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Fuel Injectors
Explosive Fuel can cause fi res and severe
burns.
Fuel system ALWAYS remains under HIGH
PRESSURE.
Wrap a shop towel completely around fuel pump
module connector. Press release button(s) and slowly
pull connector away from fuel pump module allowing
shop towel to absorb any residual fuel in high pressure
fuel line. Any spilled fuel must be completely wiped up
immediately.
Details
B
C
E
F
H
A Electrical Connection
C
Solenoid Winding
E
Valve Housing
G
Valve End
I
Director Plate
NOTE: Do not apply voltage to fuel injector(s).
Excessive voltage will burn out injector(s). Do
not ground injector(s) with ignition ON.
Injector(s) will open/turn on if relay is energized.
NOTE: When cranking engine with injectors
disconnected, fault codes will be registered in
ECU and will need to be cleared using software
fault clear or an ECU Reset and TPS Learn
Procedure.
Injector problems typically fall into three general
categories: electrical, dirty/clogged, or leakage. An
electrical problem usually causes one or both of injectors
to stop functioning. Several methods may be used to
check if injectors are operating.
24 690 01 Rev. S
WARNING
A
D
G
I
B
Upper O-ring
D
Armature
F
Valve Seat
H
Lower O-ring
KohlerEngines.com
EFI SYSTEM-ECH WITH OXYGEN SENSOR
1. With engine running at idle, listen for a buzzing or
clicking sound.
2. Disconnect 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:
1. Disconnect electrical connector from both injectors.
Plug a 12 volt noid light into one connector.
2. Make sure all safety switch requirements are met.
Crank engine and check for fl ashing of test light.
Turn key OFF for at least 10 seconds between tests
to allow ECU to go to sleep and reawake. Repeat
test at other connector.
a. If fl ashing occurs, use an ohmmeter (Rx1 scale)
and check resistance of each injector across two
terminals. Proper resistance is 11-13 Ω. If injector
resistance is correct, check whether connector
and injector terminals are making a good
connection. If resistance is not correct, replace
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 tip of valve needle),
or external (weeping around injector O-rings). Loss of
system pressure from leakage can cause hot restart
problems and longer cranking times. To check for
leakage it will be necessary to loosen or remove blower
housing which may involve removing engine from unit.
Refer to Disassembly for removal of injector.
1. Remove manifold mounting bolts and separate
throttle body/manifold from engine leaving TPS, high
pressure fuel line, injectors and fuel line connections
intact. Discard old gaskets.
2. Position manifold assembly over an appropriate
container to capture fuel and turn key switch ON to
activate fuel pump and pressurize system. Do not
turn switch to START position.
NOTE: 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 fuel pump module pins.
3. If either injector exhibits leakage of more than two to
four drops per minute from tip, or shows any sign of
leakage around outer shell, turn ignition switch OFF
and replace injector as follows.
4. Depressurize fuel system.
5. Clean any dirt accumulation from sealing/mounting
area of faulty injector(s) and disconnect electrical
connector(s).
6. Pull retaining clip off top of injector(s). Remove
screw holding injector(s) from manifold.
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