Disassembly/Inspection and Service
71
19 690 01 Rev. --
KohlerEngines.com
Clean all parts thoroughly as engine is disassembled.
Only clean parts can be accurately inspected
and gauged for wear or damage. There are many
commercially available cleaners that will quickly remove
grease, oil and grime from engine parts. When such a
cleaner is used, follow manufacturer’s instructions and
safety precautions carefully.
Make sure all traces of cleaner are removed before
engine is reassembled and placed into operation. Even
small amounts of these cleaners can quickly break down
lubricating properties of engine oil.
NOTE: This disassembly sequence removes some
components in subassemblies to enable
technician to perform internal engine servicing.
Do not disconnect every EFI and electronic
governor component.
Disconnect Spark Plug Leads
NOTE: Pull on boot only, to prevent damage to spark
plug lead.
1. Disconnect leads from spark plugs and unhook from
J-clips on valve covers.
2. Shut off fuel supply.
Drain Oil from Crankcase and Remove Oil Filter
1. Clean
oil
fi
lter and housing area.
2. Remove dipstick and 1 oil drain plug.
3. Allow ample time for oil to drain from crankcase.
4. Remove and discard oil
fi
lter.
Disconnect Fuel Lines
WARNING
Explosive Fuel can cause
fi
res and severe
burns.
Do not
fi
ll fuel tank while engine is hot or
running.
Gasoline is extremely
fl
ammable and its vapors can
explode if ignited. Store gasoline only in approved
containers, in well ventilated, unoccupied buildings,
away from sparks or
fl
ames. Spilled fuel could ignite
if it comes in contact with hot parts or sparks from
ignition. Never use gasoline as a cleaning agent.
NOTE: To prevent damage to hoses, use a hose
removal tool.
1. Wrap a shop towel completely around high pressure
fuel line connector and disconnect from Fuel Pump
Module (FPM).
Using a small screwdriver under hose connector,
press release button and slowly pull connector away
from FPM, allowing shop towel to absorb any
residual fuel in high pressure fuel line. Any spilled
fuel must be wiped up immediately.
2. Lift locking tab and squeeze to disconnect electrical
connector from FPM.
3. Disconnect pulse line and low pressure fuel line
(with fuel
fi
lter) from impulse pump.
4. Disconnect pulse line from FPM.
5. Remove and slide hoses through clamp mounted on
blower housing.
6. Remove clamp from blower housing.
Remove Fuse Cover (Optional)
Remove fasteners securing cover over fuses; remove
fuse cover.
Disconnect Wire Harness
1. Disconnect wire harness from all sensors, coils, and
injectors.
Use a small screwdriver to push red safety latch on
TMAP sensor to disconnect.
2. If equipped with an electronic governor, disconnect
harness from Governor Control Unit (GCU), and
Digital Linear Actuator (DLA).
Use a small screwdriver to unhook harness from
GCU.
3. Disconnect fuses from holders in bracket.
4. Remove diagnostic plug from fuse holder bracket.
5. Carefully pull wire harness through manifold
assembly and allow harness to hang below throttle
body.
Disconnect Breather Hose
Disconnect breather hose from elbow of large air intake
hose.
Remove Throttle Body Bracket
Remove three screws securing throttle body bracket to
crankcase.
