Kohler KDI 1903M Workshop Manual page 4

5 Information regarding discharge of liquids ....................................................................... 58
5.1 Coolant ........................................................................................................................................... 58
5.2 Engine oil ........................................................................................................................................ 59
6 Information for replacing the functional units ................................................................... 60
6.1 Injectors and injection pump replacement ................................................................................. 60
6.2 Coolant pump replacement .......................................................................................................... 68
6.3 Replace the crankshaft pulley ...................................................................................................... 69
6.4 Oil pump replacement ................................................................................................................... 70
6.5 Oil pressure valve replacement .................................................................................................... 73
6.6 Oil filter replacement ..................................................................................................................... 74
6.7 Fuel filter replacement .................................................................................................................. 74
7 Information for disassembly ............................................................................................... 76
7.1 Recommendations for disassembly ............................................................................................ 76
7.2 Electric components disassembly ............................................................................................... 76
7.3 Exhaust manifold disassembly ..................................................................................................... 78
7.4 Coolant recirculation components disassembly ........................................................................ 78
7.5 Crankshaft pulley disassembly .................................................................................................... 79
7.6 Lubrication circuit disassembly ................................................................................................... 79
7.7 Intake manifold disassembly ........................................................................................................ 81
7.8 Fuel system disassembly .............................................................................................................. 81
7.9 Timing system gear disassembly ................................................................................................. 84
7.10 Flange unit disassembly ............................................................................................................... 84
7.11 Cylinder head unit disassembly ................................................................................................... 85
7.12 Oil sump unit disassembly ............................................................................................................ 88
7.13 Engine block disassembly ............................................................................................................ 88
8 Information about overhauling ........................................................................................... 94
8.1 Recommendations for overhauls and tuning ............................................................................. 94
8.2 Crankcase ....................................................................................................................................... 94
8.3 Tappets and tappet housings....................................................................................................... 99
8.4 Crankshaft .................................................................................................................................... 100
8.5 Connecting rod - piston assembly ............................................................................................. 101
8.6 Cylinder head ............................................................................................................................... 105
8.7 Oil pump check ............................................................................................................................ 108
9 Assembly information ....................................................................................................... 110
9.1 Information on engine configuration ......................................................................................... 110
9.2 Assembly recommendations ...................................................................................................... 110
9.3 Engine block assembly ............................................................................................................... 111
9.4 Oil sump unit assembly ............................................................................................................... 117
9.5 Flange unit assembly .................................................................................................................. 119
EN
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