DELPHI EFI 7. Reverse appropriate procedures to install new injector(s) and reassemble engine. Use new Orings and retaining clips any time an injector is removed (new replacement injectors include new Orings and retaining clips). Lubricate Orings lightly with clean engine oil. Use installation tool provided with Orings to install new upper Oring. Place tool into fuel injector inlet. Place one side of Oring into Oring groove and roll Oring over tool onto fuel injector. Torque screw securing fuel injector caps and blower KRXVLQJPRXQWLQJVFUHZVWR1BPLQOEDQG intake manifold and air cleaner mounting screws to 1BPLQOE$Q(&85HVHWZLOOQHHGWREH completed.
Injector problems due to dirt or clogging are generally unlikely due to design of injectors, high fuel pressure, and detergent additives in gasoline. Symptoms that could be caused by dirty/clogged injectors include rough idle, hesitation/stumbling during acceleration, or triggering of fault codes related to fuel delivery. Injector clogging is usually caused by a buildup of deposits RQGLUHFWRUSODWHUHVWULFWLQJARZRIIXHOUHVXOWLQJLQ a poor spray pattern. Some contributing factors to injector clogging include higher than normal operating temperatures, short operating intervals, and dirty, incorrect, or poor quality fuel.
Cleaning of clogged LQMHFWRUVLVQRWUHFRPPHQGHGWKH\VKRXOGEHUHSODFHG Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. b. Connect an ohmmeter set on Rx1 scale to primary terminals of coil. Primary resistance VKRXOGEHџ c. Connect an ohmmeter set on Rx10K scale between spark plug boot terminal and B+ primary terminal. Secondary resistance should be 6400 џ G ,IVHFRQGDU\UHVLVWDQFHLVQRWZLWKLQVSHFLїHG range, coil is faulty and needs to be replaced. FUEL COMPONENTS Fuel Pump Fuel pump module is not serviceable and must be replaced if determined to be faulty.
If a fuel pump problem is suspected, make certain pump is being activated, all electrical connections are properly secured, fuses are good, and a minimum of 7.0 volts is being supplied. If during cranking, voltage drops below 7.0 volts, a reduction of fuel pressure may occur resulting in a lean starting condition. If required, testing of fuel pump may be conducted. 1. Relieve fuel pressure at fuel pump module. Fuel pump module may need to be loosened or pulled away from engine. Disconnect fuel coupler from fuel pump module and insert pressure test jumper (from Kohler EFI Service Kit) between high pressure fuel line and fuel pump module. 2. Connect black hose of Pressure Tester.
Route clear hose into a portable gasoline container or equipment fuel tank. 3. Turn on key switch to activate pump and check system pressure on gauge. It may take several key cycles to compress air introduced into system and reach regulated pressure. If system pressure of 39 psi ± 3 is observed, wiring, fuel pump, and regulator are working properly. Turn key switch OFF and depress valve button on tester to relieve system pressure. a. If pressure is too high or too low, replace fuel pump module. 4. If pump did not activate (step 3), disconnect plug from fuel pump.
Connect a DC voltmeter across terminals in plug, turn on key switch and observe if a minimum of 7 volts is present during six second prime process. Ignition Coil If a coil is determined to be faulty, replacement is necessary. An ohmmeter may be used to test wiring and coil windings. NOTE: Do not ground primary coil with ignition ON as they may overheat or spark. NOTE: Always disconnect spark plug lead from spark plug before performing following tests. NOTE: If ignition coil(s) are disabled and an ignition fault is registered, system will automatically disable corresponding fuel injector drive signal.
Fault must be corrected to ignition coil and ECU power (switch) must be turned OFF for 10 seconds for injector signal to return. This is a safety measure to prevent bore washing and oil dilution. Testing Using an ohmmeter set on Rx1 scale, check resistance in circuits as follows: 1. To check cylinder coil 1 (starter side), disconnect Black connector from ECU and test between Black SLQVDQG7RFKHFNF\OLQGHUFRLORLOїOWHUVLGH disconnect Grey connector from ECU and test between Grey pins 10 and 17. Wiring and coil primary circuits are OK if readings are 0.50.8 W. ,IUHDGLQJVDUHQRWZLWKLQVSHFLїHGUDQJHFKHFN and clean connections and retest.
,IUHDGLQJVDUHVWLOOQRWZLWKLQVSHFLїHGUDQJHWHVW coils separately from main harness as follows: a. Remove screw retaining coil to housing and disconnect primary leads connector. 36 KohlerEngines.com 24 690 01 Rev. D WARNING ([SORVLYH)XHOFDQFDXVH¿UHVDQGVHYHUH 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.