ECU
Remove Electronic Control Unit (ECU)
B
A
C
A
Electronic Control
Unit (ECU)
B
ECU Bracket
C
Starter
1. Remove screws securing ECU to bracket.
2. Disconnect Black and Grey electrical connectors
from ECU.
Remove Electronic Control Unit Bracket and
Electric Starter Motor
1. Disconnect leads from starter.
2. Remove screws, ECU bracket, and starter assembly.
Remove Oil Separator and Hardware
Remove screws securing oil separator assembly, pulling
assembly out and away from valve cover.
Remove Guard and Debris Screen
NOTE: Fan will be loose, but cannot be removed until
after blower housing is removed.
1. Remove screws securing guard to blower housing
and remove guard and spacers.
2. Remove screws securing metal screen and remove
screen.
3. Remove support ring, spacers, and washers paying
attention to curvature of spring washers between
spacers and fan.
Remove Outer Barrel Baffl
es and Blower Housing
1. Disconnect plug from rectifi er-regulator.
2. Remove silver or green plated rectifi er-regulator
ground strap/ground lead screw fastened to
crankcase. Rectifi er-regulator does not have to be
detached from blower housing.
3. Disconnect 3 fuse connectors on outer baffl e and
allow them to hang.
4. Remove screws securing outer barrel baffl es. Note
location of any lifting strap and position of short
screws for reassembly. Coil and any hoses may
remain attached to baffl e after being unplugged or
disconnected.
5. Remove outer barrel baffl es.
6. Remove remaining screws securing blower housing.
Remove blower housing.
Remove Oil Sentry
™
(If Equipped)
NOTE: This is optional. Removing Oil Sentry
™
is not
required to remove breather cover.
1. Disconnect lead from Oil Sentry
™
switch.
2. Remove Oil Sentry
™
switch from breather cover.
Remove Oil Temperature Sensor
NOTE: Unless oil temperature sensor is damaged or
malfunctioning, disassembly from breather cover
is unnecessary.
1. Disconnect lead from oil temperature sensor.
2. Remove oil temperature sensor from breather cover.
Remove Inner Baffl
es and Breather Cover
NOTE: Removing oil temperature sensor is not required
to remove breather cover or inner baffl es.
1. Remove screws securing inner baffl es to crankcase.
2. Remove inner (valley) baffl es.
3. Disconnect and remove oil temperature sensor.
4. Remove remaining screws from breather cover.
5. Pry under protruding edge of breather cover with a
screwdriver to break gasket seal. Do not pry on
sealing surfaces as it could cause damage resulting
in leaks.
6. Remove breather cover and gasket.
Remove Crankshaft Position Sensor
1. Remove screws securing crankshaft position sensor
bracket.
2. Disconnect electrical connector from crankshaft
position sensor.
Remove Manifold Absolute Pressure (MAP) Sensor
or Temperature/Manifold Absolute Pressure (TMAP)
Sensor
1. With a screwdriver, slide locking tab on electrical
connector.
2. Detach connector.
3. Remove screw and pull MAP or TMAP sensor out of
intake manifold.
Remove Fuel Injectors
1. Disconnect electrical connector.
2. Remove screw and pull injector out of intake
manifold for each injector.
3. When removed, pull metal retaining clip connecting
fuel injector to fuel injector cap. There may be some
fuel left in line. Any spilled fuel must be cleaned up
immediately.
Disassembly/Inspection and Service
66
24 690 31 Rev. D
KohlerEngines.com
