Kohler Aegis ELH775 Service Manual

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ELH775

Service Manual

IMPORTANT:

Read all safety precautions and instructions carefully before operating equipment. Refer to operating

instruction of equipment that this engine powers.

Ensure engine is stopped and level before performing any maintenance or service.

Safety

Maintenance

Speciﬁ cations

Tools and Aids

Troubleshooting

Air Cleaner/Intake

Electronic Fuel Injection (EFI) System

Lubrication System

Electrical System

Starter System

Cooling System

Disassembly/Inspection and Service

Reassembly

66 690 14 Rev. A

KohlerEngines.com

Table of Contents

Summary of Contents for Kohler Aegis ELH775

Page 1 ELH775 Service Manual IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating instruction of equipment that this engine powers. Ensure engine is stopped and level before performing any maintenance or service. Safety Maintenance Speciﬁ cations Tools and Aids Troubleshooting Air Cleaner/Intake...
Page 2: Safety Precautions
Safety SAFETY PRECAUTIONS WARNING: A hazard that could result in death, serious injury, or substantial property damage. CAUTION: A hazard that could result in minor personal injury or property damage. NOTE: is used to notify people of important installation, operation, or maintenance information. CAUTION WARNING WARNING...
Page 3: Maintenance Instructions
PRO oil and PRO ﬁ lter. ® REPAIRS/SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers. Find your local Kohler Engines dealer at KohlerEngines.com or call 1-800-544-2444 (U.S.A. and Canada). 66 690 14 Rev. A KohlerEngines.com...
Page 4: Oil Recommendations
KOHLER PRO Extended Life Oil Filter. Alternative note should then be attached to equipment and/or engine oils and oil ﬁ lters may be used with KOHLER engine as a reminder to reﬁ ll cooling system before engines but require 200-Hour oil and oil ﬁ lter change starting.
Page 5: Specifications
Speciﬁ cations Engine Dimensions-Flywheel Side 432.0 mm (17.01 in.) 325.0 mm (12.80 in.) 560.45 mm (22.07 in.) 625.33 mm (24.62 in.) 4 X Ø 10.66 mm 2 X 184.20 mm 92.10 mm (3.63 in.) 272.10 mm (10.71 in.) (0.42 in.) (7.25 in.) Mounting Hole Center 308.10 mm (12.13 in.)
Page 6 Speciﬁ cations Engine Dimensions-Oil Filter Side 152.08 mm (5.99 in.) 141.75 mm (5.58 in.) 201.0 mm (7.91 in.) 12.47 mm (0.49 in.) 38.0 mm (1.50 in.) 3/8 NPTF Plug KohlerEngines.com 66 690 14 Rev. A...
Page 7 Speciﬁ cations Engine Dimensions-Engine Mounting Surface (PTO End) 4 X 3/8-16 301.84 mm (11.88 in.) Ø 177.80 mm UNC-2B in. Starter Exhaust Ports (7.00 in.) Pilot 17.0 mm (0.66 in.) Deep 4 X 7/16-14 UNF-2B in. 30° 45° 2 X 45° 21.0 mm (0.82 in.) Deep Mounting Hole...
Page 8 Speciﬁ cations Engine Dimensions-Starter Side 119.75 mm (4.72 in.) 39.0 mm (1.54 in.) 119.78 mm (4.72 in.) Dipstick Coolant Overﬂ ow Fill Oil Fill G Ø 28.56 mm (1.13 in.) ± 24.94 mm (0.98 in.) ± 70.8 mm (2.79 in.) 54.8 mm (2.16 in.) 0.13 mm (0.01 in.) 0.13 mm (0.01 in.)
Page 9 Speciﬁ cations Engine Dimensions-Top Oil Fill Cap Radiator 66 690 14 Rev. A KohlerEngines.com...
Page 10: Engine Identification Numbers
Values are in Metric units. Values in parentheses are English equivalents. Any and all horsepower (hp) references by Kohler are Certiﬁ ed Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certiﬁ ed Power Ratings can be found at KohlerEngines.com.
Page 11 Speciﬁ cations TORQUE SEQUENCES ELH775 (Refer to Torque Speciﬁ cations for torque values). Closure Plate Fasteners Cylinder Head Bolt Fasteners Intake Manifold Mounting Fasteners Valve Cover Fasteners 66 690 14 Rev. A KohlerEngines.com...
Page 12 Speciﬁ cations TORQUE SEQUENCES ELH775 (Refer to Torque Speciﬁ cations for torque values). Water Pump Fasteners TORQUE SPECIFICATIONS ELH775 Intake Manifold Intake Manifold Fastener (torque in 2 increments) ﬁ rst to 7.4 N·m (66 in. lb.) (torque sequence on page 11) ﬁ...
Page 13 Speciﬁ cations TORQUE SPECIFICATIONS ELH775 Fan/Flywheel Rear Fan Shaft to Mounting Bracket Nut 15.8 N·m (140 in. lb.) Front Fan Assembly to Fan Shaft Nut 15.8 N·m (140 in. lb.) Fan/Pulley/Hub Assembly Fastener 6.8 N·m (60 in. lb.) Flywheel Retaining Screw 66.4 N·m (49 ft.
Page 14: Clearance Specifications
Speciﬁ cations CLEARANCE SPECIFICATIONS ELH775 Camshaft End Play (with shim) 0.076/0.127 mm (0.0030/0.0050 in.) Running Clearance 0.025/0.063 mm (0.0010/0.0025 in.) Bore I.D. 20.000/20.025 mm (0.7874/0.7884 in.) Max. Wear Limit 20.038 mm (0.7889 in.) Camshaft Bearing Surface O.D. 19.962/19.975 mm (0.7859/0.7864 in.) Max.
Page 15 Speciﬁ cations CLEARANCE SPECIFICATIONS ELH775 Cylinder Bore Cylinder Bore I.D. 83.006/83.031 mm 3.2679/3.2689 in.) Max. Wear Limit 83.069 mm (3.2704 in.) Max. Out-of-Round 0.12 mm (0.0047 in.) Max. Taper 0.05 mm (0.0020 in.) Cylinder Head Max. Out-of-Flatness 0.076 mm (0.003 in.) Governor Governor Cross Shaft to Crankcase Running 0.025/0.126 mm (0.0009/0.0049 in.)
Page 16 Speciﬁ cations CLEARANCE SPECIFICATIONS ELH775 Valves and Valve Lifters Hydraulic Valve Lifter to Crankcase Running 0.0124/0.0501 mm (0.0005/0.0020 in.) Clearance Intake Valve Stem-to-Valve Guide Running 0.038/0.076 mm (0.0015/0.0030 in.) Clearance Exhaust Valve Stem-to-Valve Guide Running 0.050/0.088 mm (0.0020/0.0035 in.) Clearance Intake Valve Guide I.D.
Page 17: General Torque Values
Speciﬁ cations GENERAL TORQUE VALUES English Fastener Torque Recommendations for Standard Applications Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners Into Aluminum Size Grade 2 Grade 5 Grade 8 Tightening Torque: N·m (in. lb.) ± 20% 8-32 2.3 (20) 2.8 (25)
Page 18: Tools And Aids
Shrader Valve Adapter Hose DTI-037 Wire Probe Set (2 pieces regular wire with clip; 1 piece fused wire) DTI-031 Hose Removal Tool, Dual Size/End (also sold as individual Kohler tool) DTI-033 Flywheel Puller SE Tools KLR-82408 For properly removing ﬂ ywheel from engine.
Page 19 For reaming worn valve guides to accept replacement oversize valves. Can be used in low-speed drill press or with handle below for hand reaming. Reamer Handle Design Technology Inc. For hand reaming using Kohler 25 455 12-S reamer. DTI-K830 AIDS Description Source/Part No.
Page 20 Tools and Aids FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL A ﬂ ywheel holding tool can be made out of an old junk A spanner wrench to lift rocker arms or turn crankshaft ﬂ ywheel ring gear and used in place of a strap wrench. may be made out of an old junk connecting rod.
Page 21: Troubleshooting Guide
Troubleshooting TROUBLESHOOTING GUIDE When troubles occur, be sure to check simple causes which, at ﬁ rst, 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 EFI engine troubles are listed below and vary by engine speciﬁ cation. Use these to locate causing factors.
Page 22 Troubleshooting ● Check intake manifold throat for dirt. Dirt in throat is Engine Loses Power further indication that air cleaner was not functioning ● Dirty air cleaner element. properly. ● Engine overheated. ● Check if oil level is within operating range on dipstick. ●...
Page 23: Crankcase Vacuum Test
Troubleshooting CRANKCASE VACUUM TEST WARNING WARNING Carbon Monoxide can cause severe nausea, Rotating Parts can cause severe injury. fainting or death. Stay away while engine is in operation. Avoid inhaling exhaust fumes. Never run engine indoors or in enclosed spaces. Keep hands, feet, hair, and clothing away from all Engine exhaust gases contain poisonous carbon moving parts to prevent injury.
Page 24: Compression Test
Troubleshooting COMPRESSION TEST A compression test is best performed on a warm engine. Clean any dirt or debris away from base of spark plug(s) before removing them. Be sure battery is fully charged, ECU is unplugged, and throttle is wide open during test. Compression should be at least 160 psi and should not vary more than 15% between cylinders.
Page 25: Air Cleaner/Intake
Air Cleaner/Intake AIR CLEANER BREATHER TUBE These systems are CARB/EPA certiﬁ ed and components Ensure both ends of breather tube are properly should not be altered or modiﬁ ed in any way. connected. AIR COOLING WARNING Hot Parts can cause severe burns. Do not touch engine while operating or just after stopping.
Page 26: Efi System
EFI System Gasoline is extremely ﬂ ammable and its vapors can WARNING explode if ignited. Store gasoline only in approved Explosive Fuel can cause ﬁ res and severe containers, in well ventilated, unoccupied buildings, away burns. from sparks or ﬂ ames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition.
Page 27: Fuel Recommendations
ECU is not reset. FUEL LINE During certain operating periods such as cold starts, Low permeation fuel line must be installed on all Kohler warm up, acceleration, high load, etc., a richer air/fuel Co. engines to maintain EPA and CARB regulatory ratio is required and system operates in an open loop compliance.
Page 28 EFI System ECU requires a minimum of 6.0 volts to operate. Throttle position sensor (TPS) is used to indicate throttle plate angle to ECU. Since throttle (by way of governor) To prevent engine over-speed and possible failure, a reacts to engine load, angle of throttle plate is directly rev-limiting feature is programmed into ECU.
Page 29 EFI System Oxygen sensor functions like a small battery, generating EFI engines are equipped with a 25 amp charging a voltage signal to ECU based upon diﬀ erence in oxygen system to accommodate combined electrical demands content between exhaust gas and ambient air. of ignition system and speciﬁ...
Page 30: Important Notes
EFI System Idle speed is only adjustment that may be performed on IMPORTANT NOTES! EFI system. Standard idle speed setting for EFI engines ● Cleanliness is essential and must be maintained at all is 1500 RPM, but certain applications might require times when servicing or working on EFI system.
Page 31: Electrical Components
EFI System ELECTRICAL COMPONENTS Grey Connector Side Pin # Description Electronic Control Unit (ECU) Not Used Pinout of ECU Not Used Black Connector Side Malfunction Indicator Light (MIL) Ground Pin # Function Not Used Ignition Coil #1 Ground Not Used Battery Ground Not Used Diagnostic Communication Line...
Page 32 ECU Reset Procedure 1. Turn key/ignition OFF. 2. Install Red wire jumper from Kohler EFI service kit on to service port (connect white wire to black wire in 4 way diagnostic port). 3. Turn key/ignition ON, then OFF and count 10 seconds.
Page 33 EFI System 66 690 14 Rev. A KohlerEngines.com...
Page 34 EFI System Crankshaft Position Sensor Throttle Position Sensor (TPS) TPS is a sealed, non-serviceable assembly. If diagnosis indicates a bad sensor, complete replacement is necessary. A magnet that sensor detects is separate, and can be replaced or reused. If a blink code indicates a problem with TPS, it can be tested as follows: Diagnostics of sensor: ECU will have electrical faults captured in fault codes P0122 and P0123.
Page 35 EFI System Replace magnet assembly Coolant Temperature Sensor A sealed, non-serviceable assembly. A faulty sensor must be replaced. If a blink code indicates a problem with coolant temperature sensor, it can be tested as follows: 1. Ensure engine is cool. When radiator is cool to touch, slowly loosen radiator cap to ﬁ...
Page 36 EFI System Temperature/Manifold Absolute Pressure (TMAP) Oxygen Sensor (O Sensor Components A sealed non-serviceable integrated sensor that checks both intake air temperature and manifold absolute pressure. Complete replacement is required if it is faulty. Pin A Sensor and wiring harness can be checked as follows. If a blink code indicates a problem with Intake Air Pin B Temperature (TMAP) Sensor Circuit (P0112 or P0113), it...
Page 37 EFI System Visual Inspection Removal Inspection 1. Look for a damaged or disconnected sensor-to- NOTE: Apply anti-seize compound only to threads. engine harness connection. Anti-seize compound will aﬀ ect sensor performance if it gets into lower shield of 2. Look for damage to sensor lead wire or associated sensor.
Page 38 EFI System Troubleshooting-Oxygen Sensor (O Condition Possible Cause Conclusion Low voltage output. Shorted sensor or sensor circuit. Replace sensor or repair wiring. Shorted lead wire. Wiring shorted to ground. Contamination of air reference. Remove source of external contamination, protect air reference area.
Page 39 EFI System Electrical Relay Fuel Injectors Electrical relay is used to supply power to electric fuel pump. When key switch is turned ON and all safety WARNING switch requirements met, relay provides 12 volts to fuel Explosive Fuel can cause ﬁ res and severe pump circuit.
Page 40 EFI System 2. Disconnect electrical connector from an injector and 3. Thoroughly clean area around manifold and listen for a change in idle performance (only running injectors. on one cylinder) or a change in injector noise or 4. Remove injector bracket mounting bolts and remove vibration.
Page 41: Fuel Components
ECU power (switch) must be turned OFF for high pressure fuel line. Insert pressure test jumper 10 seconds for injector signal to return. This is a (from Kohler EFI Service Kit) between high pressure safety measure to prevent bore washing and oil fuel line and fuel supply.
Page 42 Only Kohler replacement parts can be used because ﬁ tting is speciﬁ c to system and must be maintained. Visit KohlerEngines.com for recommended...
Page 43 EFI System TROUBLESHOOTING GUIDE Fuel pump not running. Engine temp sensor faulty. Incorrect fuel pressure. TPS faulty. TPS oﬀ set incorrect. Engine Starts Hard or Fails to Start When Old/stale fuel. Cold Low system voltage. Speed sensor loose or faulty. Faulty injectors.
Page 44 EFI System Function Test Fault Codes Example of Diagnostic Display WARNING High Pressure Fluids can puncture skin and cause severe injury or death. One second pause Do not work on fuel system without proper Fault training or safety equipment. Code One second pause Fluid puncture injuries are highly toxic and hazardous.
Page 45 EFI System Fault Code Connection or Failure Description 0230 Fuel Pump Circuit Low Voltage or Open 0232 Fuel Pump Circuit High Voltage 0336 Crankshaft Position Sensor Noisy Signal 0337 Crankshaft Position Sensor No Signal 0351 Cylinder 1 Ignition Coil Malfunction 0352 Cylinder 2 Ignition Coil Malfunction 0562...
Page 46 EFI System Code 0113 Code 0107 Component: Manifold Absolute Pressure (TMAP) Component: Intake Air Temperature (TMAP) Fault: Intake Air Temperature Sensor Circuit Fault: TMAP Circuit Low Voltage or Open High Voltage or Open Condition: Intake manifold leak, open connection or Condition: Shorted connection, faulty sensor, broken faulty sensor.
Page 47 EFI System Code 0122 Code 0131 Component: Throttle Position Sensor (TPS) Component: Oxygen Sensor Fault: TPS Circuit Low Voltage or Open Fault: O2S 1 Circuit Low Voltage Condition: Open connection, broken wire or faulty Condition: Open connection, broken wire or faulty sensor.
Page 48 EFI System Code 0171 Code 0172 Component: Fuel System Component: Fuel System Fault: Maximum adaptation limit exceeded Fault: Minimum adaptation limit exceeded Condition: Fuel inlet screen/ﬁ lter plugged, low Condition: Too high pressure at high pressure fuel pressure at high pressure fuel line, TPS line, TPS malfunction, shorted malfunction, shorted connection, faulty connection, faulty sensor or fuel pump...
Page 49 EFI System Code 0174 Code 0202 Component: Fuel System Component: Fuel Injector Fault: Lean fuel condition Fault: Injector 2 Circuit Malfunction Condition: Fuel inlet screen/ﬁ lter plugged, low Condition: Injector damaged or faulty, shorted or pressure at high pressure fuel line, TPS open connection.
Page 50 EFI System Code 0336 Code 0351 Component: Crankshaft Position Sensor Component: Ignition Coil Fault: Crankshaft Position Sensor Noisy Signal Fault: Cylinder 1 Ignition Coil Malfunction Condition: Loose sensor, faulty/bad battery, shorted Condition: Broken wire in harness (may not be or faulty connection, faulty sensor or visible), shorted connection or faulty faulty sensor grounding.
Page 51 ● Coil circuit(s), pin circuits Grey 10 and Black 1. supply to bulb will be part of vehicle wire ● ECU grounds harness. Kohler key switch model will have MIL ● ECU on engine with 12V supply to bulb. ● Vehicle safety interlocks, ground signal on safety wire.
Page 52 EFI System EFI Diagnostic Flow Diagram START OF TEST PROCEED TO START OF TEST FOR RETEST KEY ON MALFUNCTION REFER TO DIAGNOSTIC AID #1 INDICATOR LIGHT SYSTEM POWER REFER TO ARE FAULT CODES DIAGNOSTIC FAULT CODE SUMMARY PRESENT? CLEAR CODES REFER TO DIAGNOSTIC AID #3 DOES ENGINE START? MIL GOES OFF?
Page 53: Lubrication System
Lubrication System This engine uses a full pressure lubrication system. This system delivers oil under pressure to crankshaft, camshaft and connecting rod bearing surfaces. In addition to lubricating bearing surfaces, lubrication system supplies oil to hydraulic valve lifters. A high-eﬃ ciency gerotor pump is located in closure plate. Oil pump maintains high oil ﬂ ow and oil pressure, even at low speeds and high operating temperatures.
Page 54 Lubrication System 7. Reinstall oil ﬁ ll cap/dipstick and tighten securely. Testing 8. Start engine; check for oil leaks. Stop engine; correct Compressed air, a pressure regulator, pressure gauge, leaks. Recheck oil level. and a continuity tester are required to test switch. 9.
Page 55: Electrical System
Electrical System BATTERY CHARGING SYSTEM ● Disconnect rectiﬁ er-regulator plug, electronic control unit (ECU), and/or wiring harness plug before doing CAUTION any electric welding on equipment powered by engine. Also, disconnect all other electrical accessories in Electrical Shock can cause injury. common ground with engine.
Page 56 Electrical System 1. With engine oﬀ , test and record battery voltage. Fuses Voltage should be above 12 volts to proceed. With This engine has 4 blade type automotive fuses. voltmeter attached to battery, start engine. Set Replacement fuses must have same rating as blown engine speed to high RPM position, battery voltage fuse.
Page 57 Electrical System 3. With engine stopped, measure resistance across Condition Conclusion stator leads using an ohmmeter. OK (green) light comes on Disconnect tester black and stays steady. lead attached to 1 AC Condition Conclusion terminal and reconnect Resistance is 0.1/0.2 Stator is OK.
Page 58: Ignition System
Electrical System IGNITION SYSTEM Inspection Inspect each spark plug as it is removed from cylinder Spark Plug head. Deposits on tip are an indication of general Component and Details condition of piston rings, valves, and fuel mixture. Normal and fouled plugs are shown in following photos: Normal Plug taken from an engine operating under normal conditions will have light tan or gray colored deposits.
Page 59 Isolate and verify trouble is within engine. 1. If Kohler diagnostic software is available, review "Safety System Active" status in Data Display screen. If yes is displayed, equipment safety circuit is active (seat switch/PTO switch/Safety interlocks, etc.). This must be corrected prior to continuing testing.
Page 60 Electrical System Test for Spark NOTE: If 2 ignition system testers are available, testing can be performed simultaneously for both cylinders. However, if only 1 tester is available, 2 individual tests must be performed. Side not being tested must have spark plug lead connected or grounded.
Page 61: Starter System
Starter System NOTE: Do not crank engine continuously for more than 10 seconds. Allow a 60 second cool-down period between starting attempts. Failure to follow these guidelines can burn out starter motor. NOTE: If engine develops suﬃ cient speed to disengage starter but does not keep running (a false start), engine rotation must be allowed to come to a complete stop before attempting to restart engine.
Page 62 Starter System Solenoid Tests NOTE: Please perform following testing as near to conditions during failure. Before Starting ● Disable ignition system: with key oﬀ , unplug EFI Electronic Control Unit (ECU) or remove both 10 amp (red) engine mounted fuses. ●...
Page 63: Cooling System
Cooling System WARNING Liquid coolant can get extremely hot from operation. Turning radiator cap when engine is hot can allow steam and scalding liquid to blow out and burn you severely. Shut Hot liquid can cause severe burns. oﬀ machine. Only remove radiator cap when cool enough Do not loosen radiator cap while engine is to touch with bare hands.
Page 64 4. Drain cooling system. proper tension cannot be established by 5. Fill cooling system. repositioning of lower pulley shims. Use only Kohler Part No. 66 203 02-S belt if replacement is necessary. See a Kohler authorized dealer for any necessary service.
Page 65 Use only Kohler Part No. 66 203 thermostat does not touch bottom of container. Heat 02-S belt. DO NOT use a substitute belt.
Page 66 Cooling System 6. Check thermostat, and pressure test radiator cap. Gauge Needle Drops Quickly A steady drop or loss of pressure indicates serious 7. Make sure water pump and drive belt are leakage is occurring within system, which must be operational.
Page 67: Disassembly/Inspection And Service
Disassembly/Inspection and Service WARNING Accidental Starts can cause severe injury or Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect death. negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) before servicing.
Page 68 Disassembly/Inspection and Service NOTE: This disassembly sequence removes some Drain Coolant from Cooling System components in subassemblies to enable 1. Loosen radiator cap, then loosen radiator drain plug technician to perform internal engine servicing. and allow system to drain. Use a suitable container Do not disconnect every EFI component.
Page 69 Disassembly/Inspection and Service Remove Ignition Coils/Radiator Assembly/Mounting Brackets/Air Cleaner Assembly Components ECU, Fuse, & Relay Connector Mounting Upper Radiator Hose Bracket Ignition Coil Mounting Bracket E-clip Retainer Lower Radiator Hose Upper Radiator Air Cleaner Adapter Radiator Assembly Spacer Support Gasket Air Cleaner Adapter Evap Line Clip Air Cleaner Assembly...
Page 70 Disassembly/Inspection and Service Remove Radiator Assembly, Mounting Brackets and Remove Throttle and Governor Controls Attached Components Details NOTE: Do not allow cooling ﬁ ns of radiator to contact fan blades. 1. Disconnect upper radiator hose from radiator, and lower radiator hose from inlet of water pump. 2.
Page 71 If proper belt tension cannot be obtained, or condition of belt is suspect; replace it with Kohler 1. Remove front nut and washer securing fan assembly Part No. 66 203 02-S. Do not use a substitute belt.
Page 72 1. Disconnect electrical connector from crankshaft position sensor. Inspect ring gear for cracks or damage. Kohler does not provide ring gears as a serviceable part. Replace 2. Remove screws securing crankshaft position sensor ﬂ ywheel if ring gear is damaged.
Page 73 Disassembly/Inspection and Service Intake Manifold Assembly Components Intake Manifold Intake Manifold Fitting Wiring Harness Assembly Gasket Intake Manifold Fuel Injector Bracket Fuel Rail Fuel Injector Bracket Screw Screw By-Pass Hose Remove Intake Manifold, Thermostat Housing, By-Pass Hose and Wiring Harness 1.
Page 74 Disassembly/Inspection and Service Inspection and Service Water Pump Components Water Pump Details Impeller Drive Pulley Water/coolant pump consists of a sealed impeller assembly, which includes outer cover and a cogged O-ring Water Pump drive pulley. When pump is mounted to crankcase, impeller ﬁ...
Page 75 Disassembly/Inspection and Service Breather Components Remove Breather Cover NOTE: Unless breather hose or breather hose insulator are damaged, disassembly from breather cover is unnecessary. 1. Remove screws securing breather cover to crankcase. 2. Carefully pry under protruding edge of breather cover to separate and remove cover from gasket.
Page 76 Disassembly/Inspection and Service Cylinder Head Components Valve Head Hydraulic Lifter Push Rods Head Gasket Valve Stem Seal Valve Spring Cap Valve Spring Valve Spring Retainers Valve Spring Keepers Rocker Arms Rocker Arm Pivot Hydraulic Lifter Style A Rocker Arm Screw Valve Cover Gasket Valve Cover (Ribbed)
Page 77 Inspection Check base surface of hydraulic lifters for wear or damage. If lifters need to be replaced, apply a liberal coating of Kohler lubricant to base of each new lifter before it is installed. Bleeding Lifters Style A (Ribbed) To prevent a possible bent push rod or broken rocker arm, it is important to bleed any excess oil out of lifters before they are installed.
Page 78: Exhaust Valve
Disassembly/Inspection and Service Inspection and Service Valve Details EXHAUST VALVE INTAKE VALVE EXHAUST INSERT INTAKE INSERT Dimension Intake Exhaust Seat Angle 89° 89° Insert O.D. 36.987/37.013 mm (1.4562/1.4572 in.) 32.987/33.013 mm (1.2987/1.2997 in.) Guide Depth 4 mm (0.1575 in.) 6.5 mm (0.2559 in.) Guide I.D.
Page 79 Disassembly/Inspection and Service Valve Guides Lapping Valves If a valve guide is worn beyond speciﬁ cations, it will not NOTE: Exhaust valves that are black in color cannot be guide valve in a straight line. This may result in burnt ground and do not require lapping.
Page 80 Disassembly/Inspection and Service Crankcase Components Locking Tab Thrust Oil Seal Closure Plate Governor Gear Shaft Washer Governor Gear Regulating Pin Camshaft Ball Spring Oil Pump Cover O-ring Outer Gerotor Gear Oil Pump Assembly Oil Pick-Up Nipple Crankshaft Dowel Pin Governor Cross Shaft Camshaft Seal Piston Pin Retainer Piston Pin...
Page 81 Disassembly/Inspection and Service Governor Gear Assembly Oil Pump Assembly Oil pump is mounted inside closure plate. If service is Governor Shaft Press Depth Details required, continue with Disassembly, Inspection, and Reassembly. Disassembly 1. Remove screws. 2. Lift oil pump assembly from closure plate. Remove outer gerotor gear from closure plate.
Page 82 Disassembly/Inspection and Service When cylinder temperatures get too high, lacquer and Remove Connecting Rods with Pistons and Rings varnish collect on pistons causing rings to stick, which NOTE: If a carbon ridge is present at top of either results in rapid wear. A worn ring usually takes on a cylinder bore, use a ridge reamer tool to remove shiny or bright appearance.
Page 83 Disassembly/Inspection and Service Install New Piston Rings Connecting Rods Piston Ring Orientation Oﬀ set, stepped-cap connecting rods are used in all these engines. Inspection and Service Check bearing area (big end) for excessive wear, score marks, running and side clearances. Replace rod and cap if scored or excessively worn.
Page 84 Disassembly/Inspection and Service Inspect gear teeth of crankshaft. If teeth are badly worn, Governor Cross Shaft Oil Seal chipped, or some are missing, replacement of crankshaft will be necessary. Cross Shaft Oil Seal Details Inspect crankshaft bearing surfaces for scoring, grooving, etc.
Page 85 Disassembly/Inspection and Service If cylinder bore is badly scored, excessively worn, Clean Cylinder Bore After Honing tapered, or out-of-round, resizing is necessary. Use Proper cleaning of cylinder walls following boring and/ an inside micrometer to determine amount of wear, or honing is very critical to a successful overhaul. then select nearest suitable oversize of either 0.08 mm Machining grit left in cylinder bore can destroy an engine (0.003 in.), 0.25 mm (0.010 in.), or 0.50 mm (0.020 in.).
Page 86 Reassembly Crankcase Components Locking Tab Thrust Oil Seal Closure Plate Governor Gear Shaft Washer Governor Gear Regulating Pin Camshaft Ball Spring Oil Pump Cover O-ring Outer Gerotor Gear Oil Pump Assembly Oil Pick-Up Nipple Crankshaft Dowel Pin Governor Cross Shaft Camshaft Seal Piston Pin Retainer Piston Pin...
Page 87 Reassembly NOTE: Cylinders are numbered on crankcase. Make Install Flywheel End Oil Seal and Camshaft Oil Seal sure to install piston, connecting rod and end 1. Check to make sure that there are no nicks or burrs cap into its appropriate cylinder bore, as in crankshaft and camshaft seal bores of crankcase.
Page 88 Reassembly Checking/Setting Camshaft End Play Install Closure Plate Oil Seal 1. Install shim removed during disassembly onto Oil Seal Details camshaft. 2. Position end play tool on camshaft. 3. Apply pressure on end play checking tool (pushing camshaft toward crankshaft). Use a feeler gauge to measure end play between shim and end play tool.
Page 89 Reassembly 5. If alignment pins were removed previously, install Install Closure Plate Assembly them in their respective locations in crankcase. Closure Plate Sealant Pattern 6. Install closure plate on crankcase. Carefully seat camshaft and crankshaft into their mating bearings. Rotate crankshaft to help engage oil pump and governor gear meshes.
Page 90 Reassembly Cylinder Head Components Valve Head Hydraulic Lifter Push Rods Head Gasket Valve Stem Seal Valve Spring Cap Valve Spring Valve Spring Retainers Valve Spring Keepers Rocker Arms Rocker Arm Pivot Hydraulic Lifter Style A Rocker Arm Screw Valve Cover Gasket Valve Cover (Ribbed) Hydraulic Lifter Style B...
Page 91 Reassembly Install Hydraulic Lifters Install Push Rods and Rocker Arms NOTE: Hydraulic lifters should always be installed in NOTE: Push rods must always be installed in same same position as before disassembly. position as before disassembly. 1. Refer to Disassembly/Inspection and Service for 1.
Page 92 Reassembly 3. Check sealing surfaces of water pump and Install Water Pump, Drive Belt, and Transfer Tube crankcase. They must be clean and free of any nicks Assembly or damage. Water Pump Components 4. Apply a small amount of grease in several locations to hold new water pump O-ring in place.
Page 93 Reassembly Intake Manifold Assembly Components Intake Manifold Intake Manifold Fitting Wiring Harness Assembly Gasket Intake Manifold Fuel Injector Bracket Fuel Rail Fuel Injector Bracket Screw Screw By-Pass Hose Install Fuel Injectors Install Intake Manifold Assembly NOTE: Ensure all parts are clean, undamaged and free Torque Sequence of debris and make sure electrical connectors have seal in place.
Page 94 Reassembly 5. Connect wire leads to temperature warning switch, 9. Apply rubber lubricant to inside end of upper radiator audible alarm, and/or Oil Sentry switch as hose, and install hose to thermostat housing, if ™ equipped. separated for servicing. Secure with clamp. Make sure tangs of clamp point toward cylinder 1, away If thermostat and thermostat housing were removed from from fan.
Page 95 Reassembly Install Flywheel Install Crankshaft Position Sensor NOTE: Ensure all parts are clean, undamaged, and free of debris and make sure electrical connectors CAUTION have seal in place. Damaging Crankshaft and Flywheel Can 1. If removed, install crankshaft position sensor to Cause Personal Injury! bracket and torque screw to 11.3 N·m (100 in.
Page 96 Reassembly 1. Make sure sealing surfaces of crankcase and Install Breather Components breather cover are clean and free of all old gasket material. Clean with an aerosol type gasket remover or cleaning solvent. DO NOT scrape surfaces as this can result in leakage. 2.
Page 97 Reassembly 3. Insert a nail into hole in cross shaft and rotate shaft COUNTERCLOCKWISE as far as it will turn. Then torque nut to 6.8 N·m (60 in. lb.). 4. Mount main control bracket to cylinder heads with four screws. Torque screws to 10.7 N·m (95 in. lb.) into new holes, or 7.3 N·m (65 in.
Page 98 Reassembly 7. Apply Loctite ® ® to front threads of fan shaft. Install ﬂ at washer and nut to secure. Torque nut to 15.8 N·m (140 in. lb.). 8. Carefully work belt into place on pulleys. Check belt tension. There should be no more than 9.53-12.7 mm (3/8"- 1/2") belt deﬂ...
Page 99 Reassembly Install Ignition Coils/Radiator Assembly/Mounting Brackets/Air Cleaner Assembly Components ECU, Fuse, & Relay Connector Mounting Upper Radiator Hose Bracket Ignition Coil Mounting Bracket E-clip Retainer Lower Radiator Hose Upper Radiator Air Cleaner Adapter Radiator Assembly Spacer Support Gasket Air Cleaner Adapter Evap Line Clip Air Cleaner Assembly 66 690 14 Rev.
Page 100 Reassembly 5. Connect upper and lower radiator hoses to inlets of Install Air Cleaner Assembly radiator and water pump. Secure with hose clamps. 6. Check for adequate clearance between fan and shroud. Adjust lower radiator supports as required, then torque four mounting screws to 9.9 N·m (88 in.
Page 101 Reassembly External Engine Components Dipstick Spark Plug Lead Electric Starter Starter Plate Oil Drain Plug Radiator Drain Plug Oil Filter Radiator Cap Oil Fill Cap Install Starter Plate and Starter Assembly Install Oil Filter and Fill Crankcase with Oil 1. Install starter plate to crankcase. Install mounting NOTE: Make sure both oil drain plugs are installed and screws and torque screws to 15.3 N·m (135 in.
Page 102 Reassembly Install Coolant Testing Engine and Setting Speed 1. Use equal parts of ethylene glycol (antifreeze) and water only. Distilled or deionized water is recommended, especially in areas where water contains a high mineral content. Propylene glycol based antifreeze is not recommended. 2.
Page 103 66 690 14 Rev. A KohlerEngines.com...

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