder 1 or 2 Push rods should always be reinstalled in the same positions 3 Caref
9. 4 Remove the three hex flange nuts securing the Hex Flange air cleaner base See Figure 8 8 Two additional Screws lower hex flange screws must be removed from Figure 8 10 Removing Throttle Control Panel the lower air cleaner support bracket 5 Remove the base 8 3 Section 8 Disassembly Remove External Governor Controls Remove Lift Fuel Pump and Fuel Pump 1 Disconnect the governor spring attached to the Module governor lever See Figure 8 11 Note the hole location for reassembly A WA IR N N G 2 Disconnect the throttle linkage spring remove A f Explosive Fuel can cause fires the throttle linkage bushing and throttle linkage 4 and severe burns from the governor lever See Figure 8 11 Do not fill the fuel tank while the engine is hot or running Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent WARNING Explosive Fuel can cause fires and severe burns Fuel systems ALWAYS remains under HIGH PRESSURE Wa age Spring We Explosive Fuel 4 9 Governor Spring Figure 8 11 Governor Spring and Throttle Linkage
10. NOTE Ensure all parts are clean undamaged and free of debris and make sure the electrical connector has the seal in place 10 19 Section 10 Reassembly gt AL Figure 10 73 Connect the Throttle Position Sensor Install Lift Fuel Pump and Fuel Pump Module Explosive Fuel can cause fires and severe burns Do not fill the fuel tank while the engine is hot or running Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ienited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent 1 Install the lift fuel pump and lines as an assembly Connect the pulse line to the crankcase vacuum fitting See Figures 10 74 and 10 75 Figure 10 74 Install Pulse Line 10 20 2 Install the lift fuel pump to the bracket on the housing using the two hex flange screws Torque the M6 screws to 7 3 N m 68 in Ib in new holes or 6 2 N m 55 in Ib in used holes See Figure 10 75 fa 20 i a 17 J gt een iei r TCR ate Ow Lift Fuel Pu A a E Ea re de VM ted eee F 4 i Is Ie ee a mai TET E 3 f i 5 s ivt a etal Ex a e AN P TIIER Y hi F r
11. The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized Check oil BEFORE EACH USE as follows 1 Make sure the engine is stopped level and is cool so the oil has had time to drain into the sump 2 Clean the area around and beneath the oil fill cap dipstick before removing it This will help keep dirt debris and other foreign matter out of the engine See Figure 6 3 Figure 6 3 Oil Fill Cap Dipstick 3 Unscrew and remove the oil fill cap dipstick wipe off oil Reinsert the dipstick into the oil fill tube and rest the cap on the tube Do not thread the cap onto the tube 4 Remove the oil fill cap dipstick and check oil level is correct The correct oil level is between the F and L marks on the dipstick See Figure 6 4 Cil Fill Cap a Dipstick lt Figure 6 4 Oil Level Marks on Dipstick 6 2 5 If the level is low add oil of the proper type Refer to Oil Recommendations on page 6 1 and to the correct level Always check the level before adding more oil NOTE To prevent extensive engine wear or damage always maintain the oil level within the Operating Range 6 Reinstall the oil fill cap dipstick and tighten on oil fill tube Cil Disposal Protect and respect the environment Dispose of oil at your local recycling center or municipal collection center in accordance with local ordinances Changing Oil and Oil Filter Changing Oil Change
12. 2 Complete all safety interlock requirements and crank the engine for approximately 3 seconds 5 25 Section 5 EFI Fuel System 3 Remove the spark plugs and check for fuel at the tips a If there is fuel at the tips of the spark plugs the fuel pump and injectors are operating b If there is no fuel at the tips of the spark plugs check the following 1 Make sure the fuel tank contains clean fresh proper fuel 2 Make sure that the vent in the fuel tank is open 3 Make sure the fuel tank valve if so equipped is fully opened 4 Make sure the battery is supplying proper voltage 5 Check that the fuses are good and that no electrical or fuel line connections are damaged or broken 6 Test fuel pump module operation as described earlier under Fuel Pump Service Fault Codes The ECU continuously monitors engine operation against preset performance limits If the operation is outside the limits the ECU activates the MIL if equipped and stores a diagnostic code in its fault memory If the component or system returns to proper function the ECU will turn off the MIL If the MIL stays illuminated it warns the customer a fault is currently happening and dealer service is required Upon receipt the dealer technician can access the fault code s to help determine what portion of the system is malfunctioning The 4 digit fault codes available are listed on page 5 28 The codes are accessed through the key
13. Electrical System The EFI system is a 12 VDC negative ground system designed to operate down to a minimum of 6 0 volts If system voltage drops below this level the operation of voltage sensitive components such as the ECU fuel pump ignition coils and injectors will be intermittent or disrupted causing erratic operation or hard starting A fully charged 12 volt battery with a minimum of 350 cold cranking amps is important in maintaining steady and reliable system operation Battery condition and state of charge should always be checked first when troubleshooting an operational problem Keep in mind that EFI related problems are often caused by the wiring harness or connections Even small amounts of corrosion or oxidation on the terminals can interfere with the milliamp currents used in system operation Cleaning the connectors and grounds will solve problems in many cases In an emergency situation simply disconnecting and reconnecting the connectors may clean up the contacts enough to restore operation at least temporarily If a fault code indicates a problem with an electrical component disconnect the ECU connector and test for continuity between the component connector terminals and the corresponding terminals in the ECU connector using an ohmmeter Little or no resistance should be measured indicating that the wiring of that particular circuit is OK NOTE When performing voltage or continuity tests avoid putting
14. Figure 8 28 Plastic Grass Screen Remove Outer Baffles and Blower Housing 1 Disconnect the plug from the rectifier regulator See Figure 8 29 Figure 8 29 Disconnect Plug from Rectifier Regulator 8 8 2 Remove the silver plated rectifier regulator ground strap screw fastened to the crankcase The rectifier regulator does not have to be detached from the blower housing 3 Disconnect the three fuse connectors attached to the outer baffle on the starter side Allowing them to hang is fine NOTE Some engines may have two fuses mounted to a bracket above the ECU and a third in line fuse near the rectifier regulator 4 Remove the three each side hex flange screws securing the outer baffles Note the location of any lifting strap and the position of the two short screws one each side on bottom for reassembly See Figure 8 30 The coil and any hoses may remain attached to the baffle after being unplugged or disconnected 5 Remove the outer baffles See Figure 8 30 ino us y Eu d e E 171 J E T F n s Short Screw Hole W Figure 8 30 Note Location of Short Screws 6 Remove the remaining hex flange screws securing the blower housing Remove the blower housing See Figure 8 31 Section 8 Disassembly y Figure 8 31 Removing Blower Housing Figure 8 33 Removing Inner Baffles Remove Oil Sentry 3 Disconnect and remove the oil temperature 1 Disconnect the lead from
15. Gear Ruonine Ceara n Aen ere ener ene Ea 0 090 0 160 mm 0 0035 0 0063 in Governor Gear Shaft O D AI E A I E T E 5 990 6 000 mm 0 2358 0 2362 in DI Wee E E aaverasscemuset peneetevaasaeevececcedenstaossdeeasscenseee 5 977 mm 0 2353 in Governor Lever Nut DOFGUP esed nid inito bd eii N PIN EN td ada Uum tue tdt 7 1 N m 63 in Ib Ignition Spark Plug Type Champion or Equivalent eee ces RC12YC XC12YC or Platinum 3071 jocis MIU uA C e S 0 76 mm 0 030 in PE TPE forro o MR H 24 4 29 8 N m 18 22 ft Ib Ienirom Oil Pas tenet FONG ones eiie atop oU ERU RR UIS UR EH nM ERE eub coU Ede IUP TUUM QUE 10 2 N m 90 in Ib Crankshaft Position Sensor Screw TOfGUP inea ssei serae a enero Lalo dor Sce ERE 6 2 Nem 55 in Ib Crankshaft Position Sensor Bracket Screw Torque aisccisscssoesdncussesosoastannssswasacuvandy 7 3 Nem 65 in Ib Crankshant POSIBORCDODDOF A Dos aped indocied I errr err nen on tne ne DUM URS mee 0 2 0 7 mm 0 008 0 027 in Electronic Control Wit aC ei TORO UC ereraa ann a Eiai e Ei 6 2 Nem 55 in Ib Intake Manifold Intake Manifold Mounting Fastener Torque ANG HS TY TO Cab ea first to 7 8 N m 69 in Ib finally to 10 5 N m 93 in Ib Eel Inieclor Cap asec Pr ME eser a E d IUE TURPE 0E 7 3 N m 65 in Ib Manifold Absolute Pressure MAP Sensor Fastener Torque
16. Guide I D 7 040 7 060 mm 0 2772 0 2780 in 7 040 7 060 mm 0 2772 0 2780 in Valve Head Diameter 33 37 33 63 mm 1 3138 1 3240 in 29 37 29 63 mm 1 1563 1 1665 in 45 1 5 mm 0 0591 in Valve Stem Diameter 6 982 7 000 mm 0 2749 0 2756 in 6 970 6 988 mm 0 2744 0 2751 in Section 9 Inspection and Reconditioning Hard starting or loss of power accompanied by high fuel consumption may be symptoms of faulty valves Although these symptoms could also be attributed to worn rings remove and check the valves first After removal clean the valve heads faces and stems with a power wire brush Then carefully inspect each valve for defects such as warped head excessive corrosion or worn stem end Replace valves found to be in bad condition A normal valve and valves in bad condition are shown in the accompanying illustrations Normal Even after long hours of operation a valve Leakage A poor grind on face or seat of valve will can be reconditioned and reused if the face and allow leakage resulting in a burned valve on one side margin are in good shape If a valve is worn to where only the margin is less than 1 32 in do not reuse it The valve shown was in operation for almost 1000 hours under controlled test conditions Bad Condition The valve depicted here should be Coking Coking is normal on intake valves and is not replaced Note the warped head margin damaged harmful If the seat is good the valve could be reus
17. The POWER light should be lit and one of the four status lights may be lit as well See Figure 7 7 This does not represent the condition of the part Power Switch KOHLE SNTES RECTIFIER REGULATOR TE Test Button Figure 7 7 Testing the Rectifier Regulator with a Tester 5 Press the TEST button until a click is heard and then release See Figure 7 7 Momentarily one of the four status lights will illuminate indicating the partial condition of the part a If the OK green light comes on the part is good and may be used b If any other light is displayed the rectifier regulator is faulty and should not be used NOTE A flashing LOW light can also occur as a result of an inadequate ground lead connection Make certain the connection location is clean and the clamp is secure 7 5 Section 7 Electrical System and Components Troubleshooting Guide 20 25 Amp Battery Charging Systems When problems occur in keeping the battery charged or the battery charges at too high a rate the problem can usually be found somewhere in the charging system or with the battery NOTE Always zero ohmmeter on each scale before testing to ensure accurate readings Voltage tests should be made with the engine running at 3600 RPM no load The battery must be good and fully charged No Charge to Battery 7 6 1 Trace B lead from rectifier regulator to key switch or other accessible connection Disconnect it from swit
18. Unsnap the plastic linkage bushing attaching the throttle linkage to the governor lever See Figure 5 24 Unhook the damper spring from the lever separate the linkage from the bushing and remove the bushing from the lever Mark the hole position and unhook the governor spring from the governor lever 2 Pivot the throttle shaft and plate assembly into the Full Throttle position Use a locking pliers needle nose works best to temporarily clamp the plate to the stop boss Alternatively there may be a stop pin instead of the stop boss See Figure 5 25 High Speed Throttle Stop Figure 5 25 Throttle Details 5 23 Section 5 EFI Fuel System 3 Rotate the governor lever and shaft Figure 5 26 Throttle Link in Center of Hole counterclockwise until it stops Use only enough pressure to hold it in that position Check how the end of the throttle linkage aligns with the bushing hole in the governor lever See Figure 5 26 It should fall in the center of the hole If it doesn t perform the adjustment procedure as follows B Setting the Initial Adjustment 1 2 5 24 Figure 5 27 Checking Split of Clamp Check the split where the clamping screw goes through the governor lever See Figure 5 27 There should be a gap of at least 1 32 in If the tips are touching and there is no gap present the lever should be replaced If not already installed position the governor lever on the cross shaft but leave
19. bad fuse or shorted connection Possible Causes 1 Corroded Connections 2 Bad Stator 3 Bad Battery a Low output charging system b Poor magnet in flywheel c Bad or missing fuse 5 33 Section 5 EFI Fuel System 0563 Troubleshooting Flow Chart The following flow chart provides an alternative System Voltage method of troubleshooting the EFI system The chart System Voltage High will enable you to review the entire system in about 10 15 minutes Using the chart the accompanying Condition Faulty voltage regulator or shorted diagnostic aids listed after the chart and any connection signaled fault codes you should be able to quickly locate any problems within the system See Figure Possible Causes 5 30 1 Faulty Rectifier Regulator 2 Bad Stator 3 Bad Battery Fault End of Code Transmission Section 5 EFI Fuel System EFI Diagnostic Flow Diagram START OF TEST PROCEED TO START OF TEST FOR RETEST KEY ON MALFUNCTION AN LIGHT NO REFER TO DIAGNOSTIC AID 1 SYSTEM POWER REFER TO DIAGNOSTIC AID 2 FAULT CODES CLEAR CODES REFER TO DIAGNOSTIC AID 43 YES NO RUN ON YES OPERATE AT VARIOUS SPEED LOAD CONDITIONS REFER TO DIAGNOSTIC YES gt AID 2 FAULT CODES ARE FAULT CODES PRESENT DOES ENGINE START NO CRANK ENGINE DOES MIL GO OFF ARE FAULT CODES PRESENT N NO CLEAR CODES END OF TEST YES KEY OFF AND KEY ON
20. clean the engine thoroughly before disassembling it Also clean individual components as the engine is disassembled Only clean parts can be accurately inspected and gauged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow the manufacturer s instructions and safety precautions carefully Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Section 3 Troubleshooting Basic Engine Tests 4 Close the shut off clamp before stopping the engine Crankcase Vacuum Test A partial vacuum should be present in the To test the crankcase vacuum with the Vacuum crankcase when the engine is operating Pressure Pressure Gauge Kit in the crankcase normally caused by a clogged or improperly assembled breather can cause oil to be 1 Remove the dipstick or oil fill plug cap forced out at oil seals gaskets or other available spots 2 Install the adapter into the oil fill dipstick tube Crankcase vacuum is best measured with either a opening EN water manometer or a vacuum gauge see Section 2 Complete instructions are provided in the kits 3 Push the barbed fitting on the gauge solidly into the hole in the adapter To test the crankcase vacuum with the manometer 4 St
21. g pring g Fuel Fire and Burns Wrap a shop towel completely around the fuel pump module 3 Loosen the hex flange nut and remove the hi a Box the vi isis buon s and bag Pul the governor lever from the cross shaft 5ee Figure connector away from the fuel pump module allowing the shop 8 12 towel to absorb any residual fuel in the high pressure fuel line Any spilled fuel must be completely wiped up immediately Lift Fuel Pump 1 Disconnect the inlet and outlet fuel lines at the lift pump See Figure 8 13 ay Outlet to Fuel erie Figure 8 12 Removing Governor Lever Figure 8 13 Lift Fuel Pump Details 2 Disconnect the pulse vacuum hose at the lift fuel pump from the crankcase 3 Remove the two hex flange screws securing the lift fuel pump to the bracket 8 4 Section 8 Disassembly Fuel Pump Module 6 Using a side cutter or similar tool cut the Oetiker 1 Remove the three screws securing the fuel pump Clamp off to remove the inlet fuel line A new module Oetiker Clamp will need to be used for reinstall See Figure 8 16 2 Liftthe grey locking tab and squeeze the tab to disconnect the electrical connector See Figure 8 14 glide Locking Tab Figure 8 16 Remove Oetiker Clamp 7 Remove three screws securing the Fuel Pump Figure 8 14 Disconnect Electrical Connector Module Baffle which the pump was mounted to 3 Disconnect the vent hose from the top of the fuel Remove Thrott
22. 0 0025 in of the desired size remove the coarse stones and replace them with burnishing stones Continue with the burnishing stones until the bore is within 0 013 mm 0 0005 in of the desired size and then use finish stones 220 280 grit and polish the bore to its final size A crosshatch should be observed if honing is done correctly The crosshatch should intersect at approximately 23 33 off the horizontal Too flat an angle could cause the rings to skip and wear excessively and too steep an angle will result in high oil consumption 5ee Figure 9 3 Figure 9 3 Cylinder Bore Crosshatch After Honing 4 After resizing check the bore for roundness taper and size Use an inside micrometer telescoping gauge or bore gauge to take measurements The measurements should be taken at three locations in the cylinder at the top middle and bottom Two measurements should be taken perpendicular to each other at each of the three locations Clean Cylinder Bore After Honing Proper cleaning of the cylinder walls following boring and or honing is very critical to a successful overhaul Machining grit left in the cylinder bore can destroy an engine in less than one hour of operation after a rebuild Section 9 Inspection and Reconditioning The final cleaning operation should always be a thorough scrubbing with a brush and hot soapy water Use a strong detergent that is capable of breaking down the machining oil while mai
23. 10 and Black 8 may be damaged or routed near noisy signal coils alternator etc b ECU to harness connection problem Component Intake Air Temperature Sensor Fault Intake Air Temperature Sensor Circuit High Voltage or Open Condition Shorted connection faulty sensor broken wire or connection Possible Causes 1 Temperature Sensor Related a Sensor wiring or connection 2 Engine Wiring Harness Related a Pin circuits ECU Black pin 10 and 8 may be damaged b ECU to harness connection problem or broken wire 5 29 Section 5 EFI Fuel System Coolant Oil Sensor Fault Coolant Oil Temperature Sensor Circuit Low Voltage Condition Shorted connection faulty sensor or shorted wire Possible Causes 1 Temperature Sensor Related a Sensor wiring or connection 2 Engine Wiring Harness Related a Pin circuits Black 10 and Black 14 maybe damaged or routed near noisy signal coils stator etc b ECU to harness connection problem Coolant Oil Sensor Fault Coolant Oil Temperature Sensor Circuit High Voltage or Open Condition Shorted connection faulty sensor open connection or broken wire Possible Causes 1 Temperature Sensor Related a Sensor wiring or connection 2 Engine Wiring Harness Related a Pincircuits ECU Black pin 10 and 14 may be damaged b ECU to harness connection problem or broken wire 3 System Related a Engine is operating above the 176 C 350 F temperature s
24. 4 Make sure the end of the governor cross shaft is that the leads are at the bottom towards the lying against the bottom of cylinder 1 inside the crankcase crankcase See Figure 10 10 3 Install and torque the two hex flange screws to 5 Install the oil pan to the crankcase Carefully seat 6 2 N m 55 in Ib for new holes or 4 0 N m the camshaft and the crankshaft into their mating 35 in Ib for used holes See Figure 10 16 bearings Rotate the crankshatt slightly to help engage the oil pump and governor gear meshes 6 Install the ten hex flange screws securing the oil pan to the crankcase Torque the fasteners in the sequence shown in Figure 10 14 to 25 6 N m 227 in Ib One of the ten mounting screws has a thread sealant patch This screw is typically installed in the number 10 hole shown in Figure 10 14 Reapply pipe sealant with Teflon Loctite 592 PST Thread Sealant or equivalent to the number 10 oil pan screw as required See Figure 10 15 Figure 10 16 Torquing Stator Screws 4 Route the stator leads in the crankcase channel then install the backing plate Secure with the four hex flange screws See Figures 10 17 and 10 18 Torque the screws 10 7 N m 95 in Ib for new holes or 7 3 N m 65 in Ib for used holes Figure 10 14 Oil Pan Fastener Torque Sequence 10 5 Section 10 Reassembly oe h Figure 10 20 Clean and Dry Flywheel Hub Install Flywheel and Fan 1 Install the woodruff
25. 86 16 5 146 40 7 360 Noncritical Fasteners Into Aluminum 81 4 60 139 7 103 219 7 162 33 9 25 61 0 45 94 9 70 Section 1 Safety and General Information English Fastener Torque Recommendations for Standard Applications Tightening Torque N m in Ib or 20 Bolts Screws Nuts and Fasteners Assembled Into Cast Iron or Steel Q Grade 2 2 3 20 3 6 32 3 6 32 7 9 70 9 6 85 17 0 150 18 7 165 29 4 260 33 9 300 Grade 5 2 8 25 4 5 40 4 5 40 13 0 115 15 8 140 28 3 250 30 5 270 Tightening Torque N m ft Ib or 20 47 5 35 61 0 45 67 8 50 94 9 70 101 7 75 135 6 100 149 2 110 189 8 140 199 3 150 271 2 200 47 5 35 54 2 40 74 6 55 101 7 75 108 5 80 142 4 105 169 5 125 223 7 165 244 1 180 311 9 230 332 2 245 440 7 325 Torque Conversions N m in lb x 0 113 N m ft Ib x 1 356 in lb N m x 8 85 ft Ib N m x 0 737 Grade 2or5 Fasteners Into Aluminum OW 2 3 20 Grade 8 18 7 165 22 6 200 39 6 350 40 7 30 67 8 50 81 4 60 108 5 80 142 4 105 155 9 115 223 7 165 237 3 175 311 9 230 352 6 260 447 5 330 474 6 350 637 3 470 Section 1 Safety and General Information 1 16 Section 2 Tools amp Aids Certain quality tools are designed to help you perform specific disassembly repair and reassembl
26. 9 Inspection and Reconditioning Figure 9 16 Oil Pump Plastic Oil Pickup and One Piece Relief Valve Reassembly 1 Install the oil pickup to the oil pump body Lubricate the O ring with oil and make sure it remains in the groove as the pickup is being installed 2 Install the rotor 3 Install the oil pump body to the oil pan and secure with the two hex flange screws Torque the hex flange screws as follows a Install fastener into location No 1 and lightly tighten to position pump b Install fastener into location No 2 and fully torque to the recommended value c Torque fastener in location No 1 to the recommended value First Time Installation 10 7 N m 95 in Ib All Reinstallations 6 7 N m 60 in Ib 9 12 4 After torquing rotate the gear and check for freedom of movement Make sure there is no binding If binding occurs loosen the screws reposition the pump retorque the hex flange screws and recheck the movement Crankcase Breather System The breather system is designed to control the amount of oil in the head area and still maintain the necessary vacuum in the crankcase Figure 9 17 Crankcase with Breather Reed A spring steel reed and stop is mounted on each bank of the crankcase between the lifter bores See Figure 9 17 When the pistons move downward air is pushed past the reeds into the cylinder head cavities On the 2 cylinder the upper end of the head is completely sea
27. C 176 F to properly adapt These adaptive values are maintained as long as the ECU is not reset During certain operating periods such as cold starts warm up acceleration high load etc a richer air fuel ratio is required and the system operates in an open loop mode In open loop operation the oxygen sensor output is used to ensure engine is running rich and the controlling adjustments are based on the primary sensor signals and programmed maps only The system operates open loop whenever the three conditions for closed loop operation above are not being met Important Service Notes e Cleanliness is essential and must be maintained at all times when servicing or working on the EFI system Dirt even in small quantities can cause significant problems e Clean any joint or fitting with parts cleaning solvent before opening to prevent dirt from entering the system e Always depressurize the fuel system through the fuel connector on fuel pump module before disconnecting or servicing any fuel system components See fuel warning on page 5 2 e Never attempt to service any fuel system component while the engine is running or the ignition switch is ON e Do not use compressed air if the system is open Cover any parts removed and wrap any open joints with plastic if they will remain open for any length of time New parts should be removed from their protective packaging just prior to installation 5 3 Section 5 EFI
28. E 7 134 mm 0 2809 in Exhaust Valve Guide I D lU 7 040 7 060 mm 0 2772 0 2780 in Max Wear TTE ott ta eect ye acne sagan uoo tee tbepuet ueste bd or o asepeg iov a abe qoe SU Ee PR DR bdeEE 7 159 mm 0 2819 in Valve Guide Reamer Size PUPA AEC E 7 050 mm 0 2776 in DER E 5 m 7 300 mm 0 2874 in Intake Valve Minimurn LEE oo oenceasppetuseotuUursou tonio Budae ouo aie turre UM a eru RR Einer 8 07 mm 0 3177 in Exhaust Valve Minimum Lift iue ura o corte pontes ou teoniorndeaincorunesadutatuassendeceuvostesauss 8 07 mm 0 3177 in INGHAM VV Seat IG Losouso rediit spo tus stesura Um ISP TOpM REOR MO TUNUO uH MOL 45 1 13 Section 1 Safety and General Information General Torque Values Metric Fastener Torque Recommendations for Standard Applications Tightening Torque N m in Ib or 10 Property Class 2 9 26 5 8 51 9 9 88 24 4 216 1 2 11 2 5 22 4 3 38 10 5 93 1 7 15 3 2 28 5 7 50 13 6 120 Tightening Torque N m ft Ib or 10 Property Class 47 5 35 82 7 61 131 5 97 M10 217 16 M12 36 6 27 M14 58 3 43 27 1 20 47 5 35 76 4 55 4 1 36 8 1 72 14 0 124 33 9 300 66 4 49 116 6 86 184 4 136 Noncritical Fasteners Into Aluminum 2 0 18 4 0 35 6 8 60 17 0 150 5 0 44 9 7
29. Engine Inspection Data Record TP 2435 are also available use these to record inspection results Camshaft Inspection and Service Check the lobes of the camshaft for wear or damage See Section 1 for minimum lift specifications The measurement must be performed while the valve train is still assembled Inspect the cam gear for badly worn chipped or missing teeth Replacement of the camshaft will be necessary if any of these conditions exist Crankshaft Inspection and Service Inspect the gear teeth of the crankshaft If the teeth are badly worn chipped or some are missing replacement of the crankshaft will be necessary Inspect the crankshaft bearing surfaces for scoring grooving etc Measure the running clearance between the crankshaft journals and their respective bearing bores Use an inside micrometer or telescoping gauge to measure the inside diameter of both bearing bores in the vertical and horizontal planes Use an outside micrometer to measure the outside diameter of the crankshaft main bearing journals Subtract the journal diameters from their respective bore diameters to get the running clearances Check the results against the specifications in Section 1 If the running clearances are within specification and there is no evidence of scoring grooving etc no further reconditioning is necessary If the bearing surfaces are worn or damaged the crankcase and or oil pan will need to be replaced Inspect
30. Fan 1 Install the fan onto the flywheel using the four hex flange screws engines with plastic grass screen For engines with a metal grass screen leave it loosely assembled NOTE Position the locating tabs on the back of the fan into the locating holes of the flywheel See Figure 10 23 2 Torque the screws to 9 9 N m 88 in Ib Section 10 Reassembly SAU SE Figure 10 23 Installing Fan Install Cylinder Heads and Hydraulic Lifters 1 See Servicing Hydraulic Lifters in Section 9 for lifter preparation bleed down procedures 2 Apply camshatt lubricant see Section 2 to the bottom surface of each lifter See Figure 10 24 Lubricate the hydraulic lifters and the lifter bores in the crankcase with engine oil Figure 10 24 Applying Camshaft Lubricant to Bottom of Lifters 3 Note the mark or tag identifying the hydraulic lifters as either intake or exhaust and cylinder 1 or cylinder 2 Install the hydraulic lifters into their appropriate locations in the crankcase Do not use a magnet See Figure 10 25 10 7 Section 10 Reassembly Ven r Figure 10 25 Installing Figure 10 26 Match Numbers on Crankcase and v b LON At ag Hydraulic Lifters NOTE Hydraulic lifters should always be installed in the same position as before disassembly The exhaust lifters are located on the output shaft oil pan side of the engine while the intake lifters are located on the fan side of the en
31. Fuel System e Avoid direct water or spray contact with system components e Do not disconnect or reconnect the ECU wiring harness connector or any individual components with the ignition on This can send a damaging voltage spike through the ECU e Do not allow the battery cables to touch opposing terminals When connecting battery cables attach the positive cable to the positive battery terminal first followed by the negative cable to the negative battery terminal e Never start the engine when the cables are loose or poorly connected to the battery terminals e Never disconnect the battery while the engine is running e Never use a quick battery charger to start the engine e Donot charge the battery with the key switch ON e Always disconnect the negative battery cable before charging the battery and also unplug the harness from the ECU before performing any welding on the equipment Electrical Components Electronic Control Unit ECU Figure 5 1 Electronic Control Unit ECU 5 4 General The ECU is the brain or central processing computer of the entire EFI system During operation sensors continuously gather data which is relayed through the wiring harness to input circuits within the ECU Signals to the ECU include ignition on off crankshaft position and speed RPM throttle position oil temperature intake air temperature exhaust oxygen levels manifold absolute pressur
32. LISTEN FOR FUEL PUMP DOES FUEL PUMP CYCL ON THEN OFF AFTER 1 2 SECONDS O REFER TO DIAGNOSTIC AID 4 CRANKSHAFT POSITION SENSOR REFER TO DIAGNOSTIC AID 5 FUEL PU Y YES NO WHILE CRANKING CHECK IGNITION SYSTEM PROCEED TO START OF TEST FOR RETEST NO REFER TO DIAGNOSTIC AID 6 IGNITION SYSTEM YES WHILE CRANKING CHECK INJECTOR FUEL DELIVERY WET SPARK PLUG NO REFER TO DIAGNOSTIC AID 7 FUEL SYSTEM ELECTRICAL YES INSTALL IN LINE PRESSURE GAUGE AND KEY ON UEL PRESSURE IN SPECIFICATION MP REFER TO DIAGNOSTIC AID 8 NO FUEL SYSTEM YES REFER TO DIAGNOSTIC AID 9 BASIC ENGINE 1 After turning key to OFF wait 10 seconds before turning to ON to allow the ECU to go to sleep 2 The fuel pump module can be heard or a vibration can be felt to establish pump cycle Fuel pump module will run for one 4 6 second cycle when ECU wakes up after being asleep Figure 5 30 Troubleshooting Flow Chart 5 35 Section 5 EFI Fuel System Flow Chart Diagnostic Aids Diagnostic Aid 1 SYSTEM POWER MIL does not illuminate when key is turned ON NOTE MIL is installed by vehicle OEM Twelve volt supply to bulb will be part of vehicle wire harness Kohler key switch model will have MIL on engine with 12V supply to bulb Possible causes l Battery 2 Main system fuse 3 MIL light bulb burned out 4 MIL electrical circuit problem Pin circuits Grey 3 5 Ignition switch 6 Permanent EC
33. Spline Drive Lubricant Kohler 25 357 12 5 2 3 Section 2 Tools amp Aids Special Tools You Can Make Flywheel Holding Tool A flywheel holding tool can be made out of an old flywheel ring gear as shown in Figure 2 1 and used in place of a strap wrench 1 Using an abrasive cut off wheel cut out a six tooth segment of the ring gear as shown 2 Grind off any burrs or sharp edges 3 Invert the segment and place it between the ignition bosses on the crankcase so that the tool bosses will lock the tool and flywheel in posi tion for loosening tightening or removing with a puller Figure 2 1 Flywheel Holding Tool Rocker Arm Crankshaft Tool A spanner wrench to lift the rocker arms or turn the crankshaft may be made out of an old junk connecting rod 1 Find a used connecting rod from a 10 HP or larger engine Remove and discard the rod cap 2 4 Remove the studs of a Posi Lock rod or grind off the aligning steps of a Command rod so the joint surface is flat Find a 1 in long capscrew with the correct thread size to match the threads in the connecting rod Usea flat washer with the correct I D to slip on the capscrew and approximately 1 in O D Kohler Part No 12 468 05 S Assemble the cap screw and washer to the joint surface of the rod as shown in Figure 2 2 Figure 2 2 Rocker Arm Crankshaft Tool Section 3 Troubleshooting Troubleshooting Guide When troubles occur be
34. a Puller Splitting 5 Remove the woodrutf key Remove Stator and Backing Plates 1 Remove the four screws securing the backing plate See Figure 8 60 Remove the backing plate m A din Figure 8 62 Removing Oil Pan Fasteners Wa 2 Locate the splitting tab cast into the perimeter Uu got of the oil pan Insert the drive end of a 1 2 in breaker bar between the splitting tab and the crankcase and turn it to loosen seal See Figure 8 62 Do not pry on the sealing surfaces as this can cause leaks Tap with a rubber mallet to finish removing the oil pan Remove the oil seal and replace at reassembly nr P 7 ni LL EL BH a n Figure 8 60 Removing Backing Plate Governor Gear Assembly The governor gear assembly is located inside the oil pan If service is required refer to the service procedures under Governor Gear Assembly in Section 9 2 Remove the two hex flange screws and the stator See Figure 8 61 Note the position routing of the stator lead Oil Pump Assembly The oil pump is mounted inside the oil pan If service is required refer to the service procedures under Oil Pump Assembly in Section 9 8 15 Section 8 Disassembly Remove Camshaft 1 Remove the camshaft and shim if used See Figure 8 63 k Figure 8 63 Removing Camshaft Remove Governor Cross Shaft 1 Remove the retainer and nylon washer from the governor cross shaft See Figure 8 64 Figure 8 64 Removing Governor Cr
35. contamination to the sensor 1 Using a voltmeter or diagnostic software observe the voltage before the engine is started With the key ON the voltage should read about 1 0 volt This voltage is generated by the ECU If it is not present disconnect the sensor and observe the voltage at the harness connector If the voltage is now present there is a short in the sensor or associated wiring and corrective action should be taken If the voltage still is not present there is a problem with the ECU or engine harness 2 Reconnect the sensor and start the engine Run the engine at sufficient speed to bring the sensor up to operating temperature Maintain for 1 to 2 minutes to ensure that the engine has gone closed loop Once in closed loop the sensor voltage should cycle between about 100 to 250 mv and 700 to 900 mv If this cycling is not observed a determination must be made If the problem is with the engine or the sensor 3 Check engine harness for battery voltage on the heater circuit Section 5 EFI Fuel System NOTE Using the diagnostic software the wiring and ECU integrity can be checked by grounding the signal wire the output of the sensor read on the software should be around 4 mv Removal Inspection 1 If the sensor has heavy deposits on the lower shield the engine oil or fuel may be the source If heavy carbon deposits are observed incorrect engine fuel control may be occurring If the sensor is at r
36. crankcase and oil filter Upper Mounting En f 3 Remove the mounting screw and detach the oil fill tube See Figure 8 3 Figure 8 6 Removing Upper Mounting Screws 8 2 Section 8 Disassembly 2 Remove the two upper screws securing the air Remove Top Mount Control Panel cleaner to the mounting bracket and remove the Remove the throttle control shaft nut on top of air cleaner assembly See Figure 8 6 the throttle shaft and remove the throttle control lever and spring See Figure 8 9 Low Profile Air Cleaner Optional 1 Loosen the cover retaining knob and remove the 2 Remove the two screws fastening the control cover See Figure 8 7 panel and remove the panel from the blower housing See Figure 8 9 3 Remove the lower throttle control bracket from the cylinder head Throne G y Control Tli LEVELER m p Figure 8 7 Removing Low Profile Air Cleaner Cover Throttle je j amp entrol Shaft NIU 2 Remove the wing nut from the element cover Figure 8 9 Removing Throttle Control Panel 3 Remove the element cover element and precleaner 5ee Figure 8 8 Remove Bottom Mount Control Panel If So Equipped Hex Flange 1 Remove the governor lever spring Nuts ee 2 Remove the four hex flange screws fastening the throttle panel and remove the panel from the cylinder heads See Figure 8 10 Throttle Control Lower Bracket Screws Figure 8 8 Removing Low Profile Element and Precleaner
37. d ane eaa N E A E EEE D ARG E e Ee alain S E A E E en eee eee ee 5 2 5 3 B e T E OO E E E E EAE E EEE E A 5 3 lapor on eaa i 0 cc RU MM M 5 3 5 4 Electrical Components Elec Tone Control OUMA ECU enerne o e E 5 4 5 5 o A eR E E E A E E E E E T 29 SCEPC AN yy T e T E E S TELE 5 5 5 7 Sor E e e a a E A E E E E SM UEM COMI UMS 5 8 Throttle Position Sensor TPS and ECU Reset and TPS Learn Procedures esses 5 8 5 10 EO ae O Te a E a a E error Teen SENE 5 10 5 11 ntake Ar enpera S O n E A aM INEO Hd tpacUn DNE 5 11 So agai OE A T E E A E A E T E A 5 12 5 14 Manifold Absolute Pressure MAP Sensor ssssessssseessssressseressseressseeessseressseeessseeessseeessseeessseesssseessseeeesseeessseeess 5 15 PSU TOT E E E E T E EE ote mecdenneaes 5 15 5 18 POY a a oats oat cc E A E E E T 5 18 5 19 e EE e N A E EEE E E ee 5 19 Bater Chareine oy SES esrara 090 9989980 M 0 0 9000 099 cones 5400000 E E RUE Sae OE UO SER DGU 5 19 Fuel Components Ee E eee E M 5 19 5 21 PUBL EISE a E E A A E ss ttnoaeadus auebscteaiciatenoecsnstscaaiochschosanutbtecosspeasseaon UNIO ION DOE 5 21 FHen Pressure E E a e E E E A E E E emer enter erin mete 5 21 5 22 Purge ror and Vent Hose Assem Diy eon Mestoleiam aedes erei nann aai EE E SAE SEE E 5 22 Throne Body Intake Manifold Assembly erriren E E cmrT TT terme Tern 5 22 lel s ee Adjustment KREM TEE OO OO O
38. drawn into the combustion chamber ignited and burned The ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor signals for engine temperature speed RPM and throttle position load These primary signals are compared to preprogrammed maps in the ECU computer chip and the ECU adjusts the fuel delivery to match the mapped values After the engine reaches operating temperature an exhaust gas oxygen sensor provides feedback to the ECU based upon the amount of unused oxygen in the exhaust indicating whether the fuel mixture being delivered is rich or lean Based upon this feedback the ECU further adjusts fuel input to re establish the ideal air fuel ratio This operating mode is referred to as closed loop operation The EFI Section 5 EFI Fuel System system operates closed loop when all three of the following conditions are met a The oil temperature is greater than 60 C 140 F b The oxygen sensor has warmed sufficiently to provide a signal minimum 400 C 752 F c Engine operation is at a steady state not starting warming up accelerating etc During closed loop operation the ECU has the ability to readjust temporary and learned adaptive controls providing compensation for changes in overall engine condition and operating environment so it will be able to maintain the ideal air fuel ratio The system requires a minimum engine oil temperature greater than 80
39. filter to drain Before removing the oil filter clean the area around the oil filter to keep dirt and debris out of the engine Remove the old filter Wipe off the surface where the filter mounts Section 6 Lubrication System 4 Place a new replacement filter in a shallow pan with the open end up Pour new oil of the proper type in through the threaded center hole Stop pouring when the oil reaches the bottom of the threads Allow a minute or two for the oil to be absorbed by the filter material 5 Apply a thin film of clean oil to the rubber gasket on the new filter 6 Install the new oil filter to the filter adapter or oil cooler Refer to the oil filter for installation instructions 7 Reinstall the drain plug Make sure it is tightened to 13 6 N m 10 ft 1b torque 8 Fill the crankcase with new oil of the proper type to the F mark on the dipstick 9 Test run the engine to check for leaks Stop the engine allow a minute for the oil to drain down and recheck the level on the dipstick Make sure oil level is up to but not over the F mark on the dipstick Service Oil Cooler Some engines are equipped with an optional oil cooler Inspect and clean oil cooler every 100 hours of operation more frequently under severe conditions Oil cooler must be kept free of debris To service the oil cooler clean the outside of fins with a brush or compressed air Remove the hardware holding the cooler unit to the blowe
40. ft Ib Drain Plug Figure 10 93 Install Oil Drain Plug s NOTE Make sure that both oil drain plugs are installed and torqued to the above specifications to prevent oil leakage Section 10 Reassembly 5 Add oil to bring the level up to the F mark and reinstall the dipstick Connect Spark Plug Leads 1 Connect the leads to the spark plugs See Figure 10 94 Figure 10 94 Connect Spark Plug Leads Prepare the Engine for Operation The engine is now completely reassembled Before starting or operating the engine be sure to do the following 1 Make sure all hardware is tightened securely 2 Make sure the oil drain plugs Oil Sentry pressure switch and a new oil filter are installed 3 Fill the crankcase with the correct amount weight and type of oil Refer to oil recommendations and procedures in the Safety and General Information and Lubrication System sections 4 Adjust the idle speed adjusting screw as necessary Refer to Section 5 Electronic Fuel Injection System 5 Turn on fuel supply NOTE If the ECU throttle body TPS or fuel pump module were replaced an ECU Reset and TPS Learn is required See Section 5 for the ECU Reset and TPS Learn procedure 10 25 Section 10 Reassembly Sensitivity Adjustment Governor sensitivity is adjusted by repositioning the governor spring in the holes of the governor lever If speed surging occurs with a change in engine load the governor is se
41. fuel pump module is not serviceable and must be replaced if determined to be faulty If a fuel pump problem is suspected make certain the pump is being activated all electrical connections are properly secured the fuses are good and a minimum of 7 0 volts is being supplied If during cranking voltage drops below 7 0 volts a reduction of fuel pressure may occur resulting in a lean starting condition If required testing of the fuel pump may be conducted 1 Relieve fuel pressure at the fuel pump module following the instructions on page 5 2 The fuel pump module may need to be loosened or pulled away from the engine Disconnect the fuel coupler from the fuel pump module and insert the pressure test jumper from Kohler EFI Service Kit between the high pressure fuel line and the fuel pump module 2 Connect the black hose of Pressure Tester part of EFI Service Kit see Section 2 Route the clear hose into a portable gasoline container or the equipment fuel tank 3 Turn on the key switch to activate the pump and check the system pressure on the gauge It may take several key cycles to compress the air introduced into the system and reach regulated pressure If system pressure of 39 psi 3 is observed the wiring fuel pump and regulator are working properly Turn key switch OFF and depress the valve button on the tester to relieve the system pressure a If the pressure is too high replace the fuel pump module b If the pr
42. fuel system Clogged fuel line or fuel filter Loose or faulty wires or connections Faulty spark plugs Low compression Weak spark Fuel pump malfunction causing lack of fuel Engine overheated cooling air circulation restricted Quality of fuel Flywheel key sheared Intake system leak Faulty or improperly adjusted throttle controls Engine Will Not Crank b m e uo NI oe ps PTO drive is engaged Battery is discharged Safety interlock switch is engaged Loose or faulty wires or connections Faulty key switch or ignition switch Faulty electric starter or solenoid Seized internal engine components Blown fuse Insufficient voltage to electronic control unit Faulty electronic control unit Engine Runs But Misses 1 Be aS ee D Dirt or water in the fuel system Spark plug lead disconnected Poor quality of fuel Faulty spark plug s Loose wires or connections Engine overheated Faulty ignition coil or coils Incorrect crankshaft position sensor air gap Insufficient voltage to electronic control unit Engine Will Not Idle ls pt OY ipe Dy p Dirt or water in the fuel system Stale fuel or dirty fuel injectors Faulty spark plugs Fuel supply inadequate Low compression Restricted fuel tank cap vent Engine overheated cooling system air circulation problem 3 1 Section 3 Troubleshooting Engine Overheats 1 Airintake grass screen cooling fins oil
43. pulse fuel pump and a mechanical fuel pump The pumping action is created by either the oscillation of positive and negative pressures within the crankcase through a hose or by direct lever pump actuation off rocker arm movement The pumping action causes the diaphragm on the inside of the pump to pull fuel in on its downward stroke and to push it into the fuel pump module on its upward stroke Internal check valves prevent fuel from going backward through the 5 pump The fuel pump module receives the fuel from the lift pump increases and regulates the pressure for the fuel injectors Figure 5 17 Fuel Pump Module 5 19 Section 5 EFI Fuel System Figure 5 18 Pulse and Mechanical Fuel Pump The fuel pump module is rated for a minimum output of 13 5 liters per hour and regulated at 270 kilo pascals 39 psi When the key switch is turned ON and all safety switch requirements are met the ECU activates the fuel pump module for about six seconds which pressurizes the system for start up If the key switch is not promptly turned to the start position the engine fails to start or the engine is stopped with the key switch ON as in the case of an accident the ECU switches off the pump preventing the continued delivery of fuel In this situation the MIL will go on but it will go back off after 4 cranking revolutions if system function is OK Once the engine is running the fuel pump remains on 5 20 Service The
44. reinstall cylinder barrel retaining nuts ON eure s ey Kohler 25 761 06 5 To test and verify oil pressure Rectifier Regulator Tester 120 volt current Kohler 25 761 20 5 Rectifier Regulator Tester 240 volt current Kohler 25 761 41 S Used to test rectifier regulators Individual Components Available Design Technology Inc CS PRO Regulator Test Harness DTI 031 Special Regulator Test Harness with Diode ID TI 035 Spark Advance Module SAM Tester To test the SAM ASAM and DSAM on engines with SMART SPARK M Kohler 25 761 40 5 Starter Servicing Kit All Starters To remove and reinstall drive retaining rings and brushes SE Tools KLR 82411 Individual Component Available Starter Brush Holding Tool Solenoid Shift SE Tools KLR 82416 Tachometer Digital Inductive Design Technology Inc For checking operating speed RPM of an engine DTI 110 Vacuum Pressure Tester Kohler 25 761 22 5 Alternative to a water manometer 2 2 Section 2 Tools amp Aids Bids Camshaft Lubricant Valspar ZZ613 Dielectric Grease GE Novaguard G661 Dielectric Grease Fel Pro RTV Silicone Sealant Kohler 25 597 07 S Loctite 5900 Heavy Body in 4 oz aerosol dispenser Only oxime based oil resistant RTV sealants such as those listed are approved for use Loctite amp Nos 5900 or 5910 are recommended for best sealing characteristics Loctite 59106 Loctite Ultra Black 598 Loctite Ultra Blue 587 Loctite Ultra Copper 5920
45. sensed voltage and actual sensor voltage b Problem in wiring harness c ECU to harness connection problem Section 5 EFI Fuel System 4 Systems Related a Ignition spark plug plug wire ignition coil b Fuel fuel type quality injector fuel pressure too low fuel pump module or lift pump c Combustion air air cleaner dirty restricted intake leak throttle bores d Base engine problem rings valves e Exhaust system leak muffler flange oxygen sensor mounting boss etc f Fuelin the crankcase oil Fault Minimum adaptation limit exceeded Condition Too high pressure at high pressure fuel line TPS malfunction shorted connection faulty sensor or fuel pump module failure Possible Causes 1 Oxygen Sensor Related a Sensor connector or wiring b Sensor contaminated or damaged c Poor ground path d Pin circuit wiring or connectors ECU Black pin 10 or 17 2 TPS Sensor Related a Throttle plate position incorrect during Learn procedure b TPS problem or malfunction 3 Engine Wiring Harness Related a Difference in voltage between sensed voltage and actual sensor voltage b Problem in wiring harness c ECU to harness connection problem 4 Systems Related a Ignition spark plug plug wire ignition coil b Fuel fuel type quality injector fuel pressure too high fuel pump module or lift pump Combustion air air cleaner dirty restricted Base engine problem rings va
46. starter pinion and flywheel ring gear may clash resulting in damage to the starter If the starter does not crank the engine shut off the starter immediately Do not make further attempts to start the engine until the condition is corrected Do not drop the starter or strike the starter frame Doing so can damage the starter Starter Removal and Installation Refer to the Disassembly and Reassembly Sections for starter removal and installation procedures T T Section 7 Electrical System and Components Troubleshooting Guide Starting Difficulties Possible Fault Batter 1 Check the specific gravity of battery If low recharge or replace y battery as necessary 1 Clean corroded connections and tighten loose connections 2 Replace wires in poor condition and with frayed or broken insulation Starter Does Not Energize 1 By pass the switch or solenoid with a jumper wire If starter Starter Switch or cranks normally replace the faulty components Solenoid Shift Solenoid Starters Perform individual solenoid test procedure See pages 7 16 and 7 17 Batter 1 Check the specific gravity of battery If low recharge or replace y battery as necessary 1 Check for excessively dirty or worn brushes and commutator Clean using a coarse cloth not emery cloth Starter Energizes 2 Replace brushes if excessively or unevenly worn But Turns Slowly 1 Make sure the clutch or transmission is disengaged or placed in neu
47. studs from the intake manifold See Figure 4 9 3 Remove the base and gasket 4 Reverse the procedure to reassemble the components Torque the three hex flange nuts to 7 4 9 0 N m 65 5 80 in Ib and the two lower mounting screws to 2 8 N m 25 in Ib into new holes or 2 3 N m 20 in Ib into used holes 5 Reset the governor see Section 5 Air Intake Cooling System To ensure proper cooling make sure the fixed screen cooling fins and other external surfaces of the engine are kept clean at all times Every 100 hours of operation more often under extremely dusty or dirty conditions remove the blower housing and other cooling shrouds Clean the cooling fins and external surfaces as necessary Make sure the cooling shrouds are reinstalled Kohler Cleanout kits are recommended to aid inspection and cleanout of the cooling fins See Figure 4 10 NOTE Operating the engine with a blocked fixed screen dirty or plugged cooling fins and or cooling shrouds removed will cause engine damage due to overheating Figure 4 10 Cleanout Kit Installed on Blower Housing Section 5 Electronic Fuel Injection EFI oystem Contents Page s Description Fuel Pump Module Connector INEDITO VO osos tuoetgo idque rand 09S DISSI Md PU Fera cED dU ep VOR e dO QUTD SO eiaeiiio 0 2 rut oparpne PEOHEIES ETOOBOUTE aei tren tree tte Rt etry etre Teerey verte mete ett Tarren ate bU tere tr Md Terns 5 2 Puel IRC COMM NOT BOB
48. sure to check the simple causes which at first may seem too obvious to be considered For example a starting problem could be caused by an empty fuel tank Some general common causes of engine troubles are listed below Use these to locate the causing factors Refer to the specific section s within this service manual for more detailed information Engine Cranks But Will Not Start Empty fuel tank Fuel shut off valve closed Poor fuel dirt or water in the fuel system Clogged fuel line Spark plug lead s disconnected Key switch or kill switch in OFF position Faulty spark plugs Faulty ignition coil s Battery connected backwards Safety interlock system engaged Vacuum fuel pump malfunction or oil in vacuum hose 12 Vacuum hose to fuel pump leaking or cracked 13 Blown fuse 14 Faulty electronic control unit 15 Insufficient voltage to electronic control unit e cM te DS mM m Engine Starts But Does Not Keep Running 1 Restricted fuel tank cap vent Poor fuel dirt or water in the fuel system Loose wires or connections Faulty cylinder head gasket Intake system leak Faulty ignition coil or coils Faulty or improperly adjusted throttle controls Vacuum fuel pump malfunction or oil in vacuum hose 9 Vacuum hose to fuel pump leaking or cracked 10 Blown fuse 11 Insufficient voltage to electronic control unit Ue co oS pe Engine Starts Hard 1 PTO drive is engaged 2 Dirt or water in the
49. switch and displayed as blinks or flashes of the MIL Access the codes as follows 1 Check that the battery voltage is above 11 volts 2 Start with the key switch OFF 3 Turn the key switch to the ON and OFF then ON and OFF then ON leaving it on in the third sequence Do not start the engine The time between sequences must be less than 2 5 seconds 5 26 The MIL will blink a series of times The number of times the MIL blinks represents a number in the blink code Asequence of four digits make up a fault code There is a one 1 second pause between the blinks of a fault code There is a three 3 second pause between separate fault codes After the fault code s are blinked a two digit 61 is blinked to indicate the program has completed a It s a good idea to write down the codes as they appear as they may not be in numerical sequence b Code 61 will always be the last code displayed indicating the end of code transmission If code 61 appears immediately no other fault codes are present Section 5 EFI Fuel System Example of Diagnostic Display Ha Le ie GG Le ie Lt Le te Lt 0 One second pause ut 1 Fault One second pause i att ae ae ae at tO Code 0107 One second pause He Le ie Le Le oe xU Three second pause Te Ut Tt Ue Ut Lt 6 End One second pause zs 1 Code 61 This is a 0107 fault code with the 61 message end code Figure 5 29 After the problem has been correc
50. teeth for abnormal wear or damage b The surface between the pinion and the clutch mechanism for nicks or irregularities which could cause seal damage c Check the drive clutch by holding the clutch housing and rotating the pinion The pinion should rotate in one direction only Brushes and Springs Inspect both the springs and brushes for wear fatigue or damage Measure the length of each brush The minimum length for each brush is 7 6 mm 0 300 in See Figure 7 19 Replace the brushes if they are worn undersize or their condition is questionable Wear limit length 7 6 mm 0 300 in Figure 7 19 Checking Brushes Armature 1 Clean and inspect the commutator outer surface The mica insulation must be lower than the commutator bars undercut to ensure proper operation of the commutator See Figure 7 20 Section 7 Electrical System and Components Commutator O D Mica Insulation Figure 7 20 Commutator Mica Inspection 2 Usean ohmmeter set to the Rx1 scale Touch the probes between two different segments of the commutator and check for continuity See Figure 7 21 Test all the segments Continuity must exist between all or the armature is bad Insulation Figure 7 21 Checking Armature 3 Check for continuity between the armature coil segments and the commutator segments See Figure 7 21 There should be no continuity If continuity exists between any two the armature is bad 4 Check t
51. that is important but not hazard related For Your Safety These precautions should be followed at all times Failure to follow these precautions could result in injury to yourself and others A WARNING A WARNING Hot Parts can cause severe burns Do not touch engine while operating or just after stopping Accidental Starts can cause severe injury or death Disconnect and ground spark plug lead before servicing Hot Parts Accidental Starts Engine components can get extremely hot from operation To Disabling engine Accidental starting can cause severe injury prevent severe burns do not touch these areas while the engine or death Before working on the engine or equipment disable is running or immediately after it is turned off Never operate the engine as follows 1 Disconnect the spark plug lead s the engine with heat shields or guards removed 2 Disconnect negative battery cable from battery WARNING Rotating Parts can cause severe A WARNING Vj Explosive Fuel can cause fires 4 and severe burns Do not fill the fuel tank while the engine is hot or running injury Stay away while engine is in operation Explosive Fuel Rotating Parts Gasoline is extremely flammable and its vapors can explode Keep hands feet hair and clothing away from all moving if ignited Store gasoline only in approved containers in well parts to prevent injury Never operate the engine with covers venti
52. the Oil Sentry switch sensor See Figure 8 34 2 Remove the Oil Sentry switch from the NOTE This is optional Removing the oil breather cover See Figure 8 32 temperature sensor is not required to remove the breather cover or inner baffles P s p TM Figure 8 32 Removing Oil Sentry Switch Figure 8 34 Remove the Oil Temperature Sensor NOTE This is optional Removing the Oil Sentry is not required to remove the breather cover 4 Remove the two remaining hex flange screws from the breather cover See Figure 8 35 Remove Inner Baffles and Breather Cover 1 Remove the four hex flange screws securing the E inner baffles to the crankcase LF Mihe 2 Remove the inner valley baffles See Figure 8 33 Sew Figure 8 35 Remove Breather Cover Screws 8 9 Section 8 Disassembly 5 Pry under the protruding edge of the breather cover with a screwdriver to break the gasket seal See Figure 8 35 Do not pry on the sealing surfaces as it could cause damage resulting in leaks 6 Remove the breather cover and gasket See Figure 8 36 WS Figure 8 36 Removing Breather Cover Gasket Remove Valve Covers 1 Remove the four hex flange screws securing each valve cover Note valve cover differences for proper location in reassembly Ensure any brackets removed are reassembled in the same location See Figure 8 37 2 The covers should lift off without prying Figure 8 37 R
53. the components will result and the warranty will be void Because the fuel pump module is not serviceable the engines are equipped with a special 10 micron EFI fuel filter to prevent harmful contamination from entering the module See Figure 5 19 Section 5 EFI Fuel System If there are two filters in the system the one before the lift pump will be a standard 51 75 micron filter and the one after the lift pump will be the special 10 micron filter Be sure to use an approved 10 micron filter for replacement Service Periodically inspect the filter and replace every 200 operating hours or more frequently under extremely dusty or dirty conditions Use only a genuine Kohler filter and install it according to the directional arrows Failure to use the proper filter can result in engine damage and void the warranty High Pressure Fuel Line Figure 5 20 High Pressure Fuel Line with Fuel Injectors General The high pressure fuel line is an assembly of hoses injector caps and a fuel connector to the fuel pump module The high pressure fuel line feeds fuel to the top of the injectors through the injector caps The caps are fastened to the intake manifold and the injectors are locked into place A small retaining clip provides a secondary lock The high pressure fuel line is serviced as a complete assembly to prevent tampering and safety hazards The components are not individually serviceable These engines use low permeation
54. the rectifier regulator in the blower housing if removed previously then secure erounding bracket against the outer side of the rectifier regulator with a silver screw See Figure 10 59 10 16 Grounding Strap B Silver Screw Figure 10 59 Rectifier Regulator Ground Details 2 Torque the two black rectifier regulator hex flange screws to 1 4 N m 12 6 in Ib and the silver ground strap hex flange screw to 2 8 N m 25 in Ib into new holes or 2 3 N m 20 in Ib into used holes 3 Connect the plug to the rectifier regulator If the purple wire was removed verity the locking tang is raised on the terminal and push the wire terminal into the plug prior to connecting to the rectifier regulator See Figure 10 60 NOTE The rectifier regulator middle terminal B is offset not equally spaced from the outer terminals AC Verify the rectifier regulator plug is assembled to match the terminal offset of the rectifier regulator Figure 10 60 Attaching Rectifier Regulator Plug Section 10 Reassembly Install Grass Screen 5 Install the support ring on the studs so it is resting on the spacers Then install the metal Metal Grass Screen screen on top of the support ring 1 Verify the locating tabs on the back of the fan are inserted into the locating holes on the flywheel 6 Install one of the plain washers on each of the hex cap screws Apply Loctite 242 to the hex cap 2 To assist assembly find f
55. wear limits and free Install New Piston Rings of score or scuff marks the old piston may be To install new piston rings proceed as follows reused NOTE Rings must be installed correctly Ring 3 Remove the old rings and clean up the grooves installation instructions are usually included Never reuse old rings with new ring sets Follow instructions carefully Use a piston ring expander to 4 Before installing the new rings on the piston install rings See Figure 9 11 Install the place the top two rings each in turn in its bottom oil control ring first and the top running area in the cylinder bore and check the compression ring last Refer to Figure 9 12 end gap See Figure 9 9 Compare the ring gap to the specifications listed in Section 1 Piston Ring Piston Ring Expander P Figure 9 11 Installing Piston Rings Figure 9 9 Measuring Piston Ring End Gap 5 After installing the new compression top and middle rings on the piston check the piston to ring side clearance Compare the clearance to specifications listed in Section 1 If the side clearance is greater than specified a new piston must be used Refer to Figure 9 10 9 9 Section 9 Inspection and Reconditioning Piston Ring Dykem End Gap Stripe ok Identification Mark Piston Top Compression Oil Control Ring Three piece Expander Figure 9 12 Piston Ring Installation 1 Oil Control Ring Bottom Groove Install the ex
56. Assembled to Blower Housing PASTE EO o c 2 8 N m 25 in Ib into new holes 2 3 N m 20 in Ib into used holes Starter Assembly Betusgereliuilenop ec eden cauan 5 6 9 0 N m 49 79 in Ib DOT eod POLO DAN D CUm 16 0 N m 142 in Ib Brush Holder Mountine Screw TOTQHUE assisas 2 5 3 3 N m 22 29 in Ib Measure 6 mm 0 236 in above the bottom of the piston skirt at right angles to the piston pin 1 12 Section 1 Safety and General Information Solenoid Starter Iouis LOS vure TORO separei iiri iron ren ui E OI Fa Ero Pr EOS 4 0 6 0 N m 35 53 in Ib Nut Positive C Dosis Bead Torgi eget see routs o ste sear OPI oen ptr n MU QU CEN Doe EEUU 8 0 11 0 N m 71 97 in Ib Stator IVA TR Sew TOU arcsec feces cars eg hc cade ups cade Oe a du dor Ec od 6 2 N m 55 in Ib into new holes 4 0 N m 35 in Ib into used holes Valve Cover WANS CO Ver ath eroi rr 6 2 N m 55 in Ib Valves and Valve Lifters Hydraulic Valve Lifter to Crankcase Running Clearance seee 0 011 0 048 mm 0 0004 0 0019 in Intake Valve Stem to Valve Guide Running Clearance 0 040 0 078 mm 0 0016 0 0031 in Exhaust Valve Stem to Valve Guide Running Clearance 0 052 0 090 mm 0 0020 0 0035 in Intake Valve Guide I D TN 7 040 7 060 mm 0 2772 0 2780 in Max Wear iri
57. Check air intake and cooling areas clean as necessary Section 4 Replace element low profile air cleaner models Section 4 Remove and clean shrouds and cooling areas Section 4 Change oil More frequently under severe conditions Section 6 Check oil cooler fins clean as necessary if equipped Section 6 Replace fuel filter Section 5 Clean set gap or replace spark plug and set gap Section 7 Change oil filter Section 6 Every 300 Hours e Replace heavy duty air cleaner element and check inner element Annually or Every 500 Hours e Have starter serviced Section 7 Perform these maintenance procedures more frequently under extremely dusty dirty conditions Have a Kohler Engine Service Dealer perform this service Low profile air cleaner Heavy duty air cleaner Storage If the engine will be out of service for two months or Run the engine for 2 to 3 minutes to get stabilized more use the following storage procedure fuel into the rest of the system Close the fuel shut off valve when the unit is being stored or 1 Clean the exterior surfaces of the engine On transported EFI engines avoid spraying water at the wiring harness or any of the electrical components To empty the system run the engine until the tank and the system is empty 2 Change the oil and oil filter while the engine is still warm from operation See Change Oil and 4 Remove the spark plugs Add one tablespoon of Oil Filter in Section 6 en
58. Gradually increase the pressure to the switch As pressure increases through the range of 2 0 5 0 psi the tester should indicate a change to continuity switch closed The switch should remain closed as the pressure is increased to 90 psi maximum 3 Gradually decrease the pressure through the range of 2 0 5 0 psi The tester should indicate a change to no continuity switch open down to 0 psi Section 7 Electrical System and Components This section covers the operation service and repair of the electrical system components Systems and components covered in this section are e Spark Plugs e Battery and Charging System e Electric Starter Spark Plugs Engine misfire or starting problems are often caused by a spark plug that has improper gap or is in poor condition The engine is equipped with the following spark plugs The standard spark plug is a Champion RC12YC Kohler Part No 12 132 02 5 RFI compliant engines use a Champion XC12YC Kohler 25 132 14 5 spark plug A high performance spark plug Champion Platinum 3071 is also available Equivalent alternate brand plugs can also be used Gap 0 76 mm 0 030 in Thread Size 14 mm Reach 19 1 mm 3 4 in Hex Size 15 9 mm 5 8 in lype Spark Plug Service Remove the spark plugs after every 200 hours of operation Check their condition and either reset the gap or replace with new plugs as necessary To service the plugs perform the following step
59. Injector General The fuel injectors mount into the intake manifold and the high pressure fuel line attaches to them at the top end Replaceable O rings on both ends of the injector prevent external fuel leakage and also insulate it from heat and vibration A special clip connects each injector to the high pressure fuel line and holds it in place The O rings and retaining clip should be replaced any time the fuel injector is separated from its normal mounting position DO NOT reuse existing O rings or retaining clips as fuel leakage may result When the key switch is on the fuel pump module will pressurize the high pressure fuel line to 39 psi and voltage is present at the injector At the proper instant the ECU completes the ground circuit energizing the injector The valve needle in the injector is opened electromagnetically and the pressure in the high pressure fuel line forces fuel down through the inside The director plate at the tip of the injector contains a series of calibrated openings which directs the fuel into the manifold in a cone shaped spray pattern 5 15 Section 5 EFI Fuel System The injectors have sequential fueling that open and close once every other crankshaft revolution The amount of fuel injected is controlled by the ECU and determined by the length of time the valve needle is held open also referred to as the injection duration or pulse width The time the injector is open milliseconds may vary i
60. O o 5 22 5 23 minal GOVOsnor Ado OD eaan E E ud bou N dui end Oed 5 23 5 24 Troubleshooting TOn Dls OO O ree a E E E P 525 E aE e e a E E A A A E E E EE E oe meseene se 5 25 5 26 Pa CO a A E A A 5 26 5 34 Tonk Konn TOWN CiT CD 5 34 5 35 How Chart Diag nostic Alda resanse SUO E E a A A IS ANO aeei 5 96 5 37 PELS e Kole aa ye Refer to Section 2 5 1 Section 5 EFI Fuel System Description WARNING Explosive Fuel can cause fires and severe burns Do not fill the fuel tank while the engine is hot or running Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent WARNING Explosive Fuel can cause fires and severe burns Fuel systems ALWAYS remains under HIGH PRESSURE Fuel Fire and Burns Wrap a shop towel completely around the fuel pump module connector Press the release button s and slowly pull the connector away from the fuel pump module allowing the shop towel to absorb any residual fuel in the high pressure fuel line Any spilled fuel must be completely wiped up immediately The EFI f
61. P H Connector if if jj Block Figure 7 3 Wiring Diagram 20 25 Amp Regulated Battery Charging System 7 4 Rectifier Regulator The rectifier regulator is mounted on the blower housing See Figure 7 5 To replace it disconnect the connector remove the two mounting screws and metal grounding strap NOTE When installing the rectifier regulator take note of the terminal markings and install the connector accordingly Rectifier Regulato me haa eh P Figure 7 5 Rectifier Regulator Testing of the rectifier regulator may be performed as follows using the Rectifier Regulator Tester see Section 2 NOTE Disconnect all electrical connections attached to the rectifier regulator Testing may be performed with the rectifier regulator mounted or loose The figures show the part removed from the engine for clarity Repeat the applicable test procedure two or three times to determine the condition of the part 1 Connect the tester ground lead with spring clamp to the body of the rectifier regulator 2 Connect the red lead from the tester to the middle terminal labeled B 3 Connect the two black leads from the tester to both of the outer AC terminals on the rectifier regulator See Figure 7 6 Section 7 Electrical System and Components Figure 7 6 Connecting Leads to Rectifier Regulator 4 Plug the tester into the proper AC outlet power supply for tester being used Turn on the power switch
62. Possible Causes 1 Oxygen Sensor Related a Sensor connector or wiring problem b Sensor contaminated corroded or damaged c Poor ground path d Pin circuit wiring or connectors ECU Black pin 10 or 17 2 TPS Learn Procedure Incorrect a Lean condition check oxygen sensor signal with VOA and see Oxygen Sensor section 3 Engine wiring harness related such as a cut wire broken or pinched O25 1 Circuit High Voltage Condition Shorted connection or faulty sensor Possible Causes 1 Oxygen Sensor Related Sensor connector or wiring problem Sensor contaminated or damaged Poor ground path Pin circuit wiring or connectors ECU Black pin 10 or Black pin 17 ao 0 2 2 Engine Wiring Harness Related a Difference in voltage between sensed voltage and actual sensor voltage b Short in wire harness Fault Maximum adaptation limit exceeded Condition Fuel inlet screen filter plugged low pressure at high pressure fuel line TPS malfunction shorted connection faulty sensor low fuel or wrong fuel type Possible Causes 1 Oxygen Sensor Related Corrosion or poor connection Sensor contaminated or damaged Air leak into exhaust Poor ground path Pin circuit wiring or connectors 1 ECU Black pin 10 or Black pin 17 once 2 TPS Sensor Related a Throttle plate position incorrect during Learn procedure b TPS problem or malfunction 3 Engine Wiring Harness Related a Difference in voltage between
63. Remove governor cross shaft Remove connecting rods with pistons and rings Remove crankshaft Remove flywheel end oil seal Disconnect Spark Plug Leads 1 Disconnect the leads from the spark plugs See Figure 8 1 NOTE Pull on boot only to prevent damage to spark plug lead Figure 8 1 Disconnect Spark Plug Leads Shut Off Fuel Supply 8 1 Section 8 Disassembly Drain Oil From Crankcase and Remove Oil 4 Remove and discard the oil filter See Figure 8 4 Filter 1 Remove oil fill cap dipstick and one of the oil Remove Oil Cooler drain plugs See Figure 8 2 The oil cooler can now be removed from the engine 1 Usea8 mm Allen wrench to remove the oil filter threaded nipple 2 Separate the filter adapter from the oil pan leaving the oil lines attached Remove the two hex flange screws mounting the oil cooler to the blower housing Remove the cooler lines and filter adapter as an assembly Remove Muffler 1 Remove the exhaust system and attaching hardware from the engine On engines equipped with a port liner remove it now ih TE 1 ER Figure 8 2 Removing Oil Fill Cap Dipstick Remove Air Cleaner Assembly Heavy Duty Air Cleaner 1 Remove the hex flange nuts securing the air cleaner to the mounting studs See Figure 8 5 Figure 8 5 Remove Hex Nuts one is hidden behind the elbow Figure 8 4 Removing Oil Filter 2 Allow ample time for the oil to drain from the OS bw pie ae
64. SERVICE MANUAL KOHLER Command PRO ECV630 ECV749 VERTICAL CRANKSHAFT KOHLER EFI PRO 29 EDH KOHLER ENGINES Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Section 9 Section 10 Reassembly Contents Safety and General Information eeceee e eLeee ee eeeee eene enne nnn TOONS amp AIOS eR E m TOU ISS OU accesso asic Air Cleaner and Air Intake System Electronic Fuel Injection EFI System Lubrication System Electrical System and Components Disassembly Inspection and Reconditioning Section 1 Safety and General Information Safety Precautions To ensure safe operation please read the following statements and understand their meaning Also refer to your equipment manufacturer s manual for other important safety information This manual contains safety precautions which are explained below Please read carefully A WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury death or substantial property damage if the warning is ignored A CAUTION Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the caution is ignored NOTE Note is used to notify people of installation operation or maintenance information
65. SF SAMT HH 104 02 4095 241 87 AC 9 523 6 Oi Ed SOLENOID E E A Tn ER OIL STARTER 45 5 L Pras ee E COOLER G 5 REGULATOR RECTIFIER MOUNTING HOLE A 4X 9 20 362 THRU E 254 00 10 000 B C Li s ENGINE MOUNTING SURFACE A pn PTO SIDE 9 i 5 Jte F RHR E 52 26 9 2 057 OIL FILTER i id vU SPABK FLUG il A A 13 95 do 549 SS ONEREOUNTIIG SUR IDE E88 5 B38 MOUNTING d id OIL FILTER HOLE A COILDRAINPLUG U6 3 8 NPT INCH DIPSTICK Z dm om _ d 28 56 4 1 125 i OIL FILTER 7 aa 2 o 154 94 H 367 37 fe 6 100 14 463 E ez mM all m SPARK 23 LC TY a z PLUG 12 489 Mat i E T 92 j Ur S m EXHAUST Hi ou PORTH i t i 82 i 13 49 SS 531 ENGINE MOUNTING a MOUNTING OIL DRAIN PLUG 40 41 n STARTER ids 3 8 N P T INCH i591 ft SIDE Figure 1 5 Typical Engine Dimensions ECV749 with Low Profile Air Cleaner 1 7 Section 1 Safety and General Information General Specifications Power 3600 RPM exceeds Society of Automotive Engineers Small Engine Test Code J1940 Gio P 14 1 kW 19 HP qe e niaaeceeegaiees 15 7 kW 21 HP ECG E A 17 2 kW 23 HP T 18 6 kW 25 HP GC 9
66. Sensor Throttle Position Sensor TPS Crankshaft Position Sensor Oxygen Sensor Manifold Absolute Pressure Sensor MAP Wire Harness Assembly amp Affiliated Wiring Malfunction Indicator Light MIL optional Intake Air Temperature Sensor Operation The EFI system is designed to provide peak engine performance with optimum fuel efficiency and lowest possible emissions The ignition and injection functions are electronically controlled monitored and continually corrected during operation to maintain the ideal air fuel ratio The central component of the system is the Engine Control Unit ECU which manages system operation determining the best combination of fuel mixture and ignition timing for the current operating conditions A lift fuel pump is used to move fuel from the tank through an in line fuel filter and fuel line The fuel is then pumped to the fuel pump module The fuel pump module regulates fuel pressure to a system operating pressure of 39 psi Fuel is delivered from the fuel pump module through the high pressure fuel line into the injectors which inject the fuel into the intake ports The ECU controls the amount of fuel by varying the length of time that the injectors are on This can range from 2 to over 12 milliseconds depending on fuel requirements The controlled injection of the fuel occurs every other crankshaft revolution or once for each 4 stroke cycle When the intake valve opens the air fuel mixture is
67. Spec No ECV630 XXXX ECV650 XXXX ECV680 XXXX ECV730 XXXX ECV740 XXXX ECV749 XXXX C Serial No 39 05810334 Year Manufactured Code Factory Code Year 2009 2010 2011 Figure 1 2 Explanation of Engine Identification Numbers Oil Recommendations Using the proper type and weight of oil in the NOTE Using other than service class SJ or higher oil crankcase is extremely important So is checking oil or extending oil change intervals longer than daily and changing oil regularly Failure to use the recommended can cause engine damage correct oil or using dirty oil causes premature engine wear and failure NOTE Synthetic oils meeting the listed classifications may be used with oil changes Oil Type performed at the recommended intervals Use high quality detergent oil of API American However to allow piston rings to properly Petroleum Institute Service Class SJ or higher Select seat anew or rebuilt engine should be the viscosity based on the air temperature at the time operated for at least 50 hours using standard of operation as shown in the following table petroleum based oil before switching to synthetic oil ra 30 80 s 1 3 Section 1 Safety and General Information A logo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 1 3 Figure 1 3 Oil Container Logo WARNING Vj Explosive Fuel can cause fires 4 and severe burns Do not fill the
68. U power circuit problem Pin circuit Black 18 7 Switched ECU power circuit problem Pin circuit Black 15 8 ECU grounds 9 ECU Diagnostic Aid 2 FAULT CODES Refer to detailed fault code listing before flow chart and servicing information for the respective components Code 0031 Oxygen Sensor Heater Circuit High Voltage Code 0032 Oxygen Sensor Heater Circuit Low Voltage Code 0107 Manifold Absolute Pressure Sensor Circuit Low Voltage or Open Code 0108 Manifold Absolute Pressure Sensor Circuit High Voltage Code 0112 Intake Air Temperature Sensor Circuit Low Voltage Code 0113 Intake Air Temperature Sensor Circuit High Voltage or Open Code 0117 Coolant Oil Temperature Sensor Circuit Low Voltage Code 0118 Coolant Oil Temperature Sensor Circuit High Voltage or Open Code 0122 TPS Circuit Low Voltage or Open Code 0123 TPS Circuit High Voltage Code 0131 O25 1 Circuit Low Voltage or Open Code 0132 O25 1 Circuit High Voltage Code 0171 Maximum adaptation limit exceeded Code 0172 Minimum adaptation limit exceeded Code 0174 Lean fuel condition at high load or open loop Code 0201 Injector 1 Circuit Malfunction Code 0202 Injector 2 Circuit Malfunction 5 36 Code 0230 Fuel Pump Module Circuit Low Voltage or Open Code 0232 Fuel Pump Module Circuit High Voltage Code 0336 Crankshaft Position Sensor Noisy Signal Code 0337 Crankshaft Position Sensor No Signal Code 0351 Cylinder 1 Ig
69. UTI 17 036 mm 0 6707 in Crankcase Governor Cross Shaft Bore I D il P E OM 8 025 8 075 mm 0 3159 0 3179 in Maxs Wear Bir TD 8 088 mm 0 3184 in Dream Cover Pas CTT TORQUE seein 11 3 N m 100 in Ib into new holes 7 3 N m 65 in Ib into used holes OIL Te Mee SENSO TODO ee uiuis oe Lue Cet puir on JUD DU VES 7 3 N m 65 in Ib J Dram Tar TORTUE mr MM 13 6 N m 10 ft Ib Oil Pan COD EOD Wa Sherer To cetec saontsncrsceeetccsoiaouetaessonca E E dup Eedi apad 25 6 N m 227 in Ib Crankshaft Se re Md Ez TE RN S ETT 0 025 0 635 mm 0 001 0 025 in Crankshaft Bore In Crankcase ir HO 40 972 40 997 mm 1 6131 1 6141 in Max Wear LIDi asoson e spe tese easiest os HEURE a Tu EE hine roS EN Noa RE 41 011 mm 1 6146 in Crankshatt to Sleeve Bearing Oil Pan Wee Clearance NEW T 0 03 0 12 mm 0 001 0 005 in Crankshaft Bore Oil Pan NeW sicxssc ncasnorsotiodonssaanssuwesaneusceusssaneneduaatusanscacnsoweisedns 40 974 41 000 mm 1 6131 1 6141 in Crankshaft Bore Oil Pan to Crankshaft era AE e A MN Tc 0 039 0 087 mm 0 0015 0 0034 in 1 9 Section 1 Safety and General Information Crankshaft Flywheel End Main Bearing Journal QUEDA 40 913 40 935 mm 1 6107 1 6116 in AXE raid UU TT T 40 843 mm 1 608 in Max Taper ero rU ET 0 022 mm 0 0009 in Max Ouko Round M E
70. aah I A 2X 241 87 Oy 5 E Nn re 1 T l 9 760 N Mi 9 523 i 7 k Y s iL KORUR Jil N Ay T OIL COOLER cs 3 4X0920 362 THRU 0 254 00 10 00 B C MOUNTING HOLE A IO IR i Mises REGULATOR v Sil T ENGINE MOUNTING SURFACE E od PULSE FUEL PUMP 445 93 17 556 52 76 2077 135 44 OILFILTER 5 332 GSPARK mr 1445 LALAT i s EES T L s NIS SBOUECAS ING 960 N m 2641 7 040 gt 8591 OILDRAIN o FILTER 3 8 NPT un INCH 14 4831 j ENGINE MOUNTING 85 50 SURFACE 3 366 7 16 20 UNF 2B INCH 735 1 1 500 728 56 1 125 m dci 559 j l HaT ENGINE MOUNTING SURFACE 1 591 OIL DRAIN PLUG 3 8 NPT INCH 7119 914 2881 3 679 STARTER SIDE EXHAUST EXHAUST PORT 2 PORT 1 Figure 1 4 Typical Engine Dimensions ECV749 with Heavy Duty Air Cleaner 1 6 Section 1 Safety and General Information 427 72 16 839 302 03 11 891 3 383 Dimensions in millimeters COVER REMOVAL l m Inch equivalents shown in 16 31 642 SPARK PLUG FUEL FILTER 397 06 15 632
71. acturer s instructions and safety precautions carefully Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Typical Disassembly Sequence The following sequence is suggested for complete engine disassembly The sequence can be varied to accommodate options or special equipment Disconnect spark plug leads Shut off fuel supply Drain oil from crankcase and remove oil filter Remove oil cooler Remove muffler Remove air cleaner assembly Remove throttle control panel Remove external governor controls Remove lift fuel pump and fuel pump module Remove throttle body Remove electronic control unit Remove electronic control unit bracket and electric starter motor oS E E E ae E Nr oS 0 13 14 15 16 17 18 19 20 PAR 22 23 24 25 26 27 29 29 30 ok 92 Remove oil separator and hardware Remove grass screen Remove outer baffles and blower housing Remove Oil Sentry Remove inner baffles and breather cover Remove valve covers Remove crankshaft position sensor Remove manifold absolute pressure sensor Remove fuel injectors Remove intake manifold Remove spark plugs Remove cylinder heads and hydraulic lifters Remove fan and flywheel Remove stator and backing plate Remove oil pan assembly Remove camshaft
72. ad wire Wiring shorted to ground Remove source of external Contamination of air reference contamination protect air reference area Use recommended torque at installation replace gasket or sensor Air leak at sensor or gasket sensor upper shield damage Revise application exhaust Shield sensor from damage Open circuit no activity from Broken element Replace sensor sensor Sensor dropped Hard blow to engine or exhaust system Defective sensor Thermal shock Slow time response Open heater circuit Replace sensor Improper handling Carbon deposits Improper fueling Correct fueling Incorrect or contaminated fuel Use high quality fuel Excessive engine oil consumption causing exhaust contamination or Correct engine condition other exhaust side contamination Heater circuit open shorted or out Repair short in harness wires of specification replace sensor 5 14 Manifold Absolute Pressure Sensor Locking _ Tab Figure 5 11 Manifold Absolute Pressure Sensor and Connector General The manifold absolute pressure MAP sensor provides immediate manifold pressure information to the ECU The MAP measures the difference in pressure between the outside atmosphere and the vacuum level inside the intake manifold and monitors pressure in the manifold as the primary means of detecting load The data is used to calculate air density and determine the engine s mass air flow rate which in turn determine
73. all Red wire jumper Figure 5 6 from Kohler EFI service kit on to service port connect the white wire to the black wire in the 4 way diagnostic port Figure 5 6 Service Port and Jumper Connector 3 Turn key ON then OFF and count 10 seconds 4 Turn key ON then OFF and count to 10 seconds a second time 5 Remove the jumper ECU is reset A TPS Learn Procedure must be performed after the ECU Reset TPS Learn Procedure 1 Turnidle screw clockwise one full turn prior to key ON after ECU Reset 2 Start engine run at low idle until engine is warm 3 Idle speed must be above 1500 RPM If below 1500 RPM turn idle screw up to 1700 RPM and then shut down engine and perform ECU Reset again 5 10 4 Adjust idle speed down to 1500 RPM Allow engine to dwell at 1500 RPM for about 3 seconds 5 After this adjust the idle speed to the final specified speed setting 6 Turn the key OFF and count to 10 seconds Learn is complete and the engine is ready for operation Engine Oil Temperature Sensor Figure 5 7 Engine Oil Temperature Sensor General The engine oil temperature sensor Figure 5 7 is used by the system to help determine fuel requirements for starting a cold engine needs more fuel than one at or near operating temperature Mounted in the breather cover it has a temperature sensitive resistor that extends into the oil flow The resistance changes with oil temperature altering the vol
74. alves confirm by Recondition piston rings cylinder bore valves inspecting components and valve guides Restricted exhaust Repair replace restricted muffler exhaust system 3 3 Section 3 Troubleshooting Compression Test A compression test can be performed using a compression tester Follow the manufacturers instructions for performing the test Cylinder Leakdown Test A cylinder leakdown test can be a valuable alternative to a compression test By pressurizing the combustion chamber from an external air source you can determine if the valves or rings are leaking and how badly Cylinder Leakdown Tester see Section 2 is a relatively simple inexpensive leakdown tester for small engines The tester includes a quick disconnect for attaching the adapter hose and a holding tool Leakdown Test Instructions 1 Run the engine for 3 5 minutes to warm it up 2 Remove the spark plug s and the air filter from engine 3 Rotate the crankshaft until the piston of cylinder being tested is at top dead center of the compression stroke Hold the engine in this position while testing The holding tool supplied with the tester can be used if the PTO end of the crankshaft is accessible Lock the holding tool onto the crankshaft Install a 3 8 in breaker bar into the hole slot of the holding tool so it is perpendicular to both the holding tool and crankshaft PTO If the flywheel end is more accessible use a breaker
75. and Special Torque Values in Section 1 then select the nearest suitable oversize of either 0 25 mm 0 010 in or 0 50 mm 0 020 in Resizing to one of these oversizes will allow usage of the available oversize piston and ring assemblies First resize using a boring bar then use the following procedures for honing the cylinder Honing While most commercially available cylinder hones can be used with either portable drills or drill presses the use of a low speed drill press is preferred as it facilitates more accurate alignment of the bore in relation to the crankshaft crossbore Honing is best accomplished at a drill speed of about 250 RPM and 60 strokes per minute After installing coarse stones in hone proceed as follows 1 Lower hone into bore and after centering adjust so that the stones are in contact with the cylinder wall Use of a commercial cutting cooling agent is recommended 2 With the lower edge of each stone positioned even with the lowest edge of the bore start drill and honing process Move the hone up and down while resizing to prevent the formation of cutting ridges Check the size frequently NOTE Kohler pistons are custom machined to exacting tolerances When oversizing a cylinder it should be machined exactly 0 25 mm 0 010 in or 0 50 mm 0 020 in over the new diameter Section 1 The corresponding oversize Kohler replacement piston will then fit correctly 3 When the bore is within 0 064 mm
76. anks or used in conjunction with a carbon canister Kit for Tier III evaporative emissions compliance The purge port connects to the vent hose assembly and directs all fuel vapor into the throttle body If the purge port remains unused the port must remain capped to prevent dirt from entering the engine See Figure 5 21 Service No specific servicing is required for the vent hose assembly or purge port unless operating conditions indicate replacement is required All components are serviced individually Abrasion sleeves on hoses should be reused or replaced when servicing vent hoses Please note vent hose routing and replicate after service or component replacement to prevent pinching or abrasion of the vent hoses 5 22 Throttle Body Intake Manifold Assembly Figure 5 22 Throttle Body Intake Manifold Details General The EFI engines have no carburetor so the throttle function regulate incoming combustion airflow is achieved with a throttle valve in a separate throttle body attached to the intake manifold The throttle body intake manifold provides mounting for the fuel injectors throttle position sensor intake air temperature sensor high pressure fuel line idle speed screw and air cleaner assembly See Figure 5 22 Service The throttle body is serviced as an assembly with the throttle shaft TPS throttle plate and idle speed adjusting screw installed The throttle shaft rotates on needle bearings non servic
77. art the engine and bring it up to operating 1 Insert the stopper hose into the oil fill hole Leave speed 3200 3600 RPM the other tube of manometer open to atmosphere Make sure the shut off clamp is closed 5 Check the reading on the gauge If the reading is to the left of 0 on the gauge vacuum or 2 Start the engine and run at no load high speed negative pressure is indicated If the reading is to 3200 3750 RPM the right of 0 on the gauge positive pressure is present 3 Open the clamp and note the water level in the l tube Crankcase vacuum should be 4 10 inches of water If the reading is below specification or if pressure is present check the following table for The level in the engine side should be a minimum i i possible causes and remedies of 10 2 cm 4 in above the level in the open side If the level in the engine side is less than specified low no vacuum or the level in the engine side is lower than the level in the open side pressure check for the conditions in the table below No Crankcase Vacuum Pressure in Crankcase 1 Crankcase breather clogged or inoperative 1 Disassemble breather clean parts thoroughly reassemble and recheck pressure Seals and or gaskets leaking Loose or Replace all worn or damaged seals and gaskets improperly torqued fasteners Make sure all fasteners are tightened securely Use appropriate torque values and sequences when necessary Piston blowby or leaky v
78. as correct test the wire harness circuits between the sensor connector terminals and the corresponding pin terminals 4 and 13 in the main connector Correct any observed problem reconnect the sensor and perform step 5 again 7 When fault is corrected and engine starts clear fault codes following the ECU Reset procedure See page 5 10 Throttle Position Sensor TPS Pin C Pin B Figure 5 4 Throttle Position Sensor with Pinout General The throttle position sensor TPS is used to indicate throttle plate angle to the ECU Since the throttle by way of the governor reacts to engine load the angle of the throttle plate is directly related to the load on the engine Mounted on the throttle body and operated directly off the end of the throttle shaft the TPS works as a potentiometer varying the voltage signal to the ECU in direct correlation to the angle of the throttle plate This signal along with the other sensor signals is processed by the ECU and compared to the internal preprogrammed maps to determine the required fuel and ignition settings for the amount of load The correct position of the TPS is established and set at the factory Do not loosen the TPS or alter the mounting position unless absolutely required by fault code diagnosis If the TPS is loosened or repositioned the appropriate TPS Learn Procedure must be performed to re establish the baseline relationship between the ECU and the TPS Fig
79. bar and socket on the flywheel nut screw to hold it in position An assistant may be needed to hold the breaker bar during testing If the engine is mounted in a piece of equipment it may be possible to hold it by clamping or wedging a driven component Just be certain that the engine cannot rotate off of TDC in either direction Install the adapter into the spark plug hole but do not attach it to the tester at this time Connect an air source of at least 50 psi to the tester Turn the regulator knob in the increase clockwise direction until the gauge needle is in the yellow set area at the low end of the scale Connect the tester quick disconnect to the adapter hose while firmly holding the engine at TDC Note the gauge reading and listen for escaping air at the throttle body exhaust outlet and crankcase breather Check the test results against the following table Leakdown Test Results Air escaping from crankcase breather scie petitor ttt Air escaping from exhaust system essen Alr escaping Iron throtle DOG VU deoa eisdem ite cn Gauge reading in low green zone eese Gauge reading in moderate yellow zone Gauge reading in high red zone esses 3 4 Rings or cylinder worn Defective exhaust valve improper seating pde Defective intake valve improper seating Piston rings an
80. ber grommet into valve cover Push oil separator into the rubber grommet in the valve cover 2 Secure the oil separator to the blower housing placing the spacer and oil separator bracket against the blower housing and securing with the strap and two screws Torque the screws to 2 3 N m 20 in Ib See Figure 10 66 Figure 10 66 Install Oil Separator Install Electric Starter Motor and ECU Bracket 1 Install the electric starter motor using the two hex flange screws Position the ECU bracket as shown See Figure 10 67 2 Figure 10 67 Installing Starter and ECU Bracket Torque the two hex flange screws to 16 0 N m 142 in Ib Connect the leads to the solenoid Install the dipstick tube and align the mounting hole with the threaded hole in the ECU bracket Secure with the M5 hex flange screw Torque the screw to 6 2 N m 55 in Ib into new holes or 4 0 N m 35 in Ib into used holes See Figure 10 68 9 hs E S ite DL n Install Electronic Control Unit ECU k Install ECU to the ECU bracket using the two hex flange screws Torque the M5 screws to 6 2 N m 55 in Ib into new holes or 4 0 N m 35 in Ib into used holes See Figure 10 69 Connect the Black and Grey electrical connectors The connectors and ECU are keyed in such a way so they cannot be installed incorrectly 10 18 Section 10 Reassembly 8 z m 8 m E Figure 10 69 Torque ECU Scr
81. ch receives the backup washer See Figure 7 26 Figure 7 26 Installing Armature and Pivot Lever Section 7 Electrical System and Components 7 Install the backing plate followed by the rubber grommet into the matching recess of the drive end cap The molded recesses in the grommet should be out matching and aligned with those in the end cap See Figure 7 27 Figure 7 27 Installing Backing Plate and Grommet 8 Install the frame with the small notch forward onto the armature and drive end cap Align the notch with the corresponding section in the rubber grommet Install the drain tube in the rear cutout if it was removed previously See Figure 7 28 Figure 7 28 Installing Frame and Drain Tube 9 Install the flat thrust washer onto the commutator end of the armature shaft See Figure 7 29 7 13 Section 7 Electrical System and Components Figure 7 29 Installing Thrust Washer 10 Starter reassembly when replacing the Brushes Brush Holder Assembly a Hold the starter assembly vertically on the end housing and carefully position the assembled brush holder assembly with the supplied protective tube against the end of the commutator armature The mounting screw holes in the metal clips must be up out Slide the brush holder assembly down into place around the commutator and install the positive brush lead grommet in the cutout of the frame See Figure 7 30 The protective tube may be save
82. ch or connection Connect an ammeter from loose end of B lead to positive terminal of battery Connect DC voltmeter from loose end of B lead to negative terminal of battery With engine running at 3600 RPM read voltage on voltmeter If voltage is 13 8 volts or more place a minimum load of 5 amps on battery to reduce voltage Observe ammeter NOTE Turn on lights if 60 watts or more Or place a 2 5 ohm 100 watt resistor across battery terminals Remove connector from rectifier regulator With engine running at 3600 RPM measure AC voltage across stator leads using an AC voltmeter With engine stopped measure the resistance across stator leads using an ohmmeter With the engine stopped measure the resistance from each stator lead to ground using an ohmmeter If voltage is 13 7 14 7 and charge rate increases when load is applied the charging system is OK and battery was fully charged If voltage is less than 13 8 or charge rate does not increase when load is applied test rectifier regulator for proper ground Using an ohmmeter set to the Rx1 scale check the resistance from the rectifier regulator housing to the battery ground Resistance should be less than 1 ohm As an alternative connect a jumper lead from rectifier regulator housing to the battery ground and retest charging voltage If charge voltage measures 13 7 14 7 volts the charging system is functioning If resistance is greater than 1 ohm o
83. change parts from one cylinder head to the other Keepers Retainer Spring Figure 8 56 Valve Components 8 14 Valve Seal Figure 8 57 Valve Seal Location Remove Fan and Flywheel 1 Remove the four shoulder bolts securing the fan if still attached and remove fan 2 Use a flywheel strap wrench or holding tool see Section 2 to hold the flywheel and loosen the hex flange screw securing the flywheel to the crankshaft See Figure 8 58 NOTE Always use a flywheel strap wrench or holding tool to hold the flywheel when loosening or tightening the flywheel screw Do not use any type of bar or wedge to hold the flywheel Use of such tools could cause the flywheel to become cracked or damaged i E ow aa p I IL e ill Figure 8 58 Removing Flywheel Fastener Using Strap Wrench 3 Remove the hex flange screw and washer 4 Use a puller to remove the flywheel from the crankshaft See Figure 8 59 Section 8 Disassembly NOTE Always use a flywheel puller to remove the flywheel from the crankshaft Do not strike the crankshaft or flywheel as these parts could become cracked or damaged Striking the puller or crankshaft can cause the crank gear to move affecting crankshaft endplay Figure 8 61 Removing Stator Remove Oil Pan Assembly 1 Remove the ten hex flange screws securing the oil pan to the crankcase See Figure 8 62 Figure 8 59 Removing Flywheel with
84. co a S 0 025 mm 0 0010 in Crankshaft Oil Pan End Main Bearing Journal BT T 40 913 40 935 mm 1 6107 1 6116 in UD M Near LIN ees g aoe cierscneoacnapsamoxcauoezenoe NIIS INEO IUE RUNE MINUS 40 843 mm 1 608 in Ma TIP T 0 022 mm 0 0009 in Max COUP OPI OUEICL s oae careerscacemasinaseneen AE E E 0 025 mm 0 0010 in Crankshaft Connecting Rod Journal QURA M 35 950 35 973 mm 1 4153 1 4163 in UID Tas Vear DIDI ue ciccessuu neuro tuu put cou tors sous dro pES ON IPM RUDUE 35 941 mm 1 4150 in Max Taper Cimi D M er 0 018 mm 0 0007 in IVA AOE OI Od LIMil NEUE E TO E 0 025 mm 0 0010 in Crankshaft T I R PTO EOS ranis Th ENO E a stent E E RID DM NUN 0 279 mm 0 0110 in Entre Crank dri V DIOPES asset net iva Un eo e e ER 0 10 mm 0 0039 in Cylinder Bore Cylinder Bore I D New ECVO Nu Ge esM A GOl E nne 80 000 80 025 mm 3 1496 3 1506 in New ECV730 ECV740 ECV749 T 83 006 83 031 mm 3 2680 3 2689 in Max Wear Limit ECV630 ECV650 ECV680 cssssesssavessoessnessntserenceseaevsare 80 075 mm 3 1526 in Max Wear Limit ECV730 ECV740 ECV749 eese nennen 83 081 mm 3 2709 in M OTE Ol e Pine MEO TO S 0 120 mm 0 0047 in hup OM Eq qm 0 05 mm 0 0020 in Cylinder Head Cylinder Head Fastener Torque Hex Flange Nut Torque In Two Stag 68 osio
85. cooler or cooling shrouds clogged Excessive engine load Low crankcase oil level High crankcase oil level Lean air fuel mixture ar pes 9c Ted Engine Knocks Excessive engine load Low crankcase oil level Old or improper fuel Internal wear or damage Hydraulic lifter malfunction Quality of fuel Incorrect grade of oil tO IS S9 I Engine Loses Power 1 Low crankcase oil level High crankcase oil level Dirty air cleaner element Dirt or water in the fuel system Excessive engine load Engine overheated Faulty spark plugs Low compression Exhaust restriction Low battery Incorrect governor setting LO de 29 Doc X Qi Orge Mo Tu m m Engine Uses Excessive Amount of Oil 1 Incorrect oil viscosity type Clogged or improperly assembled breather Breather reed broken Worn or broken piston rings Worn cylinder bore Worn valve stems valve guides Crankcase overfilled Blown head gasket overheated O UREP ey Oil Leaks from Oil Seals Gaskets 1 Crankcase breather is clogged or inoperative Breather reed broken Loose or improperly torqued fasteners Piston blowby or leaky valves Restricted exhaust oh qug e External Engine Inspection Before cleaning or disassembling the engine make a thorough inspection of its external appearance and condition This inspection can give clues to what might be found inside the engine and the cause when it is disassembled e Check for buildup of dirt and deb
86. creen Pull the paper element out of the housing on the opposite side See Figures 4 2 and 4 3 Figure 4 3 Accessing Inlet Screen 4 1 Section 4 Air Cleaner and Air Intake System 3 After the paper element is removed check the condition of the inner element It should be replaced whenever it appears dirty typically every other time the main element is replaced or every 600 hours Clean the area around the base of the inner element before removing it so dirt does not get into the engine 4 Do not wash the paper element and inner element or use compressed air this will damage the elements Replace dirty bent or damaged elements with new genuine Kohler elements as required Handle the new elements carefully do not use if the sealing surfaces are bent or damaged 5 Check all parts for wear cracks or damage and make sure ejector area is clean See Figure 4 4 Replace any damaged components sX px Ejector Area Figure 4 4 Ejector Area 6 Install the new inner element followed by the paper element Slide each fully into place in the air cleaner housing 7 Reinstall the end caps and secure with the retaining clips See Figure 4 1 Removal 1 Remove the three hex flange nuts securing the assembly to the throttle body See Figure 4 5 4 2 Hex Flange Nuts Figure 4 5 Air Cleaner Hex Flange Nuts 2 Remove two hex flange screws securing the air cleaner assembly to air cleaner bracket
87. d and air cleaner mounting screws to 10 5 N m 93 in Ib An ECU Reset will need to be completed Follow the instructions on page 5 10 Injector problems due to dirt or clogging are generally unlikely due to the design of the injectors the high fuel pressure and the detergent additives in the gasoline Symptoms that could be caused by dirty clogged injectors include rough idle hesitation stumbling during acceleration or triggering of fault codes related to fuel delivery Injector clogging is usually caused by a buildup of deposits on the director plate restricting the flow of fuel resulting in a poor spray pattern Some contributing factors to injector clogging include higher than normal operating temperatures short operating intervals and dirty incorrect or poor quality fuel Cleaning of clogged injectors is not recommended they should be replaced Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem Ignition System Figure 5 16 Ignition Coil 5 18 General A high voltage solid state battery ignition system is used with the EFI system The ECU controls the ignition output and timing through transistorized control of the primary current delivered to the coils Based on input from the crankshaft position sensor the ECU determines the correct firing point for the speed at which the engine is running At the proper instant it interrupts the flow of primary cur
88. d and used for future servicing Figure 7 30 Installing Brush Holder Assembly with Supplied Tube Starter reassembly when not replacing the Brushes Brush Holder Assembly a Carefully unhook the retaining caps from over each of the brush assemblies Do not lose the springs See Figure 7 31 7 14 Figure 7 31 Removing Retaining Clips b Position each of the brushes back in their slots so they are flush with the I D of the brush holder assembly Insert the Brush Installation Tool with extension or use the tube described above from a prior brush installation through the brush holder assembly so the holes in the metal mounting clips are up out c Install the brush springs and snap on the four retainer caps See Figure 7 32 Figure 7 32 Brush Installation Tool with Extension d Hold the starter assembly vertically on the end housing and carefully place the tool with extension and assembled original brush holder assembly onto the end of the armature shaft Slide the brush holder assembly down into place around the commutator install the positive brush lead grommet in the cutout of the frame See Figure 7 33 using Tool with Extension 11 Install the end cap onto the armature and frame aligning the thin raised rib in the end cap with the corresponding slot in the grommet of the positive brush lead 12 Install the two thru bolts and the two brush holder mounting screws Torque the t
89. d cylinder in good condition Engine is still usable but there is some wear present Customer should start planning for overhaul or replacement m Rings and or cylinder have considerable wear Engine should be reconditioned or replaced Section 4 Air Cleaner and Air Intake System This engine is equipped with a heavy duty air cleaner low profile air cleaner or special air cleaner supplied by the equipment manufacturer Heavy Duty Air Cleaner General These engines use a heavy duty style air cleaner shown in Figure 4 1 consisting of a cylindrical housing mounted to a bracket on the throttle body intake manifold The air cleaner housing contains a paper element and inner element designed for longer service intervals The system is CARB EPA certified and the components should not be altered or modified in any way Service Weekly and every 150 hours Check filter minder if equipped perform inspection of the paper element Paper Element and inlet screen area Yearly or every 300 hours of operation more often under extremely dusty or dirty conditions replace the paper element and check the inner element Follow these steps 1 Unhook the two retaining clips on each end and remove the end caps from the air cleaner housing See Figure 4 1 Inner Element Retaining Clips Figure 4 2 Removing Elements Filter Minder Figure 4 1 Heavy Duty Air Cleaner Inlet Screen 2 Check and clean the inlet s
90. e and battery voltage The ECU compares the input signals to the programmed maps in its memory to determine the appropriate fuel and spark requirements for the immediate operating conditions The ECU then sends output signals to set the injector duration and ignition timing The ECU continually performs a diagnostic check of itself each of the sensors and the system performance If a fault is detected the ECU can turn on a Malfunction Indicator Light MIL if equipped on the equipment control panel store the fault code in its fault memory and go into a default operating mode Depending on the significance or severity of the fault normal operation may continue A technician can access the stored fault code using a blink code diagnosis flashed out through the MIL An optional computer software diagnostic program is also available see Section 2 The ECU requires a minimum of 6 0 volts to operate To prevent engine over speed and possible failure a rev limiting feature is programmed into the ECU If the maximum RPM limit 4500 is exceeded the ECU suppresses the injection signals cutting off the fuel flow This process repeats itself in rapid succession limiting operation to the preset maximum Service Never attempt to disassemble the ECU It is sealed to prevent damage to internal components Warranty is void if the case is opened or tampered with in any way All operating and control functions within the ECU are pres
91. e oxygen sensor functions after being heated to a minimum of 400 C 752 F A heater inside the sensor heats the electrode to the optimum temperature in about 10 seconds The oxygen sensor receives the ground through the wire eliminating the need for proper grounding through the muffler If problems indicate a bad oxygen sensor check all connections and wire harness The oxygen sensor can also be contaminated by leaded fuel certain RTV and or other silicone compounds fuel injector cleaners etc Use only those products indicated as O Sensor Sate 5 12 Service The temperature must be controlled very accurately and gas constituents measured to a high degree of accuracy for absolute sensor measurements Since this requires laboratory equipment it is not possible to distinguish a marginally in specification sensor from a marginally out of specification sensor with simple field diagnostic equipment Furthermore as with most devices intermittent problems are difficult to diagnose Still with a good understanding of the system and the sensor it is possible to diagnose many sensor problems in the field 1 Protection Shield 5 Upper Insulator 2 Planar Element and Heater 6 Terminal Connection to 3 Lower Insulator Element 4 Stainless Steel Housing 7 High Temp Water Seal Figure 5 10 Cutaway of Oxygen Sensor Using diagnostic software connected to the ECU is a useful technique for observing sensor performance However th
92. e user must understand that such software reads a signal generated by the ECU If there is an ECU or wiring problem the readings could be misinterpreted as a sensor problem The digital nature of the signal to the software means that it is not reading the continuous output of the sensor A voltmeter can also be used as an effective tool in diagnosing sensors It is advisable to use an electronic meter such as a digital voltmeter Simple mechanical meters may place a heavy electrical load on the sensor and cause inaccurate readings Since the resistance of the sensor is highest at low temperatures such meters will cause the largest inaccuracies when the sensor is in a cool exhaust Visual Inspection 1 Look for a damaged or disconnected sensor to engine harness connection 2 Look for damage to the sensor lead wire or the associated engine wiring due to cutting chaffing or melting on a hot surface 3 Disconnect the sensor connector and look for corrosion in the connector 4 Try reconnecting the sensor and observe if the problem has cleared 5 Correct any problems found during the visual check Sensor Signal Observation If the visual examination shows no problems connect the sensor back to the engine harness NOTE Do notcut into or pierce the sensor or engine wiring to make this connection The sensor produces a very small signal Corrosion or damage to the wiring could lead to an incorrect signal because of repairs or
93. eable capped with seals to prevent air leaks NOTE ECU Reset is required if the throttle body is replaced Idle Speed Adjustment RPM i MD j I Mile e speed Adjustment Screw 3 Pa Dpr i d j Figure 5 23 Idle Speed Adjustment General The idle speed is the only adjustment that may be performed on the EFI system The standard idle speed setting for EFI engines is 1500 RPM but certain applications might require a different setting Check the equipment manufacturer s recommendation For starting and warm up the ECU will adjust the fuel and ignition timing based upon ambient temperature engine temperature and loads present In cold conditions the idle speed will probably be different than normal for a few moments Under other conditions the idle speed may actually start lower than normal but gradually increase to the established setting as operation continues Do not attempt to circumvent this warm up period or readjust the idle speed during this time The engine must be completely warmed up in closed loop operating mode for accurate idle adjustment Adjustment Procedure 1 Make sure there are no fault codes present in the ECU memory 2 Start the engine and allow it to fully warm up and establish closed looped operation approximately 5 10 min 3 Place the throttle control in the idle slow position and check the idle speed with a tachometer Turn the idle speed screw in or ou
94. eads Connect Only Long Enough to Test Figure 7 39 Testing Hold In Coil Function Test Test 4 Solenoid Hold In Coil Contact Continuity Use an ohmmeter set to the audible or Rx2K scale and connect the two ohmmeter leads to the two large post terminals Perform the preceding test 3 and check for continuity See Figure 7 40 The meter should indicate continuity if no continuity is indicated the solenoid should be replaced Repeat test several times to confirm condition Section 7 Electrical System and Components Plunger Pushed In VOM Meter Leads Pd 12 volt Test Leads Figure 7 40 Testing Hold In Coil Solenoid Contact Continuity T 17 Section 7 Electrical System and Components 7 18 Section 8 Disassembly WARNING Accidental Starts can cause severe injury or death Disconnect and ground spark plug lead s before servicing Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery General Clean all parts thoroughly as the engine is disassembled Only clean parts can be accurately inspected and gauged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow the manuf
95. ed and too narrow These conditions could be attributed after cleaning to excessive hours or a combination of poor operating conditions 9 5 Section 9 Inspection and Reconditioning Excessive Combustion Temperatures The white deposits seen here indicate very high combustion temperatures usually due to a lean fuel mixture Stem Corrosion Moisture in fuel or from condensation are the most common causes of valve stem corrosion Condensation occurs from improper preservation during storage and when engine is repeatedly stopped before it has a chance to reach normal operating temperatures Replace corroded valves Gum Gum deposits usually result from using stale gasoline Gum is a prevalent cause of valve sticking The cure is to ream the valve guides and clean or replace the valves depending on their condition 9 6 Overheating An exhaust valve subject to overheating will have a dark discoloration in the area above the valve guide Worn guides and faulty valve springs may cause this condition Also check for clogged air intake and blocked fins when this condition is noted Valve Guides If a valve guide is worn beyond specifications it will not guide the valve in a straight line This may result in burnt valve faces or seats loss of compression and excessive oil consumption To check valve guide to valve stem clearance thoroughly clean the valve guide and using a split ball gauge measure the inside diam
96. ej nO V a 1 E wo d j Pulse Hose i 3 Connect the in line 10 micron EFI fuel filter and hose to the inlet barb of the lift fuel pump and secure with the spring clamp NOTE Some applications may have two in line fuel filters In those applications connect the in line 51 75 micron mesh fuel filter and hose to the inlet barb of the lift fuel pump and secure with a spring clamp The in line 10 micron EFI paper fuel filter and hose must be connected to the outlet barb of the lift fuel pump and secured with a spring clamp See Figure 10 75 4 Install the fuel pump module baffle to the crankcase using the three hex flange screws Torque the screws to 11 9 N m 105 in Ib See Figure 10 76 E i Figure 10 76 Install Fuel Pump Module Baffle Section 10 Reassembly NOTE Ensure all parts are clean undamaged and free of debris and make sure the electrical connector has the seal in place 5 Push the high pressure fuel line connector onto the fuel pump module fitting 6 If the Oetiker clamp was cut to remove the inlet fuel line slide a new Oetiker clamp onto the fuel line and connect the fuel line Only use an Oetiker clamp pliers to crimp Oetiker clamps The Oetiker clamp crimp must point up away from the top of the fuel pump module and the abrasion sleeve must be positioned over the Oetiker clamp Figure 10 78 Install Fuel Pump Module 7 Connect the electrical connector to the top o
97. em Engine misses hesitates or stalls under load 1 Fuel injector s fuel filter fuel line or fuel pick up dirty restricted Dirty air cleaner Insufficient fuel pressure or fuel delivery Vacuum intake air leak Improper governor setting adjustment or operation 6 TPS faulty mounting problem or TPS Learn Procedure incorrect 7 Bad coil s spark plug s or wires P pee e p Low Power 1 Faulty malfunctioning ignition system Dirty air filter Insufficient fuel delivery Improper governor adjustment Plugged restricted exhaust One injector not working Basic engine problem exists TPS faulty or mounting exists Throttle plate in throttle body not fully opening to WOT stop if so equipped pec vr aes us Do Fuel System A WARNING Fuel System Under Pressure The fuel system operates under high pressure System pressure must be relieved through the fuel connector and the fuel pump module see page 5 2 prior to servicing or removal of any fuel system components Do not smoke or work near heaters or other fire hazards Have a fire extinguisher handy and work only in a well ventilated area The function of the fuel system is to provide sufficient delivery of fuel at the system operating pressure of 39 psi 3 If an engine starts hard or turns over but will not start it may indicate a problem with the EFI fuel system A quick test will verify if the system is operating 1 Disconnect and ground the spark plug leads
98. emoving Valve Cover Remove Crankshaft Position Sensor 1 Disconnect the electrical connector to the crankshaft position sensor See Figure 8 38 8 10 Figure 8 38 Disconnect Crankshaft Position Sensor 2 Remove the two hex flange screws securing the crankshaft position sensor See Figure 8 39 Figure 8 39 Remove the Crankshaft Position Sensor Remove the Manifold Absolute Pressure MAP Sensor 1 With a screwdriver slide the locking tab on the electrical connector See Figure 8 40 Section 8 Disassembly 2 Detach the connector 3 Remove the hex flange screw and pull the MAP sensor out of the intake manifold See Figure 8 41 Figure 8 43 Remove Fuel injector i 3 When removed pull off the metal retaining clip NOD B a Ea connecting the fuel injector to the fuel injector cap See Figure 8 44 There may be some fuel left in the high pressure fuel line Any spilled fuel must be completely wiped up immediately Figure 8 41 Remove MAP Screw Remove Fuel Injectors 1 Disconnect the electrical connector See Figure 8 42 Figure 8 44 Remove Retaining Clip Remove Intake Manifold 1 Remove the hex flange screw securing a ring terminal which is part of the wiring harness See Figure 8 45 Figure 8 42 Remove Connector 2 Remove the hex flange screw and pull the injector out of the intake manifold for each injector See Figure 8 43 8 11 Section 8 Disassembly
99. ensor limit Throttle Position Sensor TPS TPS Circuit Low Voltage or Open Condition Open connection broken wire or faulty sensor Possible Causes 1 TPS Related a TPS bad or worn internally 2 Engine Wiring Harness Related a Broken or shorted wire in harness 1 ECU Black pin 10 to TPS pin 1 2 ECU Black pin 12 to TPS pin 3 5 30 3 ECU Black pin 16 to TPS pin 2 3 Throttle Body Related a Throttle shaft inside TPS worn broken or damaged b Throttle plate loose or misaligned c Throttle plate bent or damaged allowing extra airflow past or restricting movement 4 ECU Related a Circuit providing voltage or ground to TPS damaged b TPS signal input circuit damaged Throttle Position Sensor TPS TPS Circuit High Voltage Condition Shorted connection or faulty sensor Possible Causes 1 TPS Sensor Related a Sensor connector or wiring b Sensor output affected or disrupted by dirt grease oil wear c Sensor loose on throttle body manifold 2 Throttle Body Related a Throttle shaft or bearings worn damaged 3 Engine Wiring Harness Related a ECU pins Black 10 12 and 16 damaged wiring connectors b ECU pins Black 10 12 and 16 routed near noisy electrical signal coils alternator c Intermittent 5 volt source from ECU pin Black 16 d ECU to harness connection problem O25 1 Circuit Low Voltage Condition Open connection broken wire or faulty sensor
100. ervice air cleaner components as required 4 Remove the flywheel grass screen if it overlaps the blower housing 5 Remove the two oil cooler mounting screws 6 Remove the two screws for the pulse pump 7 Remove the fuse bracket if equipped 8 Remove one screw securing the ECU bracket into the blower housing 9 Remove the top nut washer and spring for the throttle control shaft and the two screws for the throttle control bracket 10 Remove oil separator mounting hardware if equipped 11 12 13 14 15 16 17 18 19 20 2L 22 Section 5 EFI Fuel System Disconnect the breather tube on top of the throttle body Disconnect the vent hose underneath the throttle body Disconnect the rectifier regulator connector Remove the blower housing mounting screws Note the location of the plated silver screw attaching the rectifier regulator ground bracket To gain access to the screw behind the dipstick tube remove the dipstick tube screw and pull the tube out Remove the blower housing Thoroughly clean the area around and including the throttle body manifold and the injectors Disconnect the throttle linkage and linkage spring from the governor lever Disconnect the TPS lead from the harness Remove the manifold mounting bolts and separate the throttle body manifold from the engine leaving the TPS high pressure fuel line injectors and fuel line connections intact Di
101. es in Sections 8 and 9 Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important so is checking oil daily and changing the oil and filter regularly Use high quality detergent oil of API American Petroleum Institute service class SJ or higher Select the viscosity based on the air temperature at the time of operation as shown in the following table mcm Figure 6 1 Viscosity Grade Table NOTE Using other than service class SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage NOTE Synthetic oils meeting the listed classifications may be used with oil changes performed at the recommended intervals However to allow piston rings to properly seat a new or rebuilt engine should be operated for at least 50 hours using standard petroleum based oil before switching to synthetic oil A logo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 6 2 S Figure 6 2 Oil Container Logo The top position of the symbol shows service class such as API SERVICE CLASS SJ The symbol may show additional categories such as SH SG CC or CD The center portion shows the viscosity grade such as SAE 10W 30 If the bottom portion shows Energy Conserving it means that oil is intended to improve fuel economy in passenger car engines 6 1 Section 6 Lubrication System Check Oil Level
102. esistance should be 0 5 0 8 Q 3 Connect an ohmmeter set on the Rx10K scale between the spark plug boot terminal and the B primary terminal Secondary resistance should be 6400 7800 Q 4 If the secondary resistance is not within the specified range the coil is faulty and needs to be replaced NOTE If the ignition coil s are disabled and an ignition fault is registered the system will automatically disable the corresponding fuel injector drive signal The fault must be corrected to the ignition coil and the ECU power switch must be turned OFF for 10 seconds for the injector signal to return This is a safety measure to prevent bore washing and oil dilution Spark Plugs EFI engines are equipped with Champion RC12YC resistor spark plugs Equivalent alternate brand plugs can also be used but must be resistor plugs or permanent damage to the ECU will occur in addition to affecting operation Proper spark plug gap is 0 76 mm 0 030 in Battery Charging System EFI engines are equipped with either a 20 or 25 amp charging system to accommodate the combined electrical demands of the ignition system and the specific application Charging system troubleshooting information is provided in Section 7 Section 5 EFI Fuel System Fuel Components Fuel Pump General An electric fuel pump module and a lift pump two types are used to transfer fuel in the EFI system See Figures 5 17 and 5 18 The two types of lift pumps are a
103. essure Fluids can puncture skin and cause severe injury or death Do not work on fuel system without proper training or safety equipment High Pressure Fluid Puncture Fuel system is to be serviced only by properly trained personnel wearing protective safety equipment Fluid puncture injuries are highly toxic and hazardous If an injury occurs seek immediate medical attention 1 2 WARNING Explosive Fuel can cause fires and severe burns Fuel systems ALWAYS remains under HIGH PRESSURE Fuel Fire and Burns Wrap a shop towel completely around the fuel pump module connector Press the release button s and slowly pull the connector away from the fuel pump module allowing the shop towel to absorb any residual fuel in the high pressure fuel line Any spilled fuel must be completely wiped up immediately Engine Identification Numbers When ordering parts or in any communication involving an engine always give the Model Specification and Serial Numbers of the engine The engine identification numbers appear on a decal or decals affixed to the engine shrouding See Figure 1 1 An explanation of these numbers is shown in Figure 1 2 Identification Decal Figure 1 1 Engine Identification Decal Location Section 1 Safety and General Information A Model No EC V 749 uH Electronic Fuel Injection EF l Command Engine Vertical Crankshaft Numerical Designation 630 650 680 730 740 749 B
104. essure is too low replace the fuel pump module 4 If the pump did not activate step 3 disconnect the plug from the fuel pump Connect a DC voltmeter across the terminals in the plug turn on the key switch and observe if a minimum of 7 volts is present during the six second prime process 5 If no voltage is observed connect the red lead of meter to the red wire of the plug and the black lead to a good ground while the key is still ON 6 If voltage is between 7 and 14 turn key switch OFF and connect an ohmmeter between the terminals on the pump to check for continuity a If there was no continuity between the pump terminals replace the fuel pump b Ifthe voltage was below 7 test the wiring harness 7 If voltage at the plug was good and there was continuity across the pump terminals reconnect the plug to the pump making sure you have a good connection Turn on the key switch and listen for the pump to activate a If the pump starts repeat steps 2 and 3 to verify correct pressure b Ifthe pump still does not operate replace it NOTE The fuel pump module pins are coated with a thin layer of electrical grease to prevent fretting and corrosion Do not attempt to remove electrical grease from the fuel pump module pins Fuel Filter Figure 5 19 In Line Fuel Filter General The precision components inside the fuel pump module are not serviceable DO NOT attempt to open the fuel pump module Damage to
105. et No internal servicing or readjustment may be performed If a problem is encountered and you determine the ECU to be faulty contact your source of supply Do not replace the ECU without factory authorization The ECU pins are coated at the factory with a thin layer of electrical grease to prevent fretting and corrosion Do not attempt to remove the grease from the ECU pins The relationship between the ECU and the throttle position sensor TPS is very critical to proper system operation If the TPS or ECU is changed or the mounting position of the TPS is altered the appropriate TPS Learn Procedure see page 5 10 must be performed to restore the synchronization Wiring Harness Figure 5 2 ECU Connectors General The wiring harness used in the EFI system connects the electrical components providing current and eround paths for the system to operate All input and output signaling occurs through two special all weather connectors that attach and lock to the ECU The connectors are Black and Grey and keyed differently to prevent being attached to the ECU incorrectly See Figure 5 2 The condition of the wiring connectors and terminal connections is essential to system function and performance Corrosion moisture and poor connections are as likely the cause of operating problems and system errors as an actual component Refer to the Electrical System section for additional information Section 5 EFI Fuel System
106. eter of the guide Then using an outside micrometer measure the diameter of the valve stem at several points on the stem where it moves in the valve guide Use the largest stem diameter to calculate the clearance by subtracting the stem diameter from the guide diameter If the intake clearance exceeds 0 078 mm 0 0031 in or the exhaust clearance exceeds 0 090 mm 0 0035 in determine whether the valve stem or guide is responsible for the excessive clearance The maximum I D wear on the intake valve guide is 7 134 mm 0 2809 in while 7 159 mm 0 2819 in is the maximum allowed on the exhaust guide The guides are not removable but can be reamed 0 25 mm 0 010 in oversize Valves with 0 25 mm oversize stems must then be used If the guides are within limits but the valve stems are worn beyond limits install new valves Valve Seat Inserts Powder metal alloy intake and exhaust valve seat inserts are press fitted into the cylinder head The inserts are not replaceable but can be reconditioned if not too badly pitted or distorted If cracked or badly warped the cylinder head should be replaced Recondition the valve seat inserts following the instructions provided with the valve seat cutter being used A typical cutter is shown in Figure 9 7 The final cut should be made with an 89 cutter as specified for the valve seat angle in Figure 9 6 Cutting the proper 45 valve face angle as specified in Figure 9 6 and the proper
107. evious season to minimize gum deposits in your fuel system and to ensure easy starting e Do not add oil to the gasoline e Do not overfill the fuel tank Leave room for the fuel to expand Fuel Type For best results use only clean fresh unleaded gasoline with a pump sticker octane rating of 87 R M 2 or higher In countries using the Research Octane Number RON it should be 90 octane minimum Leaded gasoline is not recommended and must not be used on EFI engines or on other models where exhaust emissions are regulated Gasoline Alcohol Blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends including E20 and E85 are not to be used and not approved Any failures resulting from use of these fuels will not be warranted Gasoline Ether Blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to a maximum of 15 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved EFI Fuel System Components General The Electronic Fuel Injection EFI system is a complete engine fuel and ignition management design The system includes the following principal components e Fuel Pump Module and Lift Pump e Fuel Filter e High Pressure Fuel Line Fuel Line s Fuel Injectors Throttle Body Intake Manifold Electronic Control Unit ECU Ignition Coils Engine Oil Temperature
108. ews Figure 10 71 Install Air Cleaner Bracket NOTE The ECU pins should be coated with a thin 4 Connect the breather separator hose to the top of layer of electrical grease to prevent fretting the throttle body using a pliers to compress the and corrosion and may need to be reapplied spring clip Route the hose through the housing if the ECU is being reused by pressing the hose into the cutout of the blower housing Position abrasion sleeve as shown See Install Throttle Body Figure 10 72 1 Install a new throttle body O ring prior to installation Make sure all holes align and are 5 Push the electrical connector onto the intake air open temperature sensor making sure a good connection is made by listening for a click See 2 Install the throttle body throttle position sensor Figure 10 72 intake air temperature sensor throttle linkage spring and bushing as an assembly See Figure AN EE 10 70 Figure 10 72 Install Breather Hose and Intake Air Temperature Sensor Connector Figure 10 70 Installing Throttle Body Assembly 6 Connect the 5 32 in I D vent hose from the fuel pump module to the bottom of the throttle body 3 Install the air cleaner bracket models with heavy duty air cleaner only to the throttle body with 7 Push electrical connector onto the throttle two hex flange screws Torque the screws to position sensor making sure a good connection is 9 9 N m 88 in Ib See Figure 10 71 made See Figure 10 73
109. excessive pressure on or against the connector pins Flat pin probes are recommended for testing to avoid spreading or bending the terminals 5 5 Section 5 EFI Fuel System 3 Diagnostic Communication Line 8 Intake Air Temperature IAT sensor input 9 uel Pump Ground round for IAT TPS MAP O2 and Oil Sensors 11 Manifold Absolute Pressure MAP sensor inpu hrottle Position Sensor TPS input peed Sensor Ground il Temperature Sensor input 15 nition Switch Switched 12V ower for TPS and MAP Sensors 5V xygen Sensor O2 input Battery Power Permanent 12V Un peed Sensor input Ti uel Injector Output 71 Ground uel Injector Output 72 Ground gen Sensor Heater Diagnostic Communication Line Speed Sensorinput Fuel Injector Output 1 Ground _ U he 123456789 m m m m m m m m m m m m m m m m m m 10 11 12 13 14 15 16 17 18 6 JNotUsd 8 NotUsed S 9 BatteryGround S 16 ECU S 123456789 m m m m m m m m m m m m m m m m m u 10 11 12 13 14 15 16 17 18 Pinout of the ECU 5 6 DARK GREEN DARK BLUE 6 Terminal Connecter TT Oil Pressure Nid OW Ig q38 gt Rectifier Regulator AOV Ig e J Switch Q A o 2 LL Batte ry AN y J y xX O c m co xov Ig dq3u Ania Nva M SF AOV 18 a
110. f the Install External Governor Controls fuel pump module Ensure the grey locking tab is 1 Install the governor lever onto the governor cross pulled out before connecting Push the connector shaft See Figure 10 79 onto the terminal until a click is heard then push in the grey locking tab to lock the connector See Figure 10 77 NOTE The fuel pump module pins should be coated with a thin layer of electrical grease to prevent fretting and corrosion and may be reapplied if the fuel pump module is being reused Figure 10 79 Install Governor Lever to Shaft 2 Make sure the throttle linkage linkage spring black linkage bushing are connected to the governor lever and to the throttle lever on the throttle body See Figure 10 80 Figure 10 77 Connecting Fuel Pump Module Connector 8 Install the fuel pump module to the baffle using the three hex flange screws Torque the screws to 9 2 N m 81 in Ib See Figure 10 78 Figure 10 80 Throttle Linkage Details 10 21 Section 10 Reassembly Install Throttle Control Panel Assemble Top Mount Control Panel 1 Install the lower support control bracket with throttle control shaft See Figure 10 81 Figure 10 83 Connecting Governor Spring to Governor Lever Lise Install Bottom Mount Control Panel If So Equipped 1 Install the bottom control panel and the air Figure 10 81 Installing Lower Support Control cleaner support bracket if used to the cyli
111. following sequence is suggested for complete engine reassembly This procedure assumes that all components are new or have been reconditioned and all component subassembly work has been completed The sequence may vary to accommodate options or special equipment Detailed procedures follow 1 Install flywheel end oil seal 2 Install crankshaft 3 Install connecting rods with pistons and rings 4 Install governor cross shaft 5 Install camshaft 6 i 8 Install oil pan assembly Install stator and backing plate Install flywheel and fan m Figure 10 1 Seal Bore of Crankcase 9 Install cylinder heads and hydraulic lifters 10 Install push rods and rocker arms 11 Install spark plugs 12 Install intake manifold 13 Install fuel injectors 3 14 Install manifold absolute pressure sensor driver Make sure the oil seal is installed straight Ic ASI erent POs HON OeneOr and true in the bore to the depth shown in Figure 16 Install valve covers 10 2 17 Install breather cover and inner baffles 2 Apply a light coat of engine oil to the outside diameter of the oil seal Drive the oil seal into the crankcase using a seal 10 1 Section 10 Reassembly Figure 10 2 Installing Oil Seal in Crankcase Figure 10 4 Proper Piston Connecting Rod Orientation Install Crankshaft 1 Lubricate the crankshaft journals and connecting 1 Stagger the piston rings in the grooves until the rod bearing surfaces with engine o
112. fuel tank while the engine is hot or running Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ienited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent Refer to Section 6 Lubrication System for detailed procedures on checking the oil changing the oil and changing the oil filter Fuel Recommendations General Recommendations Purchase gasoline in small quantities and store in clean approved containers A container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle and helps eliminate spillage during refueling Do not use gasoline left over from the previous season to minimize gum deposits in your fuel system and to ensure easy starting Do not add oil to the gasoline Do not overfill the fuel tank Leave room for the fuel to expand 1 4 Fuel Type For best results use only clean fresh unleaded gasoline with a pump sticker octane rating of 87 R M 2 or higher In countries using the Research Octane Number RON it should be 90 octane minimum Leaded gasoline is not recommended and must not be used on EFI engines or on other m
113. gine The cylinder numbers are embossed on the top of the crankcase and each cylinder head See Figure 10 26 Head 4 10 8 If the breather reeds and stops were removed from the crankcase reinstall them at this time and secure with the hex flange screw Torque the screw to 4 0 N m 35 in Ib See Figure 10 27 Figure 10 27 Installed Breather Reed Valve Stem Seals These engines use valve stem seals on the intake valves and on the exhaust valves Use a new seal whenever the valve is removed or if the seal is deteriorated or damaged in any way Never reuse an old seal See Figure 10 28 Valve Seals Figure 10 28 Valve Seal Location Assemble Cylinder Heads Prior to installation lubricate all components with engine oil paying particular attention to the lip of the valve stem seal valve stems and valve guides Install the following items in the order listed below using a valve spring compressor See Figures 10 29 and 10 30 Intake and exhaust valves Valve spring retainers Valve springs Valve spring caps Valve spring keepers Valve Keepers Retainer Spring Figure 10 29 Valve Components Figure 10 30 Installing Valves with Valve Spring Compressor Install Cylinder Heads NOTE Cylinder heads must be attached with the original type of mounting hardware using either hex flange screws or mounting studs with nuts and washers Do not intermix the components 1 Check to make sure the
114. gine oil into each spark plug hole Install plugs but do not connect the plug leads Crank the 3 The fuel system must be completely emptied engine two or three revolutions or the gasoline must be treated with a stabilizer to prevent deterioration If you choose to 5 Disconnect the negative battery cable or use a use a stabilizer follow the manufacturer s battery minder trickle charger while the unit is in recommendations and add the correct amount storage for the capacity of the fuel system Fill the fuel tank with clean fresh gasoline 6 Store the engine in a clean dry place 1 5 Section 1 Safety and General Information 425 17 4 EMT Mado iab Dimensions in millimeters 53M Loa 11 891 Inch equivalents shown in AIR ALTER 3 788 a e E P 55 054 4 QS cms BARN UMEN MB AN COS DNA P RNC 19 499 SPARK PLUG NE v B SEE me 15 NU SPARK PLUG FUEL x T SN 2X 89 41 2X 77 CNN 20 863 TET ANC qu M Jed PRIMARY AIR FILTER i A 25 h rp X hn ELEMENT REMOVAL 417 59 16 441 SAFETY AIR FILTER ELEMENT REMOVAL i T OIL FILL amp ik mn E 2 l y x E e 15 5 Ms o0 C ENGNE DIPSTICK TUBE 30 DD eS RC ue OIL FILTER 3000 Py pale WO NP a PORT 2 FLYWHEEL SIDE PORT 1 d P koi i 3 AT X SOLENOID RO ZAI HSS Shoe 2X 104 02 405 89 SHIFT STARTER c AL Kd Ue 4 095 15 980 CEP NL SSF
115. he installation hole is sealed with a 1 8 27 N P T F pipe plug 6 4 To install the switch follow these steps 1 If no sealant is preapplied apply pipe sealant with Teflon Loctite 592 PST Thread Sealant or equivalent to the threads of the switch 2 Install the switch into the tapped hole in the breather cover See Figure 6 8 3 Torque the switch to 4 5 N m 40 in Ib 4 Attach lead to switch terminal Testing the Switch Compressed air a pressure regulator pressure gauge and a continuity tester are required to test the switch Normally Closed Switch 1 Connect the continuity tester across the blade terminal and the metal case of the switch With 0 psi pressure applied to the switch the tester should indicate continuity switch closed 2 Gradually increase the pressure to the switch As pressure increases through the range of 2 0 5 0 psi the tester should indicate a change to no continuity switch open The switch should remain open as the pressure is increased to 90 psi maximum 3 Gradually decrease the pressure through the range of 2 0 5 0 psi The tester should indicate a change to continuity switch closed down to 0 psi 4 Replace the switch if it does not operate as specified Normally Open Switch 1 Connect the continuity tester across the blade terminal and the metal case of the switch With 0 psi pressure applied to the switch the tester should indicate no continuity switch open 2
116. he armature windings insulation for shorting Shift Fork Check that the shift fork is complete and the pivot and contact areas are not excessively worn cracked or broken 7 11 Section 7 Electrical System and Components Brush Replacement Starter Service The brushes and springs are serviced as a set 4 Clean the drive lever and armature shaft Apply Use Kohler Brush and Spring Kit if replacement is Kohler electric starter drive lubricant see Section 2 necessary Versilube G322L or Mobil Temp SHC 32 to the lever and shaft Clean and check the other starter parts for 1 Perform steps 1 5 in Starter Disassembly wear or damage as required 2 Remove the two screws securing the brush Starter Reassembly holder assembly to the end cap plate Note the 1 Apply drive lubricant see Section 2 to the orientation for reassembly later See Figure 7 22 armature shaft splines Install the drive pinion Discard the old brush holder assembly onto the armature shaft 2 Install and assemble the stop collar retainer assembly See Figure 7 24 a Install the stop collar down onto the armature shaft with the counter bore recess up b Install a new retainer in the larger rear groove of the armature shaft Squeeze with a pliers to compress it in the groove c Slide the stop collar up and lock it into place so the recess surrounds the retainer in the groove If necessary rotate the pinion outward on the armature splines against the re
117. head is flat on the gasket and dowel pins 6 Lightly lubricate the exposed upper threads of the studs with engine oil Install a flat washer and hex nut onto each of the mounting studs Torque the hex nuts in two stages first to 16 9 N m 150 in Ib then finally to 33 9 N m 300 in Ib following the sequence in Figures 10 32 and 10 34 10 9 Section 10 Reassembly ylinder Head Mounting Nuts Stud Design Heads secured with hex flange screws 2 Install a new cylinder head gasket part number facing up NOTE Match the numbers embossed on the cylinder heads and crankcase See Figure 10 26 3 Install the cylinder head and start the four hex flange screws See Figure 10 33 cra FFI Ji hap Figure 10 33 Torquing Cylinder Head Screws 4 Torque the hex flange screws in two stages first to 22 6 N m 200 in Ib then finally to 41 8 N m 370 in Ib following the sequence in Figure 10 34 10 10 Figure 10 34 Cylinder Head Fastener Torque Sequence Install Push Rods and Rocker Arms NOTE Push rods should always be installed in the same position as before disassembly 1 Note the mark or tag identifying the push rod as either intake or exhaust and cylinder 1 or 2 Dip the ends of the push rods in engine oil and install making sure that each push rod ball seats in its hydraulic lifter socket See Figure 10 35 Position 2 Apply grease to the contact surfaces of the rocker arms and
118. hru larger bolts See Figure 7 12 Section 7 Electrical System and Components Figure 7 12 Removing Thru Bolts 4 Remove the commutator end plate assembly containing the brush holder brushes springs and locking caps Remove the thrust washer from inside the commutator end See Figure 7 13 Figure 7 13 Removing Commutator End Plate Assembly 5 Remove the frame from the armature and drive end cap See Figure 7 14 Figure 7 14 Starter Frame Removed 7 9 Section 7 Electrical System and Components 6 Remove the rubber grommet and backing plate from the end cap See Figure 7 15 Figure 7 15 Rubber Grommet and Bushing Plate 7 Take out the drive lever and pull the armature out of the drive end cap See Figure 7 16 8 Remove the thrust washer from the armature shaft See Figure 7 16 Figure 7 16 Armature and Lever Removed 9 Push the stop collar down to expose the retaining ring See Figure 7 17 7 10 Figure 7 17 Retaining Ring Detail 10 Remove the retainer from the armature shaft Save the stop collar NOTE Do not reuse the old retainer Figure 7 18 Removing Retaining Ring 11 Remove the drive pinion assembly from the armature 12 Clean the parts as required NOTE Do not soak the armature or use solvent when cleaning Wipe clean using a soft cloth or use compressed air Inspection Drive Pinion Check and inspect the following areas a The pinion
119. hru bolts to 5 6 9 0 N m 49 79 in Ib Torque the brush holder mounting screws to 2 5 3 3 N m 22 29 in Ib See Figures 7 34 and 7 35 Figure 7 34 Torquing Thru Bolts I5 Figure 7 35 Torquing Brush Holder Screws Section 7 Electrical System and Components Hook the plunger behind the upper end of the drive lever and install the spring into the solenoid Insert the three mounting screws through the holes in the drive end cap Use these to hold the solenoid gasket in position then mount the solenoid Torque the screws to 4 0 6 0 N m 35 53 in Ib Connect the positive brush lead bracket to the solenoid and secure with the hex nut Torque the nut to 8 11 N m 71 97 in Ib Do not overtighten See Figure 7 36 Figure 7 36 Positive Brush Lead Connection 7 15 Section 7 Electrical System and Components Solenoid Test Procedure Solenoid Shift Style Starters Disconnect all leads from the solenoid including the positive brush lead attached to the lower stud terminal Remove the mounting hardware and separate the solenoid from the starter for testing Test 1 Solenoid Pull In Coil Plunger Actuation Use a 12 volt power supply and two test leads Connect one lead to the flat spade START terminal on the solenoid Momentarily connect the other lead to the lower large post terminal See Figure 7 37 When the connection is made the solenoid should energize audible click and the plunger ret
120. igure 10 43 manifold and rotate to original position 10 12 Section 10 Reassembly 5 Install the fuel injector cap hex flange screw into the intake manifold and torque to 7 3 N m 65 in Ib See Figure 10 45 6 Push the electrical connector on the fuel injector making sure a good connection is made 7 Repeatsteps 1 through 6 for the other fuel injector Install Manifold Absolute Pressure MAP Sensor NOTE Ensure all parts are clean undamaged and free of debris and make sure the electrical connector has the seal in place 1 Lightly oil the MAP sensor O ring and push the MAP sensor into the bore in the intake manifold 2 Torque the hex flange screw to 7 3 N m 65 in Ib See Figure 10 46 Figure 10 46 Torque the MAP Sensor Screw 3 Push the electrical connector on the MAP sensor making sure a good connection is made Install Crankshaft Position Sensor NOTE Ensure all parts are clean undamaged and free of debris and make sure the electrical connectors have the seal in place 1 Install the crankshaft position sensor and bracket assembly to the crankcase posts 2 Snug the hex flange screws and check the air gap of the sensor with a feeler gauge It must be 0 20 0 70 mm 0 008 0 027 in 3 Torque the bracket screws to the crankcase to 4 0 N m 35 in Ib into used holes or 6 2 N m 55 in Ib into new holes See Figure 10 47 E ERR Figure 10 47 Torque Crankshaft Positi
121. il end gaps are 120 apart The oil ring rails should also be staggered 2 Carefully slide the flywheel end of the crankshaft through the main bearing in the crankcase See 2 Lubricate the cylinder bore piston and piston Figure 10 3 rings with engine oil Compress the rings using a piston ring compressor 3 Make sure the Fly stamping on the piston is facing towards the flywheel side of the engine Use a hammer with a rubber grip and gently tap the piston into the cylinder as shown in Figure 10 5 Be careful that the oil ring rails do not spring free between the bottom of the ring compressor and the top of the cylinder e j Figure 10 3 Installing Crankshaft Install Connecting Rods with Pistons and Rings NOTE The cylinders are numbered on the crankcase Make sure to install the piston connecting rod and end cap into its appropriate cylinder bore as previously marked at disassembly Do not mix the end caps and connecting rods Figure 10 5 Installing Piston Assembly Using Ring Compressor Tool NOTE Proper orientation of the piston connecting rod assemblies inside the engine is extremely important Improper orientation can cause extensive wear or damage Be certain the pistons and connecting rods are assembled exactly as shown in Figure 10 4 4 Install the inner rod cap to the connecting rod using the two hex flange screws Torque in increments to 11 6 N m 103 in Ib Illustrated instructions are p
122. ion or poor compression Worn On a worn plug the center electrode will be rounded and the gap will be greater than the specified gap Replace a worn spark plug immediately 7 2 Wet Fouled A wet plug is caused by excess fuel or oil in the combustion chamber Excess fuel could be caused by a restricted air cleaner or rich air fuel ratio Oil in the combustion chamber is usually caused by a restricted air cleaner a breather problem or worn piston rings cylinder walls or valve guides Overheated Chalky white deposits indicate very high combustion temperatures This condition is usually accompanied by excessive gap erosion Lean air fuel ration an intake air leak or incorrect spark timing are normal causes for high combustion temperatures Battery General A 12 volt battery with 400 cold cranking amps is generally recommended for starting in all conditions A smaller capacity battery is often sufficient if an application is started only in warmer temperatures Refer to the following table for minimum cold cranking amp cca capacities based on anticipated ambient temperatures The actual cold cranking requirement depends on engine size application and starting temperatures The cranking requirements increase as temperatures decrease and battery capacity shrinks Refer also to the operating instructions for the piece of equipment for specific battery requirements Battery Size Recommendations Battery Required Te
123. k aa B NVL Mov T8 B a Nase0 eve E NJJH9 LH917 A 2 1 3 2 a8 mva BEN NISI i ey a LS j N33HO yava y9v19 03 aoe CN I ice 3 2 A steed yov1g a3s AOV Ig gem ll Ov IS q3M M naso sane I Xov IS q3M TL sons ABC ABC B A B A A3u9 IC Diagnost NAKE Oil Temperature Manifold Throttle Position Oxygen Crankshaft Ignition Coil Ignition Coil Fuel Injector Fuel eer Connector Air Temperature Absolute Sensor Position Sensor Pressure Sensor 2o oensor 111 Sensor Sensor Section 5 EFI Fuel System Crankshaft Position Sensor Figure 5 3 Crankshaft Position Sensor General The crankshaft position sensor is essential to engine operation constantly monitoring the rotation and speed RPM of the crankshaft There are 23 consecutive teeth cast into the flywheel One tooth is missing and is used to reference the crankshaft position for the ECU The inductive crankshaft position sensor is mounted 0 20 0 70 mm 0 008 0 027 in from the flywheel During rotation an AC voltage pulse is created within the sensor for each passing tooth The ECU calculates engine speed from the time interval between the consecutive pulses The gap from the missing tooth creates an interrupted input signal corresponding to specific crankshaft position near BDC for cylinder
124. key into the keyway of the crankshaft Make sure that the key is properly A WARNING Damaging Crankshaft and seated and parallel with the shaft taper Flywheel Can Cause Personal Injury Using improper procedures to install the flywheel can crack NOTE Make sure the flywheel key is installed or damage the crankshaft and or flywheel This not only properly in the keyway The flywheel causes extensive engine damage but can also cause personal can become cracked or damaged if the injury since broken fragments could be thrown from the key is not properly installed engine Always observe and use the following precautions and procedures when installing the flywheel 2 Install the flywheel onto the crankshaft being careful not to shift the woodruff key See Figure NOTE Before installing the flywheel make sure the 10 21 crankshaft taper and flywheel hub are clean dry and completely free of any lubricants The presence of lubricants can cause the flywheel to be over stressed and damaged when the hex flange screw is torqued to specifications See Figures 10 19 and 10 20 10 6 Figure 10 21 Carefully Align Keyway to Key 3 Install the hex flange screw and washer 4 Usea flywheel strap wrench or holding tool to hold the flywheel Torque the hex flange screw securing the flywheel to the crankshaft to 71 6 N m 52 8 ft Ib See Figure 10 22 i i Je Figure 10 22 Installing and Torquing Flywheel Fastener Install
125. kshaft 2 Thread a 3 4 in or 1 in long self tapping screw with a flat washer into the drilled hole The flat washer must be large enough to seat against the shoulder of the plug bore See Figure 9 2 3 Tighten the self tapping screw until it draws the plug out of the crankshaft Self Tapping Screw Flat Washer Plug Crankshaft Figure 9 2 Removing Crankpin Plug 9 2 Procedure to Install New Plug 1 Usea single cylinder camshaft pin Part No 47 380 09 S as a driver and tap the plug into the plug bore until it seats at the bottom of the bore Make sure the plug is tapped in evenly to prevent leakage Crankcase Inspection and Service Check all gasket surfaces to make sure they are free of gasket fragments Gasket surfaces must also be free of deep scratches or nicks Check the cylinder bore for scoring In severe cases unburned fuel can cause scuffing and scoring of the cylinder wall It washes the necessary lubricating oils off the piston and cylinder wall As raw fuel seeps down the cylinder wall the piston rings make metal to metal contact with the wall Scoring of the cylinder wall can also be caused by localized hot spots resulting from blocked cooling fins or from inadequate or contaminated lubrication If the cylinder bore is badly scored excessively worn tapered or out of round resizing is necessary Use an inside micrometer to determine the amount of wear refer to Specifications Tolerances
126. l Air in high pressure fuel line Fuel valve shut OFF Fuel filter line plugged Injector circuit s pin circuits Black 5 and Black 6 Injector ECU grounds ECU Lift pump not working ot DNO os ey Diagnostic Aid 8 FUEL SYSTEM fuel pressure Possible causes for low fuel system pressure 1 Low fuel Fuel filter plugged Fuel supply line plugged Lift fuel pump insufficient fuel supply Fuel pump lift or module internally plugged pL Possible causes for high fuel system pressure 1 Pressure regulator not functioning properly inside fuel pump module Diagnostic Aid 9 BASIC ENGINE cranks but will not run Possible causes 1 Refer to basic engine troubleshooting charts within service manual sections 3 5 and 7 5 37 Section 5 EFI Fuel System 5 38 Section 6 Lubrication System General This engine uses a full pressure lubrication system delivering oil under pressure to the crankshaft camshaft and connecting rod bearing surfaces In addition to lubricating the bearing surfaces the lubrication system supplies oil to the hydraulic valve lifters A high efficiency gerotor pump is located in the oil pan The oil pump maintains high oil flow and oil pressure even at low speeds and high operating temperatures A pressure relief valve in the oil pan limits the maximum pressure of the system Service The oil pan must be removed to service the oil pump or oil pickup Refer to the appropriate procedur
127. lated unoccupied buildings away from sparks or flames shrouds or guards removed Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent 1 1 Section 1 Safety and General Information WARNING Carbon Monoxide can cause severe nausea fainting or death Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area Lethal Exhaust Gases Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide is odorless colorless and can cause death if inhaled Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area A CAUTION Electrical Shock can cause injury Do not touch wires while engine is running Electrical Shock Never touch electrical wires or components while the engine is running They can be sources of electrical shock WARNING Cleaning Solvents can cause severe injury or death Use only in well ventilated areas away from ignition sources Flammable Solvents Carburetor cleaners and solvents are extremely flammable Keep sparks flames and other sources of ignition away from the area Follow the cleaner manufacturer s warnings and instructions on its proper and safe use Never use gasoline as a cleaning agent WARNING High Pr
128. le Body pump module See Figure 8 15 1 Disconnect the intake air temperature sensor See Figure 8 17 Release Buttons ES Vent Fitting f j le wa W i 4 E A Figure 8 15 Slowly Pull Connector Figure 8 17 Disconnect Intake Air Temperature 4 Wrap a shop towel completely around the high Sensor pressure fuel line connector 2 Disconnect the breather tube See Figure 8 18 5 Press the release button s and slowly pull the connector away from the fuel pump module allowing the shop towel to absorb any residual fuel in the high pressure fuel line Any spilled fuel must be completely wiped up immediately See Figure 8 15 NOTE Figure 8 15 depicts removing the connector without a shop towel wrapped around it for instructional purposes only 8 5 Section 8 Disassembly 5 If equipped remove the two screws securing the heavy duty air cleaner bracket take off the bracket and slide the throttle body off the intake manifold See Figure 8 21 Figure 8 18 Disconnect Breather Tube 3 Disconnect the throttle position sensor connector See Figure 8 19 Figure 8 21 Remove Air Cleaner Bracket Screws Remove the Electronic Control Unit ECU 1 Remove the two hex flange screws securing the ECU to the bracket See Figure 8 22 patien piti Il gir a pact Figure 8 19 Disconnecting the Throttle Position Sensor 4 Disconnect the vent hose from beneath the thr
129. led by the rocker cover so a low positive pressure is created in the head cavity The 1 rocker cover has a hole in it for venting The bottom nipple of an oil separator canister is fitted into the hole with a grommet From the top nipple of the canister a breather hose goes back to the air cleaner base The air moving into the 1 head cavity is filtered through the oil separator and then is drawn into the air intake See Figure 9 18 The upward travel of the pistons closes the reeds and creates a low vacuum in the lower crankcase The combination of low pressure above and low vacuum below forces any accumulated oil out of the 2 head area into the crankcase On the 1 bank you have atmospheric pressure above and vacuum below again drawing any oil toward the crankcase Figure 9 18 Oil Separator Governor Cross Shaft Oil Seal If the governor cross shaft seal is damaged and or leaks replace it using the following procedure Remove the oil seal from the crankcase and replace it with a new one Install the new seal to the depth shown in Figure 9 19 using a seal installer 2 0 mm 0 0787 in Governor Cross Shaft Seal Section 9 Inspection and Reconditioning 9 13 Section 9 Inspection and Reconditioning 9 14 Section 10 Reassembly General 18 Install oil temperature sensor NOTE Make sure the engine is assembled using 19 Install Oil Sentry all specified torque values tightening 20 Install blower h
130. ll destroy the electrolyte Battery Test To test the battery you will need a DC voltmeter Perform the following steps see Figure 7 2 1 Connect the voltmeter across the battery terminals 2 Crank the engine If the battery drops below 9 volts while cranking the battery is too small discharged or faulty DC Voltmeter Figure 7 2 Battery Voltage Test 7 3 Section 7 Electrical System and Components Battery Charging System General These engines are equipped with a 20 or 25 amp regulated charging system See Figure 7 3 for the 20 25 amp charging system diagram NOTE Observe the following guidelines to avoid damage to the electrical system and components e Make sure the battery polarity is correct A negative ground system is used e Disconnect the rectifier regulator plug and or the wiring harness plug before doing any electric welding on the equipment powered by the engine Also disconnect all other electrical accessories in common ground with the engine e Prevent the stator AC leads from touching or shorting while the engine is running This could damage the stator 20 25 Amp Regulated Charging System Battery Stator The stator is mounted on the crankcase behind the flywheel Follow the procedures in Section 8 Disassembly and Section 10 Reassembly if stator replacement is necessary Figure 7 4 20 Amp Stator and Rectifier Regulator Flywheel Stator Assembly BE B
131. lves Fuel in the crankcase oil Fuel pump module is over filled Lift pump diaphragm is ruptured 9 moan 5 31 Section 5 EFI Fuel System Lean fuel condition Condition Fuel inlet screen filter plugged low pressure at high pressure fuel line TPS malfunction shorted connection or faulty sensor Possible Causes 1 TPS Learn Incorrect a Lean condition check oxygen sensor signal with VOA and see Oxygen Sensor section 2 Engine Wiring Harness Related a Pin circuit wiring or connectors ECU pin Black 10 12 16 and 17 3 Low Fuel Pressure a Plugged filters b Bad lift pump 4 Oxygen Sensor Related a Sensor connector or wiring problem b Exhaust leak c Poor ground 5 Poor system ground from ECU to engine causing rich running while indicating lean 6 Fuel pump module connection See Fuel Components Fuel Injector Injector 1 Circuit Malfunction Condition Injector damaged or faulty shorted or open connection Possible Causes 1 Injector Related a Injector coil shorted or opened 2 Engine Wiring Harness Related a Broken or shorted wire in harness ECU pin Black 5 b Wiring from Ignition 3 ECU Related a Circuit controlling injector 1 damaged 5 32 Fuel Injector Injector 2 Circuit Malfunction Condition Injector damaged or faulty shorted or open connection Possible Causes 1 Injector Related a Injector coil shorted or opened 2 Engine Wiring Harne
132. minal 2 in the sensor plug Intake Air Temperature Sensor Figure 5 8 Intake Air Temperature Sensor General The Intake Air Temperature IAT sensor is a thermally sensitive resistor that exhibits a change in electrical resistance with a change in its temperature When the sensor is cold the resistance of the sensor is high and the voltage signal is high As the sensor warms up the resistance drops and voltage signal decreases From the voltage signal the ECU can determine the temperature of the intake air Section 5 EFI Fuel System The purpose of an air temperature sensor is to help the ECU calculate air density The higher the air temperature gets the less dense the air becomes As the air becomes less dense the ECU knows that it needs to lessen the fuel flow to achieve the correct air fuel ratio If the fuel ratio was not changed the engine would become rich possibly losing power and consuming more fuel Service The intake air temperature sensor is a non serviceable component Complete replacement is required if it is faulty The sensor and wiring harness can be checked as follows Remove the temperature sensor from the throttle 5 body 2 Allow it to reach room temperature 20 C 68 F 3 Unplug the Black connector from the ECU 4 With the sensor still connected check the temperature sensor circuit resistance between the Black pin 10 and 8 pin terminals The value should be 3100 3900 5 U
133. mperature Above 32 F 0 C If the battery charge is not sufficient to turn over the engine recharge the battery Battery Maintenance Regular maintenance is necessary to prolong battery life A WARNING Explosive Gas Batteries produce explosive hydrogen gas while being charged To prevent a fire or explosion charge batteries only in well ventilated areas Keep sources of ignition away from the battery at all times Keep batteries out of the reach of children Remove all jewelry when servicing batteries Before disconnecting the negative ground cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present 1 Regularly check the level of electrolyte Add distilled water as necessary to maintain the recommended level NOTE Do not overfill the battery Poor performance or early failure due to loss of electrolyte will result Section 7 Electrical System and Components 2 Keep the cables terminals and external surfaces of the battery clean A build up of corrosive acid or grime on the external surfaces can cause the battery to self discharge Self discharge occurs rapidly when moisture is present 3 Wash the cables terminals and external surfaces with a mild baking soda and water solution Rinse thoroughly with clear water NOTE Do not allow the baking soda solution to enter the cells as this wi
134. n and Reconditioning This section covers the operation inspection and repair reconditioning of major internal engine components The following components are not covered in this section They are covered in sections of their own Air Cleaner Section 4 Fuel Injection amp External Governor Section 5 Ignition Charging amp Electric Starter Section 7 Clean all parts thoroughly Only clean parts can be accurately inspected and gauged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow the manufacturer s instructions and safety precautions carefully Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Use an aerosol gasket remover paint stripper or lacquer thinner to remove any old sealant Apply the solvent allow time for it to work and then brush the surface with a brass wire brush After the old sealant is removed clean the surface with isopropyl alcohol lacquer thinner or aerosol electrical contact cleaner Do not scrape the surfaces as any scratches nicks or burrs can result in leaks See Service Bulletin 252 for further information Refer to A Guide to Engine Rebuilding TP 2150 A for additional information Measurement Guide TP 2159 B and
135. n duration depending on the speed and load requirements of the engine 6 Valve Seat 7 Valve End 8 Lower O ring 9 Director Plate 1 Electrical Connection 2 Upper O ring 3 Solenoid Winding 4 Armature 5 Valve Housing Figure 5 13 Fuel Injector Details Service Injector problems typically fall into three general categories electrical dirty clogged or leakage An electrical problem usually causes one or both of the injectors to stop functioning Several methods may be used to check if the injectors are operating 1 With the engine running at idle listen for a buzzing or clicking sound 2 Disconnect the electrical connector from an injector and listen for a change in idle performance only running on one cylinder or a change in injector noise or vibration If an injector is not operating it can indicate either a bad injector or a wiring electrical connection problem Check as follows 5 16 NOTE Do not apply voltage to the fuel injector s Excessive voltage will burn out the injector s Do not ground the injector s with the ignition ON Injector s will open turn on if relay is energized 1 Disconnect the electrical connector from both injectors Plug a 12 volt noid light part of EFI Service Kit see Section 2 into one connector Figure 5 14 Volt Noid Light 2 Make sure all safety switch requirements are met Crank the engine and check for flashing of the test light Turn key OFF for a
136. n the positions specified Pin location shown in Figure 5 4 SM Pin 3000 7000 If the resistance values in steps 3 4 and 5 are within specifications go to step 6 If the resistance values are not within specifications or a momentary short or open circuit was detected during rotation step 4 the TPS needs to be replaced go to step 7 Check the TPS circuits input ground between the TPS plug and the main harness connector for continuity damage etc The input pin is 12 and the ground is pin 10 a Repair or replace as required b Turn the idle speed screw back in to its original setting c Reconnect connector plugs start engine and retest system operation Remove the two mounting screws from the TPS Save the screws for reuse Remove and discard the faulty TPS Install the replacement TPS and secure with the original mounting screws a Reconnect the Black and TPS connector plugs b Perform the TPS Learn Procedure integrating the new sensor to the ECU 5 9 Section 5 EFI Fuel System ECU Reset and TPS Learn Procedure Any service to the ECU TPS Throttle Body including idle speed increase over 300 RPM or the fuel pump module should include ECU Reset This will clear all trouble codes all closed loop learned offsets all max values and all timers besides the permanent hour meter The system will NOT reset when the battery is disconnected ECU Reset Procedure 1 Turn key OFF 2 Inst
137. nder Bracket heads using the four hex flange screws Torque the screws to 10 7 N m 95 in Ib into new holes 2 Install top mount control panel over throttle or 7 3 N m 65 in Ib into used holes See Figure control shaft Secure the control panel to the 10 84 blower housing with the two screws See Figure 10 82 Figure 10 84 Bottom Mount Control Panel Figure 10 82 Installing Throttle Control Panel 2 Connect the governor spring from the throttle control bracket to the previously marked hole in 3 Assemble the throttle control lever and applicable the governor lever hardware to the throttle control shaft NOTE To identify the various parts and assembly of 4 Attach governor spring to the previously marked the throttle control panel see Figure 10 85 hole on the governor lever See Figure 10 83 10 22 Section 10 Reassembly Description Bracket speed control Clamp cable Lever throttle control top Lever throttle actuator bottom Screw M5x0 8x20 Washer spring Washer flat 2 Spring return Nut M5x0 8 lock OOnNOOKRWDND Figure 10 85 Throttle Control Bracket Detail Install Air Cleaner Assembly Refer to Section 4 for the air cleaner reassembly procedure Heavy Duty Air Cleaner 1 Install the air cleaner assembly onto the throttle body mounting studs Secure and torque the hex flange nuts to 7 4 9 0 N m 65 5 80 in Ib See Figure 10 86 Figure 10 87 Installing Upper Mou
138. necessary If voltage is more than 14 7 volts the rectifier regulator is faulty Replace rectifier regulator Fuses This engine has three 3 blade type automotive fuses Replacement fuses must have the same rating as the blown fuse Use the fuse chart below to determine the correct fuse Fuse Rating 2 Purple Wires 30 amp Fuse 1 Red Wire with Black Stripe dana M 1 Red Wire with White Stripe P 2 Red Wires 10 amp Fuse To Replace a Fuse 1 Shut engine off and remove key 2 Locate the fuse holders 3 Remove the fuse cover and pull out fuse 4 Inspect the fuse for a solid fusible link or a broken fusible link Replace the fuse if the fusible link is broken If you are not sure if the fusible link is broken replace the fuse 5 Insert the fuse into the fuse holder until it is seated properly Install the fuse cover Electric Starting Motors These engines use solenoid shift starters Starting Motor Precautions NOTE NOTE NOTE NOTE Do not crank the engine continuously for more than 10 seconds at a time If the engine does not start allow a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor If the starter cranks the engine but does not start the engine the engine rotation must be allowed to come to a complete stop before attempting to restart the engine again If the starter is engaged while the flywheel is rotating the
139. nition Coil Malfunction Code 0352 Cylinder 2 Ignition Coil Malfunction Code 0562 System Voltage Low Code 0563 System Voltage High Code 61 End of Code Transmission Diagnostic Aid 3 RUN ON MIL remains ON while engine is running Possible causes 1 All current fault codes will turn on MIL when engine is running NOTE Either incandescent or LED type bulbs can be used for the MIL as long as they do not draw more than 0 1 amps The bulb needs to be rated at 1 4 Watts or less or needs to have a total resistance of 140 Q or more LEDs typically draw less than 0 03 amps Diagnostic Aid 4 CRANKSHAFT POSITION SENSOR MIL does not turn off during cranking Possible causes 1 Crankshaft position sensor 2 Crankshaft position sensor circuit problem pin circuits Black 4 and Black 13 3 Crankshaft position sensor toothed wheel air gap 4 Toothed wheel 5 Flywheel key sheared 6 ECU Diagnostic Aid 5 FUEL PUMP fuel pump not turning on Possible causes 1 Main fuse 2 Fuel pump circuit problem pin circuits Black 9 and Grey 17 3 Fuel pump module Diagnostic Aid 6 IGNITION SYSTEM no spark Possible causes 1 Spark plug 2 Plug wire 3 Coil 4 Coil circuit s pin circuits Grey 10 and Black 1 5 ECU grounds Section 5 EFI Fuel System 6 ECU 7 Vehicle safety interlocks ground signal on safety wire Diagnostic Aid 7 FUEL SYSTEM ELECTRICAL no fuel delivery Possible causes 1 No fue
140. nocrtet esto orbe cuin rtob an Erbe ere Des tpNR MEE first to 16 9 N m 150 in Ib finally to 33 9 N m 300 in Ib Head Dolt Torqucin DO S HB cynnen oae Pan Mp tuti pA M REM geb ONE first to 22 6 N m 200 in Ib finally to 41 8 N m 370 in Ib Cylinder Head Max Cut ob IHE SS irat reto Et ates stores enge uebP ppc Ip SUPPE 0 076 mm 0 003 in FROG eig vote EO c T A T 11 9 N m 105 in Ib Fan Flywheel LOC PHSIERBE TOTOUO oos opui nU REM E EN DANUM UU FN IPIE EUREN ANERUDONP Fc iRURdE 9 9 N m 88 in Ib Piw heel Retaining Serr TOE OG sees td eppi esa eiusdem NH 71 6 N m 52 8 ft Ib Fuel Pump bue rump Mod Gre Batle Fastener Torg Go puoe doro Qusto obutoott a 11 9 N m 105 in Ib Enel Pip Module Fastener OFGUD sedia at agutenu ko seisd ata porsu tox pios atado st eee 9 2 N m 81 in Ib Paulse Tum p Bracke as Peet TOP UE ooo ioci ub aO Es eee pu IS EQ OMM S 2 1 N m 25 in Ib Pulse Pump Fastener lo Bracket Or Que caavsssisenostsssuciaecsetesssencentuscstasoussoonoasonnnents 7 3 N m 68 in Ib into new holes 6 2 N m 55 in Ib into used holes 1 10 Section 1 Safety and General Information Governor Governor Cross Shaft to Crankcase Running Clearance 0 025 0 126 mm 0 0009 0 0049 in Governor Cross Shaft O D lU 7 949 8 000 mm 0 3129 0 3149 in Max Wear iri P 7 936 mm 0 3124 in Governor Gear Shaft to Governor
141. nplug the sensor from the wire harness and check the sensor resistance separately across the two pins Resistance value should again be 3100 3900 a If the resistance is out of specifications replace the temperature sensor b Ifitis within specifications proceed to Step 6 6 Check the circuits input ground from the main harness connector to the sensor plug for continuity damage etc Connect one ohmmeter lead to Black pin 8 in the main harness connector as in step 4 Connect the other lead to terminal 1 in the sensor plug see Figure 5 8 Continuity should be indicated Repeat the test between Black pin 10 and terminal 2 in the sensor plug 5 11 Section 5 EFI Fuel System Oxygen Sensor Figure 5 9 Oxygen Sensor General The oxygen sensor functions like a small battery generating a voltage signal to the ECU based upon the difference in oxygen content between the exhaust gas and the ambient air The tip of the sensor protruding into the exhaust gas is hollow see cutaway Figure 5 10 The outer portion of the tip is surrounded by the exhaust gas with the inner portion exposed to the ambient air When the oxygen concentration on one side of the tip is different than that of the other side a voltage signal up to 1 0 volt is generated and sent to the ECU The voltage signal tells the ECU if the engine is straying from the ideal fuel mixture and the ECU then adjusts the injector pulse accordingly Th
142. ntaining a good level of suds If the suds break down during cleaning discard the dirty water and start again with more hot water and detergent Following the scrubbing rinse the cylinder with very hot clear water dry it completely and apply a light coating of engine oil to prevent rusting Measuring Piston to Bore Clearance Before installing the piston into the cylinder bore it is necessary that the clearance be accurately checked This step is often overlooked and if the clearances are not within specifications engine failure will usually result NOTE Do not use a feeler gauge to measure piston to bore clearance it will yield inaccurate measurements Always use a micrometer Use the following procedure to accurately measure the piston to bore clearance 1 Usea micrometer and measure the diameter of the piston 6 mm 0 24 in above the bottom of the piston skirt and perpendicular to the piston pin See Figure 9 4 6 mm 0 24 in o _ Measure 6 mm above the Bottom of Piston Skirt at Right Angles to Piston Pin Figure 9 4 Measuring Piston Diameter 2 Use an inside micrometer telescoping gauge or bore gauge and measure the cylinder bore Take the measurement approximately 63 5 mm 2 5 in below the top of the bore and perpendicular to the piston pin 3 Piston to bore clearance is the difference between the bore diameter and the piston diameter step 2 minus step 1 9 3 Section 9 Inspecti
143. nting Screws Low Profile Air Cleaner 1 Verify O ring is present around the machined O D of the throttle body and place air cleaner base onto throttle body studs Secure the air cleaner base using three hex flange nuts Attach e Flang Nuts the air cleaner base bracket to the cylinder heads with four hex flange screws behind any control 4 i be LA d j Torque Hex z panel or bracket Attach the air cleaner base to the Figure 10 86 Torquing Hex Nuts lower bracket with the two M5 screws through the lower section of the base Torque the hex 2 Install and tighten the two upper mounting flange nuts to 7 4 9 0 N m 65 5 80 in Ib and the screws securing the air cleaner to the mounting two lower M5 mounting screws to 2 3 N m bracket Torque the screws to 9 9 N m 20 in Ib See Figures 10 88 and 10 89 88 in Ib See Figure 10 87 10 23 Section 10 Reassembly p j 2 Install the air cleaner components as described in Section 4 Setting Initial Governor Adjustment 1 Move the governor lever toward the throttle body as far as it will go wide open throttle and hold in position 2 Insert a nail into the hole on the cross shaft and rotate the shaft counterclockwise as far as it will turn then torque the hex nut to 7 1 N m 63 in Ib See Figure 10 90 10 24 Figure 10 90 Setting Governor Adjustment Figure 10 91 Install Oil Cooler Install Muffler 1 Install the po
144. odels where exhaust emissions are regulated Gasoline Alcohol Blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends including E20 and E85 are not to be used and not approved Any failures resulting from use of these fuels will not be warranted Gasoline Ether Blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to a maximum of 1576 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved Periodic Maintenance Instructions WARNING Accidental Starts can cause severe injury or death Disconnect and ground spark plug lead before servicing Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery Maintenance Schedule Normal maintenance replacement or repair of emission control devices and systems may be performed by any repair establishment or individual however warranty repairs must be performed by a Kohler authorized service center Section 1 Safety and General Information Maintenance Required m Check oil level Section 6 Daily or Before Fill fuel tank Section 5 Starting Engine Check air cleaner for dirty loose or damaged parts Section 4
145. of two revolutions to check longblock assembly and overall proper operation Install Spark Plugs 1 Use new Champion or equivalent spark plugs 2 Setthe gap at 0 76 mm 0 030 in 10 11 Section 10 Reassembly 4 Place wire harness conduit in clip and snap clip together Figure 10 40 Installing Intake Manifold with Wiring Harness Install Fuel Injectors NOTE Ensure all parts are clean undamaged and free of debris and make sure the electrical connectors have the seal in place The O rings and retaining clips should be replaced any time the fuel injector is separated from its normal mounting position Figure 10 41 Intake Manifold Torque Sequence 1 Lightly lubricate the fuel injector O rings with clean engine oil 2 Install ground terminal to the crankcase post with a silver hex flange screw Torque to 4 0 N m 35 2 Push the retaining clip onto the fuel injector in Ib into used holes or 6 2 N m 55 in Ib in aligning the clip as shown in Figure 10 44 new holes See Figure 10 42 LT F Figure 10 44 Install Fuel Injector Retaining Clip Figure 10 42 Install Ground Terminal 3 Press the fuel injector into the fuel injector cap 3 Install the wire harness clip to the other crankcase until the retaining clip snaps into place post Torque to 4 0 N m 35 in Ib into used holes or 6 2 N m 55 in Ib in new holes See 4 Press the fuel injector into the bore in the intake F
146. oil after every 100 hours of operation more frequently under severe conditions Refill with oil as specified in the Viscosity Grades Table See Figure 6 1 Change the oil while the engine is still warm The oil will flow more freely and carry away more impurities Make sure the engine is level when filling checking or changing the oil Cil Drain Cil Filter dm BU f1 Les Jill p Cil Drain Figure 6 6 Oil Drain Plug Oil Filter Side Change the oil as follows 1 To keep dirt debris etc out of the engine clean the area around the oil fill cap dipstick before removing it See Figure 6 3 Remove one of the oil drain plugs and the oil fill cap dipstick Allow ample time for complete drainage See Figures 6 4 and 6 5 Reinstall the drain plug and torque to 13 6 N m 10 ft Ib Fill the crankcase with new oil of the proper type to the F mark on the dipstick Refer to Oil Recommendations Always check the level with the dipstick before adding more oil Reinstall the oil fill cap dipstick and tighten securely Changing Oil Filter Replace the oil filter at least every other oil change every 200 hours of operation Always use a genuine Kohler oil filter Replace the oil filter as follows 1 Drain the oil from the engine crankcase Remove one of the oil drain plugs and the oil fill cap dipstick Allow ample time for complete drainage See Figures 6 3 6 5 and 6 6 Allow the oil
147. on Sensor 4 Push the electrical connector on the crankshaft position sensor making sure a good connection is rae 10 Install Valve Covers 1 Make sure the sealing surfaces are clean 2 Make sure there are no nicks or burrs on the sealing surfaces 3 Install a new O ring in the groove of each cover 4 Position the covers on the cylinder heads Locate the cover with the oil separator hole on the number 1 cylinder Install the four hex flange screws in each cover and finger tighten 5 Torque the valve cover fasteners to 6 2 N m 55 in Ib using the sequence shown in Figure 10 48 10 13 Section 10 Reassembly Figure 10 48 Valve Cover Fastener Torque Figure 10 50 Installing Screws Locations 3 and Sequence 4 Install Breather Cover and Inner Baffles 4 Install the inner baffles using the remaining two 1 Besure the sealing surfaces of the crankcase and hex flange screws see Figures 10 51 and 10 52 breather cover are clean of old gasket material and finger tighten Do not torque the screws at Do not scrape the surfaces as this could result in this time they will be tightened after the blower leakage Use a new gasket when installing the housing and outer battles are installed breather cover See Figure 10 49 Figure 10 49 Breather Cover and Gasket 2 Check to make sure there are no nicks or burrs on the sealing surfaces 3 Position the breather gasket and cover on the crankcase Install the firs
148. on and Reconditioning Flywheel Inspection Inspect the flywheel for cracks and the flywheel keyway for damage Replace flywheel if it is cracked Replace the flywheel the crankshaft and the key if the flywheel key is sheared or the keyway is damaged Inspect the ring gear for cracks or damage Kohler does not provide ring gears as a serviceable part Replace the flywheel if the ring gear is damaged Cylinder Head and Valves Inspection and Service After cleaning check the flatness of the cylinder head and the corresponding top surface of the crankcase using a surface plate or piece of glass and feeler gauge as shown in Figure 9 5 The maximum allowable out of flatness is 0 076 mm 0 003 in EXHAUST VALVE E F A G Seat Angle Guide Depth 4 mm 0 1575 in Valve Face Angle 45 Valve Margin Min 1 5 mm 0 0591 in A B C D E F G H Figure 9 6 Valve Details 9 4 Figure 9 5 Checking Cylinder Head Flatness Carefully inspect the valve mechanism parts Inspect the valve springs and related hardware for excessive wear or distortion Check the valves and valve seat area or inserts for evidence of deep pitting cracks or distortion Check clearance of the valve stems in the guides See Figure 9 6 for valve details and specifications T INTAKE VALVE EXHAUST G INSERT INTAKE INSERT Insert O D 36 987 37 013 mm 1 4562 1 4572 in 32 987 33 013 mm 1 2987 1 2997 in 4 mm 0 1575 in
149. oom temperature measure between the signal leads the black wire Pin C and grey wire Pin D attached to the sensor see Figure 5 9 If the resistance is less than one megohm the sensor has an internal short With the sensor at room temperature measure the heater circuit resistance purple wire Pin A and white wire Pin B resistance should be 8 1 11 1 Q If a damaged sensor is found identify the root cause which may be elsewhere in the application The table on the following page summarizes sensor symptoms and corrections It includes items which apply to both diagnostics and application system design A special dry to touch anti seize compound is applied to all new oxygen sensors at the factory If the recommended mounting thread sizes are used this material provides excellent anti seize capabilities and no additional anti seize is needed If the sensor is removed from the engine and reinstalled the anti seize compound should be reapplied Use a oxygen sensor safe type anti seize compound It should be applied according to the directions on the label NOTE Apply the anti seize compound only to the threads Anti seize compound will affect sensor performance if it gets into the lower shield of the sensor 5 13 Section 5 EFI Fuel System Oxygen Sensor Symptoms and Corrections CONDITION POSSIBLE CAUSE CORRECTION Low voltage output Shorted sensor or sensor circuit Replace sensor or repair wiring Shorted le
150. orrect loose sensor open or shorted connection or faulty sensor Possible Causes 1 Crankshaft Position Sensor Related a Sensor connector or wiring b Sensor loose or air gap incorrect 2 Crankshaft Position Sensor Wheel Related a Damaged teeth 3 Engine Wiring Harness Related a Pin circuit wiring or connectors ECU pin Black 4 or Black 13 b ECU to harness connection problem 4 If code is stored in fault history and starts normally Clear code no other service required Section 5 EFI Fuel System Ignition Coil Cylinder 1 Ignition Coil Malfunction Condition Broken wire in harness may not be visible shorted connection or faulty sensor Possible Causes 1 Engine Wiring Harness Related a Connection to ignition or fuse b Pin circuit wiring or connectors ECU pin Black 1 c ECU to harness connection problem 2 Ignition System Related a Incorrect spark plug s used b Poor connection to spark plug Ignition Coil Cylinder 2 Ignition Coil Malfunction Condition Broken wire in harness may not be visible shorted connection or faulty sensor Possible Causes 1 Engine Wiring Harness Related a Connection to ignition or fuse b Pin circuit wiring or connectors ECU pin Grey 10 c ECU to harness connection problem 2 Ignition System Related a Incorrect spark plug s used b Poor connection to spark plug System Voltage System Voltage Low Condition Faulty voltage regulator
151. oss Shaft Retainer 2 Remove the cross shaft through the inside of the crankcase See Figure 8 65 8 16 Figure 8 65 Removing Governor Cross Shaft Remove Connecting Rods with Pistons and Rings 1 Remove the two hex flange screws securing the closest connecting rod end cap Remove the end cap See Figure 8 66 Figure 8 66 Removing Connecting Rod End Cap NOTE Ifa carbon ridge is present at the top of either cylinder bore use a ridge reamer tool to remove it before attempting to remove the piston 2 Carefully remove the connecting rod and piston assembly from the cylinder bore See Figure 8 67 NOTE The cylinders are numbered on the crankcase Use the numbers to mark each end cap connecting rod and piston for reassembly Do not mix end caps and connecting rods Section 8 Disassembly Figure 8 67 Removing Connecting Rod and Piston Figure 8 69 Removing Crankshaft Assembly Remove Flywheel End Oil Seal 3 Repeat the above procedure for the other 1 Remove the oil seal from the crankcase See connecting rod and piston assembly Figure 8 70 4 Remove piston pin from piston for inspection Use a small screwdriver to pry the pin retainer out of the groove See Figure 8 68 Figure 8 70 Removing Oil Seal Figure 8 68 Remove Piston Pin Remove Crankshaft 1 Carefully pull the crankshaft from the crankcase See Figure 8 69 8 17 Section 8 Disassembly 8 18 Section 9 Inspectio
152. ottle body See Figure 8 20 Figure 8 22 Remove ECU Screws 2 Disconnect the Black and Grey electrical connectors from the ECU See Figure 8 23 Figure 8 20 Disconnect the Vent Hose 8 6 Figure 8 23 Disconnect ECU Electrical Connectors Remove Electric Starter Motor and Electronic Control Unit Bracket 1 Disconnect the leads from the starter 2 Remove the two hex flange screws See Figure 8 24 Figure 8 24 Removing Electric Starter Motor Remove Oil Separator and Hardware 1 Remove the two screws securing the oil separator assembly pulling the assembly out and away from the valve cover See Figure 8 25 Section 8 Disassembly Figure 8 25 Remove Oil Separator Assembly Remove Grass Screen 1 Remove the four socket head cap screws securing the metal grass screen and remove the screen See Figure 8 26 Pie e ea Figure 8 26 Remove Grass Screen 2 Remove the four spacers paying attention to the curvature of the spring washers between the spacers and the fan NOTE The fan will be loose but cannot be removed until after the blower housing is removed 3 If there is a plastic grass screen attached to the fan remove the four screws securing the grass screen Removing the screen will expose the four screws fastening the fan to the flywheel See Figure 8 27 and Figure 8 28 8 7 Section 8 Disassembly Remove Four Screws Figure 8 27 Plastic Grass Screen Remove Four Screws
153. our intake manifold screw threads studs with M6 thread at least 100 mm in length to be used as guide pins Insert the intake manifold studs through the cooling fan mounting holes and thread them 4 or 5 turns into the flywheel 7 Carefully remove two of the studs and replace with two of the hex cap screws Torque the screws to 9 9 N m 88 in Ib See Figure 10 63 Repeat the procedure for the other two studs and 3 Install a spring washer on each stud with the hex cap screws concave side down toward the cooling fan See Figure 10 61 Spring Washer Oh im Figure 10 63 Torque Metal Grass Screen Figure 10 61 Spring Washer with Concave Side Plastic Grass Screen Down 1 Place the plastic grass screen on the fan and secure with four hex screws Torque the four 4 Install a spacer on each stud with the stepped end screws to 4 0 N m 35 in Ib See Figures 10 64 down The smaller diameter should extend and 10 65 through the spring washer and fan so the tip is resting on the flywheel and the shoulder is resting on the spring washer See Figure 10 62 Hex Bolt Spacer Flywheel V E Figure 10 64 Torque Plastic Grass Screen Hex Screws Figure 10 62 Spacer Shoulder Resting on Spring Washer 10 17 Section 10 Reassembly Figure 10 65 Torque Plastic Grass Screen Hex Screws Install Oil Separator and Hardware 1 Ensure the rubber oil separator grommet is in good condition Insert rub
154. ousing and outer baffles sequences and clearances Failure to observe 21 Install grass screen specifications could cause severe engine wear 22 Install oil separator and hardware or damage Always use new gaskets Apply a 23 Install electronic control unit bracket and electric small amount of oil to the threads of critical starter motor fasteners before assembly unless a Sealant or 24 Install electronic control unit Loctite is specified or preapplied 25 Install throttle body 26 Install lift fuel pump and fuel pump module Make sure all traces of any cleaner are removed before 27 Install external governor controls the engine is assembled and placed into operation 28 Install throttle control panel Even small amounts of these cleaners can quickly 29 Install air cleaner assembly see Section 4 break down the lubricating properties of engine oil 30 Install muffler 31 Install oil cooler Check the oil pan crankcase and cylinder heads tobe 32 Install oil filter and fill crankcase with oil certain that all old sealing material has been removed 33 Connect spark plug leads Use gasket remover lacquer thinner or paint remover to remove any remaining traces Clean the surfaces Install Flywheel End Oil Seal with isopropyl alcohol acetone lacquer thinner or 1 Make sure that the seal bore of the crankcase is electrical contact cleaner clean and free of any nicks or burrs See Figure 10 1 Typical Reassembly Sequence The
155. overnor cross shaft clockwise until the lower end of the shaft contacts the cylinder Make sure the cross shaft remains in this position while installing the camshaft See Figure 10 10 4 Slide the camshaft into the bearing surface of the crankcase positioning the timing mark of camshaft gear at the 6 o clock position Make sure the camshaft gear and crankshaft gear mesh with both timing marks aligned See Figure 10 10 5 Install the shim removed during disassembly onto the camshaft Figure 10 7 Installing Governor Cross Shaft 10 3 Section 10 Reassembly Governor Cross Shaft Figure 10 10 Aligning Crankshaft and Camshaft Timing Marks Oil Pump Assembly The oil pump is mounted inside the oil pan If service was required and the oil pump was removed refer to the assembly procedures under Oil Pump Assembly in Section 9 Governor Gear Assembly The governor gear assembly is located inside the oil pan If service was required and the governor was removed refer to the assembly procedures under Governor Gear Assembly in Section 9 Install Oil Seal in Oil Pan 1 Check to make sure that there are no nicks or burrs in the crankshaft bore of the oil pan 2 Apply a light coat of engine oil to the outside diameter of the oil seal 3 Drive the oil seal into the oil pan using a seal driver Make sure the oil seal is installed straight and true in the bore to the depth shown in Figures 10 11 and 10 12 10 4
156. overnor gear assembly See Figure 9 13 Figure 9 13 Removing Governor Gear 2 Remove the locking tab thrust washer located under the governor gear assembly 3 Carefully inspect the governor gear shaft and replace it only if it is damaged After removing the damaged shaft press or lightly tap the replacement shaft into the oil pan to the depth shown in Figure 9 14 Gear Shaft 34 0 mm 1 3386 in 33 5 mm 1 3189 in Figure 9 14 Governor Shaft Press Depth Section 9 Inspection and Reconditioning Reassembly 1 Install the locking tab thrust washer on the governor gear shaft with the tab down 2 Position the regulating pin within the governor gear flyweight assembly and slide both onto governor shaft Oil Pump Assembly Disassembly 1 Remove the two hex flange screws 2 Remove the oil pump assembly from the oil pan Mounting Screws Figure 9 15 Removing Oil Pump 3 Remove the oil pump rotor Unhook the locking clip and carefully pull it free from the oil pump housing The relief valve is a one piece style staked to the oil pump housing See Figure 9 16 Removal should not be attempted nor is internal servicing possible If a problem with the relief valve is encountered the oil pump should be replaced Inspection Inspect the oil pump housing gear and rotors for nicks burrs wear or any visible damage If any parts are worn or damaged replace the oil pump 9 11 Section
157. ow Voltage Condition System voltage too low open connection or faulty sensor Possible Causes 1 Engine Wiring Harness Related a Pin circuit wiring or connectors 1 ECU Black pin 7 2 Broken wire 2 Oxygen Sensor Related a Sensor connector or wiring problem 3 Poor system ground from ECU to engine or battery to engine Manifold Absolute Pressure Sensor Fault Fault MAP Circuit Low Voltage or Open Condition Intake manifold leak open connection or faulty sensor Possible Causes 1 MAP Sensor Related a Sensor malfunction b Vacuum leaks from loose manifold or sensor 2 Wire Harness Related a Poor grounding or open circuit b Wire harness and connectors loose damaged or corroded c Pin circuit wiring or connectors at Black 10 11 and 16 3 Bad TPS Learn Fault MAP Circuit High Voltage Condition Intake manifold leak shorted connection or faulty sensor Possible Causes 1 MAP Sensor Related a Sensor malfunction b Vacuum leaks from loose manifold or sensor 2 Wire Harness Related a Poor grounding b Pin circuit wiring or connectors at Black 11 3 Bad TPS Learn Component Intake Air Temperature Sensor Fault Intake Air Temperature Sensor Circuit Low Voltage Condition Shorted connection faulty sensor or shorted wire Possible Causes 1 Temperature Sensor Related a Sensor wiring or connection 2 Engine Wiring Harness Related a Pin circuits Black
158. pander and then the rails Make sure the ends of the expander are not overlapped 2 Middle Compression Ring Center Groove Install the center ring using a piston ring expander tool Make sure the identification mark is up or the dykem stripe if contained is to the left of the end gap 3 Top Compression Ring Top Groove Install the top ring using a piston ring expander Make sure the identification mark is up or the dykem stripe if contained is to the left of the end gap Connecting Rods Offset stepped cap connecting rods are used in all these engines Inspection and Service Check the bearing area big end for excessive wear score marks running and side clearances refer to Section 1 Specifications Tolerances and Special Torque Values Replace the rod and cap if scored or excessively worn 9 10 Service replacement connecting rods are available in STD crankpin size and 0 25 mm 0 010 in undersize The 0 25 mm 0 010 in undersized rods have an identification marking on the lower end of the rod shank Always refer to the appropriate parts information to ensure that correct replacements are used Hydraulic Lifters Inspection Check the base surface of the hydraulic lifters for wear or damage If the lifters need to be replaced apply a liberal coating of Kohler lubricant see Section 2 to the base of each new lifter before it is installed Bleeding the Lifters To prevent a possible ben
159. r charge voltage is less than 13 7 then re establish ground between the ground strap and mounting screw If voltage is less than 13 8 or charge rate does not increase when load is applied test stator Tests 2 and 3 If the voltage is low and does not increase and there is no charging amperage output disconnect and reconnect the rectifier regulator plug and retest a If the ammeter shows charge for a short time but then drops back to zero the rectifier regulator is functioning correctly but the battery is faulty Replace the battery If no amperage charge rate appears during the retest go to step 2 If voltage is 28 volts or more stator is OK Rectifier regulator is faulty Replace the rectifier regulator If voltage is less than 28 volts stator is probably faulty and should be replaced Test stator further using an ohmmeter Test 3 If resistance is 0 064 0 2 ohms the stator is OK If the resistance is infinity ohms stator is open Replace stator If the resistance is infinity ohms no continuity the stator is OK not shorted to ground If resistance or continuity is measured the stator leads are shorted to ground Replace stator Battery Continuously Charges at High Rate 1 Perform same test as step 1 1 above Section 7 Electrical System and Components If the voltage is 14 7 volts or less the charging system is OK The battery is unable to hold a charge Service battery or replace as
160. r housing Clean the inside of the cooler with a brush or compressed air See Figure 6 7 After cleaning reinstall the oil cooler to the blower housing with the mounting hardware Figure 6 7 Blower Housing Mounted Oil Cooler 6 3 Section 6 Lubrication System Oil Sentry General Some engines are equipped with an optional Oil Sentry switch This switch is designed to prevent the engine from being started in a low oil or no oil condition The Oil Sentry may not shut down a running engine before damage occurs In some applications this switch may activate a warning signal Read your equipment manual for more information The pressure switch is designed to make contact as the oil pressure decreases below 2 5 psi depending upon the application and switch specified On stationary or unattended applications pumps generators etc the pressure switch can be used to ground the ignition module to stop the engine On vehicular applications lawn tractors mowers etc the pressure switch can only be used to activate a low oil warning light or signal NOTE Make sure the oil level is checked BEFORE EACH USE and is maintained up to the F mark on the dipstick This includes engines equipped with Oil Sentry Installation The Oil Sentry pressure switch is installed into the breather cover See Figure 6 8 E E E 5 E Figure 6 8 Location of Oil Sentry Switch On engines not equipped with Oil Sentry t
161. ract Repeat the test several times If the solenoid fails to activate it should be replaced NOTE DO NOT leave the 12 volt test leads connected to the solenoid for any time over what is necessary for performing each of the individual tests Internal damage to the solenoid may otherwise occur 12 volt Test Leads Momentary Connection Only Figure 7 37 Testing Pull In Coil Plunger Actuation Test 2 Solenoid Pull In Coil Contact Continuity Use an ohmmeter set to the audible or Rx2K scale and connect the two ohmmeter leads to the two large post terminals Perform the preceding test 1 and check for continuity See Figure 7 38 The ohmmeter should indicate continuity if no continuity is indicated the solenoid should be replaced Repeat test several times to confirm condition 7 16 12 volt Test Leads Momentary Connection Only VOM Leads Figure 7 38 Testing Pull In Coil Solenoid Contact Continuity Test 3 Solenoid Hold In Coil Function Test Connect one 12 volt test lead to the flat spade START terminal on the solenoid and the other lead to the body or mounting surface of the solenoid Then manually push the plunger in and check if the Hold In coil holds the plunger retracted See Figure 7 39 Do not allow the test leads to remain connected to the solenoid for a prolonged period of time If the plunger fails to stay retracted the solenoid should be replaced Manually Push Plunger In 12 volt Test L
162. rated fuel lines certified to comply with California and U S EPA evaporative emission requirements Fuel lines that do not meet these requirements may not be used Order replacement hose through a Kohler Service Center caution Low permeation high pressure fuel line with an SAE 30R9 or 30R12 rating 1 4 in I D is required for safe and reliable operation due to higher operating pressure of the EFI system Low permeation low pressure fuel line with a SAE 30R7 rating 1 4 in I D may only be used between the fuel tank and lift pump between the lift pump and fuel pump module or as otherwise configured in the application 5 21 Section 5 EFI Fuel System Service The high pressure fuel line is mounted to the intake manifold No specific servicing is required unless operating conditions indicate that it needs replacement It can be detached by removing the two mounting screws wire ties and the injector retaining clips Thoroughly clean the area around all joints and relieve any pressure before starting any disassembly by following the instruction on page 5 2 Purge Port and Vent Hose Assembly Figure 5 21 Purge Port Location General The vent hose assembly is intended to vent fuel vapor out of the fuel pump module and direct the fuel vapor into the throttle body All EFI engines are equipped with an engine mounted purge port on the 2 cylinder barrel baffle This capped purge port can be used by the OEM to vent fuel t
163. re are no nicks or burrs on the sealing surfaces of the cylinder head or the crankcase Heads secured with mounting studs nuts and washers 2 If all of the studs were left intact go to Step 6 If any studs were disturbed or removed install new studs as described in Step 3 Do not use reinstall any loosened or removed studs 3 Install new mounting stud s into the crankcase a Thread and lock two of the mounting nuts together on the smaller diameter threads Section 10 Reassembly b Thread the opposite end of the stud with the preapplied locking compound into the crankcase until the specified height from the crankcase surface is achieved See Figure 10 31 When threading in the studs use a steady tightening motion without interruption until the proper height is obtained Otherwise the frictional heat from the engaging threads may cause the locking compound to set up prematurely NLA Figure 10 31 Installing New Mounting Studs to Specified Height The studs closest to the lifters must have an exposed height of 75 mm 2 15 16 in The studs furthest from the lifters must have an exposed height of 69 mm 2 3 4 in c Remove the nuts and repeat the procedure as required 4 Check that the dowel pins are in place and install a new cylinder head gasket part number facing up 5 Install the cylinder head Match the numbers on the cylinder heads and the crankcase See Figure 10 26 Make sure the
164. rent in the coil causing the electromagnetic flux field to collapse The flux collapse induces an instantaneous high voltage in the coil secondary which is strong enough to bridge the gap on the spark plug Each coil fires every other revolution Service If a coil is determined to be faulty replacement is necessary An ohmmeter may be used to test the wiring and coil windings NOTE Do not ground the coils with the ignition ON as they may overheat or spark NOTE Always disconnect the spark plug lead from the spark plug before performing the following tests Testing 1 Using an ohmmeter set on the Rx1 scale check the resistance in circuits as follows a Disconnect the Black connector from the ECU to check the number one cylinder coil starter side Test between Black pin 1 and Black pin T5 b Disconnect the Grey connector from the ECU to check the number two cylinder coil oil filter side Test between Grey pin 10 and Grey pin 17 A reading of 0 5 0 8 O in each test indicates that the wiring and coil primary circuits are OK c If reading s are not within specified range check and clean connections and retest d If reading s are still not within the specified range test the coils separately from main harness as follows 1 Remove the screw retaining the coil to the housing and disconnect the primary leads connector 2 Connect an ohmmeter set on the Rx1 scale to the primary terminals of the coil Primary r
165. ressures on a specific area of the piston Detonation generally occurs from using low octane fuels Preignition or ignition of the fuel charge before the timed spark can cause damage similar to detonation Preignition damage is often more severe than detonation damage Preignition is caused by a hot spot in the combustion chamber from sources such as glowing carbon deposits blocked cooling fins an improperly seated valve or wrong spark plug s See Figure 9 8 for some common types of piston and ring damage Mis D pall azur mE E nd uus T amp i eti NL Bell ABI Zh uH i 1 f ul iit F 7 A ii Lun L1 S t TPE Tat m Ti Vl ID 1 t bu sul d o His m 1 i a c aa mar I neqne i EN L E TRT Scored Piston and Rings Section 9 Inspection and Reconditioning Replacement pistons are available in STD bore size and 0 25 mm 0 010 in and 0 50 mm 0 020 in oversize Replacement pistons include new piston ring sets and new piston pins Replacement ring sets are also available separately for STD 0 25 mm 0 010 in and 0 50 mm 0 020 in oversize pistons Always use new piston rings when installing pistons Never use old rings Some important points to remember when servicing piston rings 1 The cylinder bore must be deglazed before service ring sets are used Figure 9 10 Measuring Piston Ring Side Clearance 2 If the cylinder bore does not need reboring and if the old piston is within
166. ris on the crankcase cooling fins grass screen and other 3 2 external surfaces Dirt or debris on these areas are causes of higher operating temperatures and overheating e Check for obvious fuel and oil leaks and damaged components Excessive oil leakage can indicate a clogged or improperly assembled breather worn damaged seals and gaskets or loose or improperly torqued fasteners e Check the air cleaner cover and base for damage or indications of improper fit and seal e Check the air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could allow unfiltered air into the engine Also note if the element is dirty or clogged These could indicate that the engine has been under serviced e Check the oil level Note if the oil level is within the operating range on the dipstick or if it is low or overfilled e Check the condition of the oil Drain the oil into a container the oil should flow freely Check for metal chips and other foreign particles Sludge is a natural by product of combustion a small accumulation is normal Excessive sludge formation could indicate weak ignition overextended oil change intervals or wrong weight or type of oil was used to name a few NOTE Itis good practice to drain oil at a location away from the workbench Be sure to allow ample time for complete drainage Cleaning the Engine After inspecting the external condition of the engine
167. rocker arm pivots Install the rocker arms and rocker arm pivots on one cylinder head and start the two hex flange screws 3 Torque the hex flange screws to 11 9 N m 105 in Ib See Figure 10 36 Section 10 Reassembly 3 Install new plugs and torque to 24 4 29 8 N m 18 22 ft Ib See Figure 10 38 Figure 10 36 Torquing Rocker Arm Screws 4 Useaspanner wrench or rocker arm lifting tool see Section 2 to lift the rocker arms and position Figure 10 38 Installing Spark Plugs the push rods underneath See Figure 10 37 Install Intake Manifold 1 Install the intake manifold and new gaskets with wiring harness attached to the cylinder heads Slide any wiring harness clips onto the appropriate bolts before installing Make sure the gaskets are in the proper orientation See Figures 10 39 and 10 40 Using the sequence shown in Figure 10 41 torque the four screws in two stages first to 7 8 N m 69 in Ib then to 10 5 N m 93 in Ib Figure 10 37 Using Spanner Wrench to Lift Rocker Arm Over Push Rod 5 Repeat the above steps for the remaining cylinder Do not interchange parts from the cylinder heads 6 Rotate the crankshaft to check for free operation of the valve train Check the clearance between the valve spring coils at full lift Minimum allowable clearance is 0 25 mm 0 010 in Figure 10 39 Installing Intake Manifold Gaskets Check Assembly Important Rotate the crankshaft a minimum
168. rovided in the service rod package See Figure 10 6 10 2 Section 10 Reassembly NOTE Align the chamfer of the connecting rod with the chamfer of its mating end cap When installed the flat faces of the connecting rods should face each other The faces with the raised rib should be toward the outside Figure 10 8 Setting Governor Cross Shaft End Play Install Camshaft 1 Liberally apply camshaft lubricant see Section 2 to each of the cam lobes Lubricate the camshaft Figure 10 6 Torquing Connecting Rod End Cap bearing surfaces of the crankcase and camshaft with engine oil See Figure 10 9 5 Repeat the above procedure for the other connecting rod and piston assembly Install Governor Cross Shaft 1 Lubricate the governor cross shaft bearing surfaces in the crankcase with engine oil 2 Slide the small lower washer onto the governor cross shaft and install the cross shaft from the inside of the crankcase 3 Install the nylon washer onto the governor cross shaft then start the push on retaining ring Hold the cross shaft up in position place a 0 50 mm 0 020 in feeler gauge on top of the nylon washer and push the retaining ring down the Figure 10 9 Apply Camshaft Lubricant to Cam shaft to secure Remove the feeler gauge which Lobes will have established the proper end play See Figures 10 7 and 10 8 2 Position the timing mark of the crankshaft gear at the 12 o clock position 3 Turn the g
169. rt liners if equipped Install exhaust gaskets and the muffler Install the oxygen sensor torque to 50 1 N m 37 ft Ib and connect to wire harness Install remaining muffler support hardware screws and nuts and torque to 9 9 N m 88 in Ib Install the hex flange nuts to the exhaust studs Torque hex flange nuts to 27 8 N m 246 in Ib Install Oil ler Figure 10 89 Low Profile Air Cleaner and Bracket bars GONG Secure the adapter to the oil pan with the oil filter nipple Torque the oil filter nipple to 28 5 N m 21 ft Ib 2 Verify all fuel and vent hoses are routed properly and not pinched Install the two hex flange screws to secure the oil cooler to the blower housing Torque the top screw to 2 8 N m 25 in Ib and the lower screw to 2 3 N m 20 in Ib See Figure 10 91 i 1 a h n Aq ee Pt tee iy c C T Frrr Install Oil Filter and Fill Crankcase with Cil NOTE Iftesting oil pressure after completing reassembly install the oil pressure adapter instead of the oil filter 1 Prefill a new oil filter following the instructions in Section 6 2 Apply a thin film of clean oil to the rubber gasket on the oil filter and thread the filter onto the adapter nipple See Figure 10 92 3 Refer to oil filter for specific installation instructions Figure 10 92 Installing and Tightening Oil Filter 4 Install the oil drain plug s See Figure 10 93 Torque plug s to 13 6 N m 10
170. s 1 Before removing a spark plug clean the area around the base of the plug to keep dirt and debris out of the engine 2 Remove the plug and check its condition See Inspection following this procedure Replace the plug if necessary NOTE Do not clean spark plugs in a machine using abrasive grit Some grit could remain in the spark plug and enter the engine causing extensive wear and damage 3 Check the gap using a wire feeler gauge Adjust the gap to 0 76 mm 0 030 in by carefully bending the ground electrode See Figure 7 1 Wire Gauge Spark Plug 0 76 mm 0 030 in Gap Electrode Figure 7 1 Servicing Spark Plug 4 Reinstall the spark plug into the cylinder head and torque to 24 4 29 8 N m 18 22 ft Ib Inspection Inspect each spark plug as it is removed from the cylinder head The deposits on the tip are an indication of the general condition of the piston rings valves and fuel injection system Normal and fouled plugs are shown in the following photos 7 1 Section 7 Electrical System and Components Normal A plug taken from an engine operating under normal conditions will have light tan or grey colored deposits If the center electrode is not worn a plug in this condition could be set to the proper gap and reused Carbon Fouled Soft sooty black deposits indicate incomplete combustion caused by a restricted air cleaner over rich fuel mixture weak ignit
171. s described in Precleaner Service 4 Do not wash the paper element or use pressurized air as this will damage the element Replace a dirty bent or damaged element with a genuine Kohler element Handle new elements carefully do not use if the sealing surfaces are bent or damaged 5 Check the rubber sleeve seal for any damage or deterioration Replace as necessary 6 Reinstall the paper element precleaner element cover and wing nut 7 Reinstall the air cleaner cover and secure retaining knob Air Cleaner Components Whenever the air cleaner cover is removed or the paper element or precleaner are serviced check the following Air Cleaner Element Cover and Seal Make sure element cover is not bent or damaged Make sure the rubber sleeve seal is in place on the stud to prevent dust or dirt entry through the stud hole Air Cleaner Base Make sure the base is secured tightly to the throttle body and not cracked or damaged NOTE Damaged worn or loose air cleaner components can allow unfiltered air into the engine causing premature wear and failure Tighten or replace all loose or damaged components Disassembly Reassembly Low Profile If the base plate on the low profile air cleaner has to be removed proceed as follows 4 4 1 Remove the air cleaner components from the base see Figures 4 8 and 4 9 2 Remove the two hex flange screws securing base to the bracket and the three hex flange nuts from the
172. s the required ideal fueling The MAP also stores instant barometric pressure reading when the key is turned ON Service The manifold absolute pressure sensor is a sealed non serviceable assembly A faulty sensor must be replaced If a blink code indicates a problem with the manifold absolute pressure sensor it can be tested as follows 1 Make sure all connections are making proper contact and are free of dirt and debris Remove the blower housing Slide the locking tab out and pull off the manifold absolute pressure connector Turn the key switch to ON and check with a volt meter by contacting the red lead to pin 1 and the black lead to pin 2 See Figure 5 11 for pin location There should be 5 volts present indicating the ECU and wiring harness are functioning 2 Check continuity in wire harness Ohms between Pin 3 at the sensor connector and Black pin 11 connector at ECU should be near zero ohms If no continuity is measured or very high resistance replace wire harness Section 5 EFI Fuel System 3 Check to make sure the intake manifold is not loose and the MAP sensor is not loose Loose parts would allow a vacuum leak making the MAP sensor report misleading information to the ECU a Tighten all hardware and perform an ECU Reset and a TPS Learn Procedure to see if the MIL will display a fault with the MAP sensor again If the MIL finds a fault with the MAP sensor replace it Fuel Injectors Figure 5 12 Fuel
173. scard the old gaskets Position the manifold assembly over an appropriate container to capture fuel and turn the key switch ON to activate the fuel pump and pressurize the system Do not turn switch to START position If either injector exhibits leakage of more than two to four drops per minute from the tip or shows any sign of leakage around the outer shell turn the ignition switch OFF and replace the injector as follows Depressurize the fuel system following the procedure in the fuel warning on page 5 2 Clean any dirt accumulation from the sealing mounting area of the faulty injector s and disconnect the electrical connector s Pull the retaining clip off the top of the injector s Remove the screw holding the injector s from the manifold 5 17 Section 5 EFI Fuel System 23 Reverse the appropriate procedures to install the new injector s and reassemble the engine Use new O rings and retaining clips any time an injector is removed new replacement injectors include new O rings and retaining clips Lubricate O rings lightly with clean engine oil Use the installation tool provided with the O rings to install the new upper O ring Place the tool into the fuel injector inlet Place one side of the O ring into the O ring groove and roll the O ring over the tool onto the fuel injector Torque the screw securing the fuel injector caps and blower housing mounting screws to 7 3 N m 65 in Ib and the intake manifol
174. secure using the four M6 hex flange screws Install two M6 screws 20 mm long into the intake port side of the cylinder heads including any lifting strap Install two M6 screws 16 mm long into the exhaust port side of the cylinder head Install the two short M5 screws 10 mm long in the upper mounting holes of the outer baffles into the backing plate See Figures 10 56 and 10 57 Be sure any leads are routed out through the proper offsets or notches so they will not be pinched between the blower housing and baffles Figure 10 56 Tightening Outer Baffle Screws 10 15 Section 10 Reassembly Figure 10 57 Tightening Short Screws for Outer Baffles 3 Insert and tighten all remaining blower housing and baftle screws with the exception of the rectifier regulator grounding bracket screw Torque all blower housing and baffle M6 screws assembled into aluminum to 10 7 N m 95 in Ib for a new hole or 7 3 N m 65 in Ib for a used hole Torque all blower housing and baffle M5 screws assembled into sheet metal backing plate to 2 8 N m 25 in Ib for new holes or 2 3 N m 20 in Ib for used holes 4 Torque the four breather cover screws to 11 3 N m 100 in Ib into new holes or 7 3 N m 65 in Ib into used holes in the sequence shown in Figure 10 58 Note the first screw is torqued a second time Figure 10 58 Breather Cover Fastener Torque Sequence Install Reconnect Rectifier Regulator 1 Install
175. sing Screws Rechner Regulator Fastener TOPOUE eeue 1 4 N m 12 6 in Ib Camshaft It arc diosa CVV Gs OU RR Rm 0 051 0 381 mm 0 002 0 015 in Values are in Metric units Values in parentheses are English equivalents Lubricate threads with engine oil prior to assembly 1 8 Section 1 Safety and General Information Rana C IG EOD eee ene eee eee exei EUR ne ner te eee rect cere eee 0 025 0 105 mm 0 001 0 004 in RH Bore I D DU 20 000 20 025 mm 0 7874 0 7884 in Max Wear Linii NER ETE 20 038 mm 0 7889 in Camshaft Bearing Surface O D lU n 19 920 19 975 mm 0 7843 0 7864 in Max cid Siri 19 914 mm 0 7840 in Connecting Rod Cap Fastener Torgue torgue m TOCROPOTIS sisne e dr dosi ern D obe 11 6 N m 103 in Ib Connecting Rod to Crankpin Running Clearance e 21 C 70 F hi HO 0 043 0 073 mm 0 0017 0 0029 in Max Year Linii RENE UT 0 088 mm 0 0035 in Connecting Rod to Crankpin Side Clearance eseeseeeseeeeeersesrrsrsresrrresresersess 0 26 0 63 mm 0 0102 0 0248 in Connecting Rod to Piston Pin Running Clearance 21 C 70 F 0 015 0 028 mm 0 0006 0 0011 in Connecting Rod Piston Pin End I D 21 C 70 F hi e 17 015 17 023 mm 0 6699 0 6702 in Max Year Linii RR m
176. ss Related a Broken or shorted wire in harness ECU pin Black 6 b Wiring from Ignition 3 ECU Related a Circuit controlling injector 2 damaged Fault Faut Circuit Low Voltage or Open Condition Shorted or open connection Possible Causes 1 Fuel Pump Related a Fuel pump module open or shorted internally 2 Engine Wiring Harness related a Broken or shorted wire in harness ECU pin Black 9 or Grey 17 3 ECU Related a The ECU is damaged Circuit High Voltage Condition Shorted connection Possible Causes 1 Fuel Pump Related a Fuel pump module damaged internally 2 Charging Output System Too High Crankshaft Position Sensor Fault Crankshaft Position Sensor Noisy Signal Condition Air gap incorrect loose sensor faulty bad battery shorted or faulty connection faulty sensor or faulty sensor grounding Possible Causes 1 Crankshaft Position Sensor Related a Sensor connector or wiring b Sensor loose or air gap incorrect 2 Crankshaft Position Sensor Wheel Related a Damaged teeth b Gap section not registering 3 Engine Wiring Harness Related a Pin circuit wiring or connectors ECU pin Black 4 and Black 13 b ECU to harness connection problem 4 Ignition System Related a Non resistor spark plug s used b Faulty or disconnected ignition coil or secondary lead Crankshaft Position Sensor Fault Crankshaft Position Sensor No Signal Condition Air gap inc
177. t as required to obtain 1500 RPM or the idle speed specified by the equipment manufacturer See Figure 5 23 4 Ifthe idle speed is adjusted up over 1800 RPM you must first decrease idle RPM to 1500 RPM and then up to final idle speed setting for the TPS to be properly learned by the ECU 5 The idle speed adjustment can affect the high idle speed setting Move the throttle control to the full throttle position and check the high idle speed Adjust as necessary to 3750 RPM or the speed specified by the equipment manufacturer Initial Governor Adjustment The initial governor adjustment is especially critical on EFI engines because of the accuracy and sensitivity of the electronic control system Incorrect adjustment can result in overspeed loss of power lack of response or inadequate load compensation If you encounter any of these symptoms and suspect them to be related to the governor setting the following should be used to check and or adjust the governor and throttle linkage Section 5 EFI Fuel System If the governor throttle components are all intact but you think there may be a problem with the adjustment follow Procedure A to check the setting If the governor lever or the throttle body was loosened or removed go immediately to Procedure B to perform the initial adjustment Throttle _ Linkage Bushing Figure 5 24 Throttle Linkage Governor Lever Connection A Checking the Initial Adjustment 1
178. t least 10 seconds between tests to allow ECU to go to sleep and reawake Repeat test at other connector NOTE When cranking engine with injectors disconnected fault codes will be registered in the ECU and will need to be cleared using software fault clear or an ECU Reset and TPS Learn Procedure a If flashing occurs use an ohmmeter Rx1 scale and check the resistance of each injector across the two terminals Proper resistance is 11 13 Q If injector resistance is correct check whether the connector and injector terminals are making a good connection If the resistance is not correct replace the injector Check all electrical connections connectors and wiring harness leads if resistance is incorrect Injector leakage is very unlikely but in those rare instances it can be internal past the tip of the valve needle or external weeping around the injector O rings See Figure 5 15 The loss of system pressure from the leakage can cause hot restart problems and longer cranking times To check for leakage it will be necessary to loosen or remove the blower housing which may involve removing the engine from the unit Check for Leaks Figure 5 15 Injector Inspection Points 1 Engine must be cool Depressurize fuel system as stated on page 5 2 2 Disconnect spark plug leads from spark plugs 3 Remove the air cleaner by removing the two top screws and the three nuts securing the air cleaner base to the throttle body S
179. t push rod or broken rocker arm it is important to bleed any excess oil out of the lifters before they are installed 1 Cuta 50 75 mm 2 3 in piece from the end of an old push rod and chuck it in a drill press 2 Lay arag or shop towel on the table of the drill press and place the lifter open end up on the towel 3 Lower the chucked push rod until it contacts the plunger in the lifter Slowly pump the plunger two or three times to force the oil out of the feed hole in the side of the lifter Oil Pan Assembly Inspection Inspect the oil seal in the oil pan and remove it if it is worn or damaged Refer to Install Oil Seal in Oil Pan in Section 10 for new oil seal installation Inspect the main bearing surface for wear or damage refer to Section 1 Specifications Tolerances and Special Torque Values Replace the oil pan assembly if required Governor Gear Assembly Inspection Inspect the governor gear teeth Replace the gear if it is worn chipped or if any teeth are missing Inspect the governor weights They should move freely in the governor gear Disassembly The governor gear must be replaced once it is removed from the oil pan NOTE The governor gear is held onto the shaft by small molded tabs in the gear When the gear is removed from the shaft these tabs are destroyed and the gear must be replaced Therefore remove the gear only if absolutely necessary 1 Remove the regulating pin and g
180. t too sensitive If a big drop in speed occurs when normal load is applied the governor should be set for greater sensitivity See Figure 10 95 and adjust as follows Governor Lever Figure 10 95 Governor Lever 1 Toincrease the sensitivity move the spring closer to the governor lever pivot point 2 To decrease the sensitivity move the spring away from the governor lever pivot point Testing the Engine It is recommended that the engine be operated on a test stand or bench prior to installation in the piece of equipment 1 Set the engine up on a test stand Start engine inspect for leaks and check to make certain that oil pressure 20 psi or more is present Run the engine at idle for 2 3 minutes then 5 6 minutes more between idle and midrange 2 Adjust the idle speed screw located on the throttle body as necessary The standard idle speed setting for EFI engines is 1500 RPM but certain applications might require a different setting 3 Adjust the high speed stop as necessary located on the control panel if so equipped Make sure the maximum engine speed does not exceed 4200 RPM no load 10 26 KOH LER FORM NO 24 690 02 Rev C 9 ISSUED 5 10 FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 YN I DATA 1P24 690 KohlerEngines com HUNI ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 2010 by Kohler Co All rights reserved 90951
181. t two hex flange screws in locations 3 and 4 shown in Figure 10 50 Finger tighten at this time Figure 10 52 Finger Tighten Two Remaining Cover Screws 10 14 Install Oil Temperature Sensor NOTE Ensure part is clean undamaged and free of debris and make sure the electrical connector has the seal in place 1 Lightly oil the oil temperature sensor O ring and install the oil temperature sensor into the breather cover 2 Torque the sensor to 7 3 N m 65 in Ib See Figure 10 53 Figure 10 53 Torque Oil Temperature Sensor 3 Push the electrical connector on the oil temperature sensor making sure a good connection is made Install Oil Sentry If So Equipped 1 Apply pipe sealant with Teflon Loctite 592 PST Thread Sealant or equivalent to the threads of the Oil Sentry switch and install it into the breather cover See Figure 10 54 Torque to 4 5 N m 40 in Ib Oil Sentry Figure 10 54 Oil Sentry Switch If So Equipped Section 10 Reassembly M 2 Connect the wire lead green to the Oil Sentry terminal Install Blower Housing and Outer Baffles NOTE Do not completely tighten screws until all items are installed to allow shifting for hole alignment 1 Slide the blower housing into position over the front edge of the inner baftles See Figure 10 55 Start a few of the screws to hold it in place Figure 10 55 Installing Blower Housing 2 Position the outer baffles and
182. tage sent to the ECU Using a table stored in its memory the ECU correlates the voltage drop to a specific temperature Using the fuel delivery maps the ECU then knows how much fuel is required for starting at that temperature Service The temperature sensor is a sealed non serviceable assembly A faulty sensor must be replaced If a blink code indicates a problem with the temperature sensor it can be tested as follows 1 Remove the temperature sensor from the breather cover and cap or block the sensor hole 2 Wipe the sensor clean and allow it to reach room temperature 25 C 77 F 3 Unplug the Black connector from the ECU 4 With the sensor still connected check the temperature sensor circuit resistance between the Black pin 10 and 14 terminals The value should be 9000 11000 Q 5 Unplug the sensor from the wire harness and check the sensor resistance separately across the two pins Resistance value should again be 9000 11000 Q a If the resistance is out of specifications replace the temperature sensor b If itis within specifications proceed to Step 6 6 Check the circuits input ground from the wire harness connector to the sensor plug for continuity damage etc Connect one ohmmeter lead to Black pin 14 in the wire harness connector as in step 4 Connect the other lead to terminal 1 in the sensor plug see Figure 5 7 Continuity should be indicated Repeat the test between Black pin 10 and ter
183. tainer to help seat the collar around the retainer Figure 7 22 Removing Brush Holder 3 Clean the component parts as required 4 The new brushes and springs come preassembled in a brush holder with a protective sleeve that will also serve as an installation tool See Figure 7 23 IT F r j J l if rj L b j r 1 2 j ai Figure 7 24 Installing Stop Collar and Retainer NOTE Always use a new retainer Do not reuse old retainers which have been removed Figure 7 23 Service Brush Kit 5 Perform Steps 10 13 in the Starter Reassembly sequence Installation must be done after the armature drive lever and frame are installed if the starter has been disassembled 7 12 3 Install the offset thrust stop washer so the smaller offset of the washer faces the retainer collar See Figure 7 25 Figure 7 25 Installing Thrust Washer 4 Apply a small amount of oil to the bearing in the drive end cap and install the armature with the drive pinion 5 Lubricate the fork end and center pivot of the drive lever with drive lubricant see Section 2 Position the fork end into the space between the captured washer and the rear of the pinion 6 Slide the armature into the drive end cap and at the same time seat the drive lever into the housing NOTE Correctly installed the center pivot section of the drive lever will be flush or below the machined surface of the housing whi
184. ted the fault codes may be cleared by following the ECU Reset and TPS Learn Procedures The chart on the following page lists the fault codes and what they correspond to Following the chart is a list of the individual codes with an explanation of what triggers them what symptoms might be expected and the probable causes A MIL may not be provided with the engine If the equipment manufacturer has not added a MIL to the equipment one can be added easily for quick diagnostics The main engine to vehicle connection will have a tan wire which is the ground for the MIL Either incandescent or LED type bulbs can be used for the MIL as long as they do not draw more than 0 1 amps The bulb needs to be rated at 1 4 Watts or less or needs to have a total resistance of 140 Q or more LEDs typically draw less than 0 03 amps Attach 12 volts to the positive terminal of the bulb and attach the ground terminal of the bulb to the tan wire 5 27 Section 5 EFI Fuel System Diagnostic Code Summary 5 28 Oxygen Sensor Heater Section 5 EFI Fuel System Manifold Absolute Pressure Sensor O25 Heater Circuit High Voltage Condition System voltage too high shorted connection or faulty sensor Possible Causes 1 Oxygen Sensor Related a Sensor connector or wiring problem b Sensor damaged c Pin circuit wiring or connectors at Black 7 2 ECU Related a ECU to harness connection problem Oxygen Sensor Heater O25 Heater Circuit L
185. the clamping screw loose Follow the instructions in Step 2 of Checking the Initial Adjustment then reattach the throttle linkage to the governor lever with the bushing clip It is not necessary to reattach the damper or governor springs at this time Figure 5 28 Adjusting Governor Shaft Insert a nail or Allen wrench into the hole in the top of the cross shaft Using light pressure rotate the governor shaft counterclockwise as far as it will turn then torque the hex nut on the clamping screw to 6 8 N m 63 in Ib See Figure 5 28 Make sure that the governor arm has not twisted up or down after the nut has been tightened 4 Verify that the governor has been set correctly With the linkage still retained in the Full Throttle position Step 2 unsnap the bushing clip separate the linkage from the bushing and remove the bushing from the lever Follow Steps 3 and 4 in Checking the Initial Adjustment Reconnect the dampening spring into its governor lever hole from the bottom Reinstall the bushing and reattach the throttle linkage See Figure 5 24 Reattach the governor spring in the marked hole Start the engine and allow it to fully warm up and establish closed loop operation approximately 5 10 min Check the speed settings and adjust as necessary first the low idle speed and then the high speed setting NOTE Throttle body and air cleaner assembly must be securely fastened with three hex flange nu
186. the crankshaft keyways If worn or chipped replacement of the crankshaft will be necessary Inspect the crankpin for score marks or metallic pickup Slight score marks can be cleaned with crocus cloth soaked in oil If wear limits as stated in Specifications and Tolerances are exceeded it will be necessary to either replace the crankshaft or regrind the crankpin to 0 25 mm 0 010 in undersize If reground a 0 25 mm 0 010 in undersize connecting rod big end must then be used to achieve proper running clearance Measure the crankpin for size taper and out of round NOTE If the crankpin is reground visually check to ensure that the fillet blends smoothly with the crankpin surface See Figure 9 1 9 1 Section 9 Inspection and Reconditioning High Point from Fillet Intersections The Fillet Must Blend Smoothly with the Bearing 45 Journal Surface Minimum This Fillet Area Must Be Completely Smooth Figure 9 1 Crankpin Fillets The connecting rod journal can be ground one size under When grinding the crankshaft grinding stone deposits can get caught in the oil passages which could cause severe engine damage Removing the crankpin plug when the crankshaft is ground provides easy access for removing any grinding deposits that may collect in the oil passages Use the following procedure to remove and replace the plug Procedure to Remove Crankshaft Plug 1 Drill a 3 16 in hole through the plug in the cran
187. tle wear takes place in the piston boss piston pin area If the original piston and connecting rod can be reused after new rings are installed the original pin can also be reused but new piston pin retainers are required The piston pin is included as part of the piston assembly if the pin boss in the piston or the pin are worn or damaged a new piston assembly is required 9 7 Section 9 Inspection and Reconditioning Ring failure is usually indicated by excessive oil consumption and blue exhaust smoke When rings fail oil 1s allowed to enter the combustion chamber where it is burned along with the fuel High oil consumption can also occur when the piston ring end gap is incorrect because the ring cannot properly conform to the cylinder wall under this condition Oil control is also lost when ring gaps are not staggered during installation When cylinder temperatures get too high lacquer and varnish collect on pistons causing rings to stick which results in rapid wear A worn ring usually takes on a shiny or bright appearance Scratches on rings and pistons are caused by abrasive material such as carbon dirt or pieces of hard metal Overheated or Deteriorated Oil Figure 9 8 Common Types of Piston Damage 9 8 Detonation damage occurs when a portion of the fuel charge ignites spontaneously from heat and pressure shortly after ignition This creates two flame fronts which meet and explode to create extreme hammering p
188. tral This is especially important on equipment with Transmission or hydrostatic drive The transmission must be exactly in neutral to Engine prevent resistance which could keep the engine from starting 2 Check for seized engine components such as the bearings connecting rod and piston Solenoid Shift Electric Starters Operation Solenoid Shift Starter When power is applied to the starter the electric solenoid moves the drive pinion out onto the drive ane f shaft and into mesh with the flywheel ring gear When Ring 5 Plunger the pinion reaches the end of the drive shaft it rotates Stop aoi the flywheel and cranks the engine ws Spring yee Lever When the engine starts and the start switch is released T the starter solenoid is deactivated the drive lever moves back and the drive pinion moves out of mesh with the ring gear into the retracted position Armature Solenoid Plug Frame amp Field Brush Holder Nut CE Frame Screw Bolt Figure 7 8 Completed Delco Remy Starter Figure 7 9 Delco Remy Starter 7 8 Starter Disassembly 1 Remove the hex nut and disconnect the positive brush lead bracket from the solenoid terminal 2 Remove the three screws securing the solenoid to the starter See Figure 7 10 Torx Head Screws NOTE Test procedure for checking starter solenoid on pages 7 16 and 7 17 Figure 7 11 Solenoid Removed from Starter 3 Remove the two t
189. ts to the intake manifold prior to attempting to set the governor Troubleshooting General When troubleshooting a problem on an engine with EFI basic engine operating problems must be eliminated first before faulting the EFI system components What appears to be an EFI problem could be something as simple as a fuel tank with debris in the bottom or a plugged vent Be sure the engine is in good mechanical operating condition and all other systems are operating properly before attempting to troubleshoot the EFI system Troubleshooting Guide Engine starts hard or fails to start when cold 1 Fuel pump not running 2 Faulty spark plugs 3 Old stale fuel 4 Incorrect fuel pressure 5 Crankshaft position sensor loose or faulty 6 TPS set incorrect ECU Reset and TPS Learn 7 TPS faulty 8 Engine temp sensor faulty 9 Faulty coils 10 Low system voltage 11 Faulty injectors 12 Faulty battery 13 Loose or corroded connections Engine starts hard or fails to start when hot 1 Faulty spark plugs Fuel pump not running Fuel pressure low Insufficient fuel delivery TPS set incorrect ECU Reset and TPS Learn Crankshaft position sensor loose or faulty TPS faulty Engine temp sensor faulty Faulty injectors DUUM a ee Engine stalls or idles roughly cold or warm 1 Faulty spark plugs Insufficient fuel delivery TPS set incorrect TPS faulty Faulty engine temperature sensor Faulty injectors oo fu Section 5 EFI Fuel Syst
190. uel system remains under high pressure even when the engine is stopped Before attempting to service any part of the fuel system the pressure must be relieved by following Fuel Pump Module Fuel Connector Removal instructions below Fuel Pump Module Fuel Connector Removal Wrap a shop towel completely around the fuel pump module connector Press the release button s and slowly pull the connector away from the fuel pump module allowing the shop towel to absorb any residual fuel in the high pressure fuel line Any spilled fuel must be completely wiped up immediately Initial Starting Priming Procedure Important The EFI fuel system must be purged of air primed prior to the initial start up and or any time the system has been disassembled or the fuel tank run dry 1 Turn the key switch to the ON RUN position You will hear the fuel pump cycle on and off When the fuel pump stops cycling approximately 20 seconds the system is primed start the engine 5 2 2 Acompletely dry system may require repeating step 1 several times Wait a minimum of 10 seconds between key OFF and key ON Fuel Recommendations General Recommendations Purchase gasoline in small quantities and store in clean approved containers An approved container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle and helps prevent spillage during refueling e Do not use gasoline left over from the pr
191. ully remove the push rods cylinder heads and head gaskets See Figure 8 51 Figure 8 51 Removing Cylinder Head 4 Remove the lifters from the lifter bores Use a hydraulic lifter tool Do not use a magnet to remove lifters Mark the lifters by location as either intake or exhaust and cylinder 1 or 2 Hydraulic lifters should always be reinstalled in the same position See Figure 8 52 and 8 53 Section 8 Disassembly Hydraulic Lifter Tool Figure 8 52 Removing Hydraulic Lifters Figure 8 53 Mark the Lifters By Location Disassemble Cylinder Heads 1 Remove the two hex flange screws rocker arm pivots and rocker arms from the cylinder head See Figure 8 54 Figure 8 54 Removing Rocker Arm 2 Compress the valve springs using a valve spring compressor See Figure 8 55 8 13 Section 8 Disassembly Figure 8 55 Removing Valves with Valve Spring Compressor 3 Once the valve spring is compressed remove the valve spring keepers then remove the following items See Figures 8 56 and 8 57 Valve spring retainers Valve springs Valve spring caps Intake and exhaust valves mark position Valve stem seals intake and exhaust NOTE These engines use valve stem seals on the intake and exhaust valves Use a new seal whenever the valve is removed or if the seal is deteriorated or damaged in any way Never reuse an old seal 4 Repeat the above procedure for the other cylinder head Do not inter
192. ure 5 5 TPS Location Service The TPS is a sealed non serviceable assembly If diagnosis indicates a bad sensor complete replacement is necessary If a blink code indicates a problem with the TPS it can be tested as follows 1 Counting the number of turns back out the idle speed adjusting screw counterclockwise until the throttle plates can be closed completely Write this number down for reference later 2 Disconnect the Black connector from the ECU but leave the TPS mounted to the throttle body 3 a Usean ohmmeter and connect the red positive ohmmeter lead to Black pin 12 terminal and the black negative ohmmeter lead to Black pin 10 terminal to test b Hold the throttle closed and check the resistance It should be 1400 1800 Q Throttle Between Resistance Continuit EC Terminal Value Q y Section 5 EFI Fuel System Leave the leads connected to the pin terminals as described in step 3 Rotate the throttle shaft slowly to the full throttle position Monitor the dial during rotation for indication of any momentary short or open circuits Note the resistance at the full throttle position It should be 4600 5200 without a stop pin or 3200 4100 with a stop pin Disconnect the main wiring harness connector from the TPS leaving the TPS assembled to the throttle body Refer to the following chart and perform the resistance checks indicated between the terminals in the TPS switch with the throttle i
193. valve seat angle 44 5 half of the full 89 angle will achieve the desired 0 5 1 0 full cut interference angle where the maximum pressure occurs on the outside diameters of the valve face and seat Section 9 Inspection and Reconditioning Valve Seat x Cutter fr Figure 9 7 Typical Valve Seat Cutter Lapping Valves Reground or new valves must be lapped in to provide proper fit Use a hand valve grinder with a suction cup for final lapping Lightly coat the valve face with a fine grade of grinding compound then rotate the valve on its seat with the grinder Continue grinding until a smooth surface is obtained on the seat and on the valve face Thoroughly clean the cylinder head in soap and hot water to remove all traces of grinding compound After drying the cylinder head apply a light coating of SAE 10 oil to prevent rusting Valve Stem Seal These engines use valve stem seals on the intake and exhaust valves Always use a new seal when the valves are removed from the cylinder head The seals should also be replaced if deteriorated or damaged in any way Never reuse an old seal Pistons and Rings Inspection Scuffing and scoring of pistons and cylinder walls occurs when internal engine temperatures approach the welding point of the piston Temperatures high enough to do this are created by friction which is usually attributed to improper lubrication and or overheating of the engine Normally very lit
194. ve Side Clearance Leuu cooper orto renta petite itaem sss 0 050 0 095 mm 0 0019 0 0037 in Middle Compression Ring to Groove Side Clearance 0 030 0 075 mm 0 0012 0 0030 in Oil Control Ring to Groove Side Clearance eee 0 010 0 011 mm 0 0004 0 0043 in Top and Middle Compression Ring End Gap NOU DO pereina E O E T Oud dein ur 0 025 0 56 mm 0 010 0 022 in Used Bore Max ECV630 ECV650 ECV680 ssscsssssssssssecsssercsssenessaes 0 080 mm 0 0315 in Used Bore Max ECV730 ECV 740 ECV 749 sscssescscssccssssseesessscsssesensnens 0 094 mm 0 0370 in Piston Thrust Face O D ECVO OU EC VOU ECV OOU cere a 79 962 79 980 mm 3 1481 3 1488 in ECV AO BC VO ECV os eener S e E E E E 82 949 82 967 mm 3 2657 3 2664 in Max Wear Limit EC V630 ECV650 EC VOOSUuisnss eset nen bantur NU yid RP o aate 79 831 mm 3 1430 in Max Wear Limit ECV730 ECV740 ECV749 cccccccsssscsstcessseeseseeceseeessneeeees 82 818 mm 3 2606 in Piston Thrust Face to Cylinder Bore Running Clearance New ECV G00 EC VSSU BE VODU sonerii i donee quU Drei Su DN S PEDES RU 0 020 0 063 mm 0 0008 0 0024 in News BC 700 EC VZTU BG ZAO ases vem RESI UAR a Iste IA HAM 0 0039 0 082 mm 0 0015 0 0032 in Speed Control Bracket Assembled to Cylinder Heads BAST EOS m T 10 7 N m 95 in Ib into new holes 7 3 N m 65 in Ib into used holes Speed Control Bracket
195. y procedures By using tools designed for the job you can properly service engines easier faster and safer In addition you ll increase your service capabilities and customer satisfaction by decreasing engine downtime Here is the list of tools and their source Separate Tool Suppliers Kohler Tools SE Tools Design Technology Inc Contact your source of supply 415 Howard St 768 Burr Oak Drive Lapeer MI 48446 Westmont IL 60559 Phone 810 664 2981 Phone 630 920 1300 Toll Free 800 664 2981 Fax 630 920 0011 Fax 810 664 8181 Tos ooo E Source Part No i peur mai tir RA and if cylinder piston rings or valves are worn EFI Service Kit For troubleshooting and setting up an EFI engine Kohler 24 761 01 5 Individual Components Available Design Technology Inc Fuel Pressure Tester JOTI 019 Noid Light DTI 021 90 Adapter DTI 023 In line T Fitting DTI 035 Code Plug Red Wire DTI 027 Code Plug Blue Wire DTI 029 Shrader Valve Adapter Hose DTI 037 Flywheel Holding Tool CS Series SE Tools KLR 82407 Si LG eae SE Tools KLR 82408 To remove flywheel from engine Flywheel Strap Wrench To hold flywheel during removal P 2 1 Section 2 Tools amp Aids Tools Continued NENNEN Description Source Part No Hydraulic Valve Lifter Tool To remove and install hydraulic lifters ia eons Ignition System Tester For testing output on all systems including CD KOR OTAPA ien Offset Wrench K amp M Series To remove and

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