Club Car Carryall 300 2021, Maintenance And Service Manual

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33 17 690 15 Rev. -- KohlerEngines.com
EFI SYSTEM
Oxygen Sensor (O2)
Detail
Pin D
Pin C
Pin B
Pin A
A
B
Pin A
Purple Wire,
Pin B
White Wire,
Heater -
Pin C
Grey Wire, Sensor
Output
Pin D
Black Wire, Sensor
Ground
A
14 mm or 9/16 in.
Wrench Size
B
12 mm x 1.25
Thread Size
Installation Torque 18 N·m (159 in. lb.)
Cutaway Oxygen Sensor (O2) Components
A
B
C
D
E
F
G
A Protection Shield B
Planar Element
and Heater
C Lower Insulator D
Stainless Steel
Housing
E Upper Insulator F
Terminal Connection
to Element
G
High Temp
Water Seal
Temperature must be controlled very accurately and gas
constituents measured to a high degree of accuracy for
absolute sensor measurements. This requires laboratory
equipment to determine a good or bad sensor in fi eld.
Furthermore, as with most devices, intermittent problems
are diffi cult to diagnose. Still, with a good understanding
of system and sensor, it is possible to diagnose many
sensor problems in fi eld.
Using diagnostic software connected to ECU is a useful
technique for observing sensor performance. However,
user must understand that such software reads a signal
generated by ECU. If there is an ECU or wiring problem,
readings could be misinterpreted as a sensor problem.
Digital nature of signal to software means that it is not
reading continuous output of sensor. A voltmeter can
also be used as an eff ective 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 sensor and cause inaccurate
readings. Since resistance of sensor is highest at
low temperatures, such meters will cause largest
inaccuracies when sensor is in a cool exhaust.
Visual Inspection
Sensor Wire Detail
A
A
Keep a minimum of 25 mm (1.0 in.) radius at
grommet.
NOTE: Always route harness away from hot exhaust
and away from moving parts.
NOTE: Do not attempt to clean sensor. Replace as
needed.
1. Look for a damaged or disconnected sensor-to-
engine harness connection.
2. Look for damage to sensor lead wire or associated
engine wiring due to cutting, chaffi ng or melting on a
hot surface.
3. Disconnect sensor connector and look for corrosion
in connector.
4. Try reconnecting sensor and observe if problem has
cleared.
5. Correct any problems found during visual check.
6. Inspect for any exhaust system leaks upstream or
downstream of oxygen sensor. Confi rm oxygen
sensor is secured to 18 N·m (159 in. lb.).
All leaks must be repaired and an ECU/TPS reset
must be performed before proceeding with sensor
testing.
7. Using diagnostic software, document any trouble
codes. Determine if historic trouble codes are
logically related to current fault experienced. If
uncertain, clear codes and retest.