Table Of Contents - Kohler ECV940 Service Manual

Table of Contents

Contents1
Safety Information2
Maintenance Instructions3
Maintenance Schedule3
Oil Recommendations4
Fuel Recommendations4
Storage4
Engine Dimensions5
Specifications6
Engine Identification Numbers6
Tools And Aids13
Troubleshooting16
External Engine Inspection17
Cleaning Engine17
Crankcase Vacuum Test18
Compression Test19
Cylinder Leakdown Test19
Air Cleaner/Intake20
Breather Tube20
Efi System21
Efi System Electrical Components25
Electronic Control Unit (Ecu)25
Ecu Reset Procedure26
Tps Learn Procedure26
Wiring Diagram27
Crankshaft Position Sensor28
Throttle Position Sensor (Tps)28
Engine (Oil) Temperature Sensor28
Intake Air Temperature Sensor29
Oxygen Sensor29
Sensor Signal Observation30
Oxygen Sensor Removal Inspection30
Troubleshooting-Oxygen Sensor31
Manifold Absolute Pressure Sensor (Map)31
Fuel Injectors32
Fuel Components33
Ignition Coil33
Fuel Pump33
High Pressure Fuel Line34
Purge Port And Vent Hose Assembly34
Throttle Body/Intake Manifold Assembly34
Fuel System Troubleshooting Guide34
Fuel Syste Function Test36
Fault Codes36
Diagnostic Code Summary37
Troubleshooting Flow Chart43
Efi Diagnostic Flow Diagram44
Governor System45
Electronic Governor Components45
Digital Linear Actuator (Dla)45
Governor System - Linkage46
Dla Details46
Gcu/Harness Diagnostics And Troubleshooting46
Gcu Blink Code Tests48
Electronic Governor Troubleshooting Flow Chart50
Basic Electrical Diagram Of Electronic Governor System52
Mechanical Governor53
Governor Adjustments54
Lubrication System55
Lubrication Components View55
Check Oil Level55
Change Oil And Filter55
Oil Cooler56
Electrical System57
Spark Plugs57
Battery58
Battery Charging System59
Stator59
Rectifier Regulator59
Charging System Troubleshooting60
Fuses61
Fuse Replacement61
Starter System62
Troubleshooting - Starting Difficulties62
Solenoid Shift Starters63
Solenoid Shift Starter Components63
Starter Disassembly63
Starter Inspection63
Armature Components And Details64
Brush Replacement64
Starter Reassembly64
Solenoid Tests65
Disassembly/Inspection And Service66
External Engine Components View66
Disconnect Spark Plug Leads67
Drain Oil From Crankcase And Remove Oil Filter67
Remove Cylinder Shrouds And Blower Housing67
Remove Fuel Pump Module/Fuel Pump Assembly67
Flywheel/Backing Shroud/Intake And Throttle Body Assembly Components68
Remove #2 Barrel And Valley Baffles68
Remove Speed Sensor69
Remove Flywheel/Fan/Hex Stud Assembly69
Remove Backing Shroud Assembly69
Remove Oil Filter Housing69
Cylinder Head Components70
Remove Valve Covers70
Remove Cylinder Heads And Hydraulic Lifters71
Disassemble Cylinder Heads71
Cylinder Heads And Hydraulic Lifters Inspection71
Valve Details View72
Valve Guides72
Valve Seat Inserts72
Breather/Oil Pan Components View73
Remove Breather Assembly74
Remove Oil Pan Assembly74
Oil Pump Assembly Disassembly/Inspection/Reassembly74
Crankcase Components View75
Remove Camshaft75
Remove Connecting Rods With Pistons And Rings75
Connecting Rods Inspection And Service75
Piston And Rings Components And Details76
Install New Piston Rings76
Remove Crankshaft77
Crankshaft Components And Details View77
Clearance Specifications - Connecting Rod Journal77
Remove Crankshaft Plug77
Remove Governor Gear Assembly (Mechanical Governor Only)78
Remove Governor Yoke, Cross Shaft, And Seal (Mechanical Governor Only)78
Crankcase Inspection And Service78
Honing78
Measuring Piston-To-Bore Clearance79
Electronic Governor Intake And Throttle Body Assembly Components80
Remove Throttle Body (Electronic Governor)80
Remove Gcu (Electronic Governor)80
Mechanical Governor Intake And Throttle Body Assembly Components81
Remove Throttle Body (Mechanical Governor)81
Remove Ecu82
Remove Fuel Injectors82
Remove Manifold Absolute Pressure (Map) Sensor82
Fuel Pump Module/Fuel Pump Assembly Components View82
Crankcase Components83
Install Flywheel End Oil Seal83
Install Lifter Feed Chamber Gasket And Cover83
Reassembly84
Install Governor Shafts, Seal, And Governor Gear84
Install Crankshaft84
Piston Details View84
Install Camshaft85
Determining Camshaft End Play85
Breather/Oil Pan Components86
Install Oil Pan Seal And Crankshaft Bearing (Pto)86
Pto Oil Seal Details View87
Install Oil Pan Assembly87
Check Crankshaft End Play87
Install Breather Assembly87
Cylinder Head Components View88
Install Hydraulic Lifters88
Valve Stem Seals88
Assemble Cylinder Heads88
Install Cylinder Heads89
Install Guide Plate, Pivot Studs, Push Rods And Rocker Arms89
Adjust Valve Clearance (Avt Only)89
Install Valve Covers90
Install Spark Plugs90
Oil Cooler/Filter Components View90
Install Oil Filter Housing Assembly90
Backing Shroud/Intake Manifold/Throttle Body/Air Cleaner Components91
Install Intake Manifold/Throttle Body/Air Cleaner/Backing Shroud92
Install Breather Hose92
Install Ground Lead And Rectifier - Regulator Connector92
Install Flywheel/Fan Assembly92
External Engine Components93
Install Valley And Cylinder Barrel Baffles94
Install Fuel Pump Module/Fuel Pump Assembly94
Install Electric Starter94
Install Blower Housing/Guard Assembly94
Mechanical Governor Control Bracket Components95
Install Governor Lever (Mechanical Governor Only)95
Install Oil Sentry95
Install Muffler95
Install Oil Filter And Add Oil To Crankcase96
Prepare Engine For Operation96
Testing Engine96