kohler cv740 manual
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kohler cv740 manualWith extended maintenance intervals and fuel-efficient operation, KOHLER Command PRO engines work as hard as you do. Height is top of air cleaner cover to mounting feet. Actual engine power and torque are lower and affected by accessories (air cleaner, exhaust, charging, cooling, fuel pump, etc.), application, engine speed, ambient operating conditions (temperature, humidity and altitude) and other factors. For more information, contact Kohler Co. Engine Engineering Department. Kohler Co. reserves the right to change product specifications, designs and standard equipment without notice and without incurring obligation. These are printed on a silver decal, which is normally affixed to the blower housing of the engine. Make a note of your engine identification numbers in your owner's manual for handy reference. Use model number to locate manuals for your engine. We have 6 Kohler Command CV740 manuals available for free PDF download: Service Manual, Owner's Manual Vertical Crankshaft. Check oil level to assure crankcase oil level is at the “FULL” mark on the dipstick. Because of equipment design or application, there may be more stringent restrictions regarding the angle of operation. Engine damage could result from insufficient lubrication. Warranty repairs must be performed by an authorized Kohler service outlet. Before working on the engine or equipment, disable the engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (-) battery cable from battery. They should also be included as part of any seasonal tune-up. Operating the engine with blocked or dirty air intake and cooling areas can cause extensive damage due to overheating.To prevent severe burns, do not touch these areas while the engine is running, or immediately after it is turned off. Never operate the engine with heat shields or guards removed. Overspeed is hazardous and will void the engine warranty. The maximum allowable high idle speed for these engines is 3750 RPM, no load.
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Not necessary on Delco starters. Have a Kohler Engine Service Dealer perform these services. Page 3 Section 1 Safety and General Information 1 Section 1 Safety and General Information Safety Precautions To ensure safe operation please read the following statements and understand their meaning. Also refer to your equipment manufacturer's manual for other important safety information. This manual contains safety precautions which are explained below. Please read carefully. Page 4 Section 1 Safety and General Information WARNING WARNING Explosive Fuel can cause fires and severe burns. Carbon Monoxide can cause severe nausea, fainting or death. Do not fill the fuel tank while the engine is hot or running. Avoid inhaling exhaust fumes, and never run the engine in a closed building or confined area. Explosive Fuel! Gasoline is extremely flammable and its vapors can explode if ignited. Page 5 Section 1 Safety and General Information Engine Identification Numbers When ordering parts, or in any communication involving an engine, always give the Model, Specification and Serial Numbers, including letter suffixes if there are any. 1 Identification Decal The engine identification numbers appear on a decal, or decals, affixed to the engine shrouding. See Figure 1-1. An explanation of these numbers is shown in Figure 1-2. Figure 1-1. Engine Identification Decal Location. A. Model No. Page 6 Section 1 Safety and General Information Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important. So is checking oil daily and changing oil regularly. Failure to use the correct oil, or using dirty oil, causes premature engine wear and failure. Oil Type Use high-quality detergent oil of API (American Petroleum Institute) Service Class SG, SH, SJ or higher. Select the viscosity based on the air temperature at the time of operation as shown in the following table. Page 7 Section 1 Safety and General Information Periodic Maintenance Instructions 1 WARNING: Accidental Starts. Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, disable the engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (-) battery cable from battery. Maintenance Schedule These required maintenance procedures should be performed at the frequency stated in the table. Page 8 Section 1 Safety and General Information Dimensions in millimeters. Page 16 Section 1 Safety and General Information Piston, Piston Rings, and Piston Pin cont. By using tools designed for the job, you can properly service engines easier, faster, and safer. In addition, you’ll increase your service capabilities and customer satisfaction by decreasing engine downtime. Here is the list of tools and their source. Separate Tool Suppliers: Kohler Tools Contact your source of supply. SE Tools 415 Howard St. Flyw heel St r ap Wr ench To hold flywheel during removal. S E Tools KLR-82409 Hydr aulic Valve Lift er Tool To remove and install hydraulic lifters. Kohler 25 761 38-S Ignit ion Syst em Test er For testing output on all systems, except CD. For testing output on capacitive discharge (CD) ignition system. Page 24 Section 3 Troubleshooting Section 3 Troubleshooting Troubleshooting Guide When troubles occur, be sure to check the simple causes which, at first, may seem too obvious to be considered. For example, a starting problem could be caused by an empty fuel tank. Some general common causes of engine troubles are listed below. Use these to locate the causing factors. Refer to the specific section(s) within this service manual for more detailed information. Drain the oil into a container - the oil should flow freely. Check for metal chips and other foreign particles. Sludge is a natural by-product of combustion; a small accumulation is normal.http://www.statcardsports.com/node/9536 Excessive sludge formation could indicate overrich carburetion, weak ignition, overextended oil change intervals or wrong weight or type of oil was used, to name a few. NOTE: It is good practice to drain oil at a location away from the workbench. Loose or improperly torqued fasteners. 2. Replace all worn or damaged seals and gaskets. Make sure all fasteners are tightened securely. Use appropriate torque values and sequences when necessary. 3. Page 28 Section 3 Troubleshooting Leakdown Test Results Air escaping from crankcase breather. Rings or cylinder worn. Air escaping from exhaust system. Air escaping from carburetor. Gauge reading in “low” (green) zone. Page 29 Section 4 Air Cleaner and Air Intake System Section 4 Air Cleaner and Air Intake System Air Cleaners General These engines are equipped with a replaceable, highdensity paper air cleaner element. Most are also equipped with an oiled-foam precleaner which surrounds the paper element. Three different types are used. The “standard” type air cleaner is shown in Figure 4-1. The “commercial mower” type is shown in Figure 4-2, and the “heavyduty” air cleaner is shown in Figure 4-9. Page 30 Section 4 Air Cleaner and Air Intake System Precleaner Paper Element Service (Standard and Commercial Mower Types) Every 100 hours of operation (more often under extremely dusty or dirty conditions), replace the paper element. See Figures 4-5 or 4-6, and follow these steps: 1. Unhook the latches or loosen the cover retaining knob and remove the cover. 2. Remove the wing nut, element cover, and air cleaner element. Element Figure 4-3. Precleaner on Standard Air Cleaner. Make sure the rubber sleeve seal is in place on the stud to prevent dust or dirt entry through the stud hole. 4. Remove the base and gasket. Carefully feed the breather hose through the base. 5. Reverse procedure to reassemble components. The air cleaner housing contains a paper element and inner element, designed for longer service intervals.http://addi800.com/images/contraindications-manual-lumbar-traction.pdf Page 35 Section 5 Fuel System and Governor Section 5 Fuel System and Governor Description The Command vertical twins use two different types of fuel systems; carbureted, or electronic fuel injection (EFI). This section covers the standard carbureted fuel systems. The EFI fuel systems are covered in subsection 5B. The governor systems used are covered at the end of this section. WARNING: Explosive Fuel. Gasoline is extremely flammable and its vapors can explode if ignited. Page 36 Section 5 Fuel System and Governor Fuel Filter Most engines are equipped with an in-line filter. Periodically inspect the filter and replace with a genuine Kohler filter every 200 operating hours. Fuel Line In compliance with CARB Tier III Emission Regulations, carbureted engines with a “Family” identification number beginning with “6” or greater (See Figure 5-1), must use Low Permeation SAE 30 R7 rated fuel line; certified to meet CARB requirements. Standard fuel line may not be used. Page 37 Section 5 Fuel System and Governor Fuel System Tests When the engine starts hard, or turns over but will not start, it is possible that the problem is in the fuel system. To find out if the fuel system is causing the problem, perform the following tests. General These engines are equipped with a pulse type fuel pump. The pumping action is created by the oscillation of positive and negative pressures within the crankcase. This pressure is transmitted to the pulse pump through a rubber hose connected between the pump and crankcase. Page 39 Section 5 Fuel System and Governor Slow Circuit: (See Figure 5-3) At low speeds the engine operates only on the slow circuit. As a metered amount of air is drawn through the slow air bleed jet, fuel is drawn through the main jet and further metered through the slow jet. Air and fuel are mixed in the body of the slow jet and exit to the transfer port. From the transfer port this air fuel mixture is delivered to the idle progression chamber. As a metered amount of air is drawn through the main air bleed jet, fuel is drawn through the main jet. The air and fuel are mixed in the main nozzle and then enter the main body of airflow, where further mixing of the fuel and air takes place. This mixture is then delivered to the combustion chamber. The carburetor has a fixed main circuit; no adjustment is possible. Adjust the low or stalls at idle speed.Clogged air cleaner. Clean or replace. black, sooty exhaust smoke, b. Choke partially closed during operation. Page 42 Section 5 Fuel System and Governor High Altitude Operation When operating the engine at altitudes of 1500 m (5000 ft.) and above, the fuel mixture tends to get overrich. This can cause conditions such as black, sooty exhaust smoke, misfiring, loss of speed and power, poor fuel economy, and poor or slow governor response. To compensate for the effects of high altitude, special high altitude jet kits are available. The kits include a new main jet, slow jet (where applicable), necessary gaskets and O-Rings. Page 43 Section 5 Fuel System and Governor NOTE: The tip of the idle fuel adjusting needle is tapered to critical dimensions. Damage to the needle and the seat in the carburetor body will result if the needle is forced. Low Idle Fuel Adjustment (Some Models) 5. Low Idle Fuel Needle Setting: Place the throttle into the “idle” or “slow” position. Remove the fuel bowl retaining screw or fuel shut-off solenoid and drain the fuel into a safe container. Remove the bowl from the carburetor body. Governed Idle Spring Tab 16.5 mm (0.65 in.) Figure 5-7. Governed Idle Spring Location. Hold Throttle Lever Against Screw Figure 5-8. Holding Throttle Lever Against Idle Stop Screw (One-Barrel Carburetor). Page 45 Section 5 Fuel System and Governor Disassembly Use the carburetor repair kit (and the float repair kit if float components are to be replaced). Refer to Figure 5-10 for parts identification. The Kohler part number and the Nikki lot number are stamped on the choke side flange on top of the carburetor body. Refer to the parts manual for the carburetor involved to ensure the correct repair kits and replacement parts are used. Disassemble carburetor as follows after removal from the engine. Repair kits are available which include new gaskets and other components. Page 48 Section 5 Fuel System and Governor 8. When the proper float height is obtained, carefully reinstall the fuel bowl, with the O-Ring(s) in place, onto the carburetor. Secure with the four original screws. See Figure 5-16. Figure 5-14. Installing Float Assembly. 6. Hold the carburetor body so the float assembly hangs vertically and rests lightly against the fuel inlet needle. Page 49 Section 5 Fuel System and Governor 2. Remove the float pin screw and lift out the old float, pin, and inlet needle. See Figure 5-18. Discard all of the parts. The seat for the inlet needle is not serviceable, and should not be removed. Figure 5-18. Removing Float and Inlet Needle. 3. Remove and discard the round plug from the bottom of the slow jet tower of the carburetor body. Use an appropriate size flat screwdriver, and carefully remove the slow and main jets from the carburetor. Page 50 Section 5 Fuel System and Governor 11. Install the float and inlet needle down into the seat and carburetor body. Insert the new pivot pin through the float hinge and secure with the new retaining screw. See Figure 5-24. Figure 5-21. Installing Slow Jet. Figure 5-24. Installing Float Assembly. 12. Hold the carburetor body so the float assembly hangs vertically and rests lightly against the fuel inlet needle. Page 51 Section 5 Fuel System and Governor 14. When the proper float height is obtained, carefully install the new O-Rings for the fuel bowl and the accelerator pump transfer passage (if so equipped). See Figure 5-26. Figure 5-28. Installing Idle Fuel Adjusting Screw and Spring. Figure 5-26. Installing Fuel Bowl O-Rings. 15. Install the fuel bowl onto the carburetor. Remove the cover, spring, and diaphragm. See Figure 5-30. Figure 5-32. Check Valve and Retaining Ring Installed. Figure 5-30. Accelerator Pump Cover and Diaphragm Removed. 3. Remove the retaining ring over the rubber check valve, using a snap ring pliers. Remove the check valve from the fuel delivery chamber. See Figure 5-31. Figure 5-31. Removing Retaining Ring. 4. Page 53 Section 5 Fuel System and Governor 5. Use a screw extractor (easy out) and remove the original choke shaft bushing with the old choke lever from the carburetor housing. Save the bushing to use as a driver for installing the new bushing. Discard the old lever. 6. Clean the I.D. of both choke shaft bores as required. Figure 5-34. Installing Accelerator Pump Housing Screws and Hose. 7. Insert the new bushing through the new choke lever from the outside, and start the bushing in the outer shaft bore. Page 54 Section 5 Fuel System and Governor 9. Install the new return spring onto the new choke shaft, so the upper leg of the spring is between the two formed “stops” on the end of the choke shaft. See Figure 5-38. Note: Make sure it stays in this location during the following step. Figure 5-38. Choke Shaft and Spring Details. 10. Slide the choke shaft and spring, into the carburetor. Page 55 Section 5 Fuel System and Governor Adjustment NOTE: Carburetor adjustments should be made only after the engine has warmed up. The carburetor is designed to deliver the correct fuelto-air mixture to the engine under all operating conditions. The idle fuel adjusting needle is also set at the factory and normally does not need adjustment. Depending on model and application, engines may also be equipped with a “Governed Idle System. Page 56 Section 5 Fuel System and Governor Adjust to Midpoint Lean Adjust to Midpoint Lean Governed Idle Spring Tab Rich Rich Left Side Right Side Figure 5-40. Optimum Low Idle Fuel Settings. Figure 5-41. Governed Idle Spring Location. Models with Governed Idle System An optional governed idle control system is supplied on some engines. The purpose of this system is to maintain a desired idle speed regardless of ambient conditions (temperature, parasitic load, etc.) that may change. Page 57 Section 5 Fuel System and Governor Fuel Bowl Bowl Drain Screw Figure 5-43. Fuel Bowl Removed From Carburetor. 3. Remove the float pin screw and lift out the old float, pin and inlet needle. See Figure 5-44. Discard all of the parts. Figure 5-45. Float and Inlet Needle Details. 6. Install the float and inlet needle down into the seat and carburetor body. Page 58 Section 5 Fuel System and Governor Fuel Bowl Bowl Drain Screw Figure 5-47. Checking Float Height. NOTE: Be sure to measure from the casting surface, not the rubber gasket, if still attached. 9. When the proper float height is obtained, carefully reinstall the fuel bowl, using new O-Rings onto the carburetor. Main Jets and Nozzles Removed. 4. Remove the screw securing the flat washer and ground lead (if equipped), from the top of the carburetor; then carefully pull (lift) out the two slow jets. Note the small O-Ring on the bottom of each jet. See Figure 5-52 and 5-53. Installing Main Nozzles and Main Jets. 9. Make sure the O-Ring near the bottom of each slow jet is new, or in good condition. Align and insert the two slow jets into the top of carburetor. See Figure 5-53. Figure 5-56. Float and Inlet Needle Details. 13. Install the float and inlet needle down into the seat and carburetor body. Page 61 Section 5 Fuel System and Governor 4. Note the position of the spring legs and the choke plate for correct reassembly later. See Figure 5-60. Remove the two screws attaching the choke plate to the choke shaft. Pull the shaft out of the carburetor body and discard the removed parts. Figure 5-58. Checking Float Height. NOTE: Be sure to measure from the casting surface, not the rubber gasket, if still attached. 16. Page 62 Section 5 Fuel System and Governor 8. Turn the old bushing upside down and use it as a driver to carefully press or tap the new bushing into the carburetor body until it bottoms. Check that the choke lever pivots freely without restriction or binding. Position and install the new choke plate to the flat side of the choke shaft. Start the two screws. It is designed to hold the engine speed constant under changing load conditions. The governor works as follows: General The governed speed setting is determined by the position of the throttle control. Page 65 Section 5 Fuel System and Governor Sensitivity Adjustment Governor sensitivity is adjusted by repositioning the governor spring in the holes of the governor lever. If speed surging occurs with a change in engine load, the governor is set too sensitive. If a big drop in speed occurs when normal load is applied, the governor should be set for greater sensitivity. See Figure 5-66 and adjust as follows: 1. To increase the sensitivity, move the spring closer to the governor lever pivot point. 2. Page 66 Section 5 Fuel System and Governor Choke Lever Choke Lever Detail Screw Spring Washer Spacer Washer Lock Nut Bushing Fastener Choke Lever (See Detail at Left) Screw and Nut Choke Cable Control Bracket Linkage Control Lever Fastener Lock Nut Throttle Cable Clamp Blower Housing Washer Spring Fuel Pump Clamp Clip Bushing Fuel Line Spring Linkage Bushing Throttle Shaft Bracket Lever Spring Washer Locker Nut Spacer Throttle Lever Deflector (If So Equipped) (Place Between Valley Baffle and Thro Page 67 Section 5 Fuel System and Governor Screw Washer Lock Nut Spring Washer Spacer Bushing Choke Linkage Hex Nut Screw Choke Cable Throttle Control Lever Clamp and Screw 5 Lock Nut Control Bracket Screw Washer Spring Throttle Cable Throttle Linkage Fuel Pump Bushing Linkage Spring Clamp Fuel Throttle Shaft Bushing Throttle Shaft Bracket Governor Lever Governor Spring Washer Spacer Lock Nut Throttle Lever Deflector (If So Equipped) Figure 5-69. The fuel pump will run for about three seconds and stop. Turn the switch off and back on to restart the fuel pump. Repeat this procedure until the fuel pump has cycled five times, then start the engine. Explosive Fuel can cause fires and severe burns. Fuel system ALWAYS remains under HIGH PRESSURE. In “open loop” operation the oxygen sensor output is not used, and the controlling adjustments are based on the primary sensor signals and programmed maps only. The system operates “open loop” whenever the three conditions for closed loop operation (above) are not being met. Page 72 Section 5B EFI Fuel System Two different ECU styles have been used in CV EFI production. Each has a plastic case, but they differ in having a 24 pin or 32 pin connector block, and are identified as MSE 1.0 or MSE 1.1 respectively. See Figures 5B-1 and 5B-2. Basic function and operating control remains the same between the two, however due to differences in the internal circuitry as well as the wiring harness, the ECU’s are not interchangeable. Page 73 Section 5B EFI Fuel System General The engine speed sensor is essential to engine operation; constantly monitoring the rotational speed (RPM) of the crankshaft. A ferromagnetic 60-tooth ring gear with two consecutive teeth missing is mounted on the flywheel. During rotation, an AC voltage pulse is created within the sensor for each passing tooth. Page 74 Section 5B EFI Fuel System General The throttle position sensor (TPS) is used to indicate throttle plate angle to the ECU. See Figure 5B-7. a. Repair or replace as required. b. Turn the idle speed screw back in to its original setting. c. Page 76 Section 5B EFI Fuel System 11. Reconnect the battery cable and all external loads. Remove the rubber band from the throttle lever. Readjust the idle speed to the equipment manufacturer’s specified setting and recheck the high-speed, no-load RPM setting. Observe the overall performance. TPS Initialization Procedure For “32 Pin” (MSE 1.1) Plastic-Cased ECU Only (“Auto-Learn” Initialization) 1. Page 77 Section 5B EFI Fuel System General The engine (oil) temperature sensor (Figure 5B-8) is used by the system to help determine fuel requirements for starting (a cold engine needs more fuel than one at or near operating temperature). Mounted in the oil filter adapter housing, it has a temperature-sensitive resistor that extends into the oil flow. The resistance changes with oil temperature, altering the voltage sent to the ECU. A cold oxygen sensor will require approximately 1-2 minutes at moderate engine load to warm sufficiently to generate a voltage signal. Proper grounding is also critical. The oxygen sensor grounds through the metal shell, so a good, solid, unbroken ground path back through the exhaust system components, engine, and wiring harness is required. Page 79 Section 5B EFI Fuel System ?, the b. If the resistance is less than 1.0 M? sensor is bad, replace it. 5. With the oxygen sensor disconnected and engine not running, disconnect the main harness connector from the ECU and set the meter to the Rx1 scale. Page 80 Section 5B EFI Fuel System 2. Connect the black lead of VOA meter to a chassis ground location. Set meter to test resistance (Rx1). Turn ignition switch from “off” to “on.” Meter should indicate continuity (ground circuit is completed) for 1 to 3 seconds. Turn key switch back off. a. Clean the connection and check wiring if circuit was not completed. Page 81 Section 5B EFI Fuel System 1 2 3 5 4 6 7 Figure 5B-15. Style 2 Fuel Injector. Replaceable O-Rings on both ends of the injector prevent external fuel leakage and also insulate it from heat and vibration. A special clip connects each injector to the fuel rail and holds it in place. The O-Rings should be replaced anytime the injector is removed. Page 82 Section 5B EFI Fuel System Listen Here Figure 5B-17. Checking Injectors. 3. Disconnect the electrical connector from an injector and listen for a change in idle performance (only running on one cylinder) or a change in injector noise or vibration. Check as follows: NOTE: Do not apply voltage to the fuel injector(s). Excessive voltage will burn out the injector(s). Page 83 Section 5B EFI Fuel System 10. Discard the old gaskets. Check For Leaks Figure 5B-19. Injector Inspection Points. 1. Engine must be cool. Depressurize fuel system through test valve in fuel rail. 2. Disconnect spark plug leads from spark plugs. 3. Page 84 Section 5B EFI Fuel System Ignition System General A high-voltage, solid-state, battery ignition system is used with the EFI system. The ECU controls the ignition output and timing through transistorized control of the primary current delivered to the coils. Based on input from the speed sensor, the ECU determines the correct firing point for the speed at which the engine is running. At the proper instant, it releases the flow of primary current to the coil. Page 85 Section 5B EFI Fuel System EFI engines are equipped with Champion RC12YC (Kohler Part No. 12 132 02-S) resistor spark plugs. Equivalent alternate brand plugs can also be used, but must be resistor plugs or permanent damage to the ECU will occur, in addition to affecting operation. Proper spark plug gap is 0.76 mm (0.030 in.). The condition of the wiring, connectors, and terminal connections is essential to system function and performance. Page 86 Section 5B EFI Fuel System pump preventing the continued delivery of fuel. In this situation, the MIL will go on, but it will go back off after 4 cranking revolutions if system function is OK. Once the engine is running, the fuel pump remains on. Service The fuel pumps are non-serviceable and must be replaced if determined to be faulty. The pressure regulating spring presses against the valve holder (part of the diaphragm), pressing the valve against the valve seat. Page 88 Section 5B EFI Fuel System 6. Install the new regulator by carefully pushing and rotating it slightly into the base or housing. Fuel Rail a. External Regulators with Square Base Housing Only; Install a new O-Ring between the regulator and the mounting bracket. Set the mounting bracket into position. Fuel Rail b. Secure the regulator in the base with the original retaining ring or screws. Be careful not to dent or damage the body of the regulator as operating performance can be affected. 7. Page 89 Section 5B EFI Fuel System General Special low permeation high-pressure fuel line with an SAE 30 R9 rating is required for safe and reliable operation, due to the higher operating pressure of the EFI system. If hose replacement is necessary, order Fuel Line Service Kit Part No. 25 111 37-S (containing 60” of high-pressure hose and 10 Oetiker clamps), or use only the type of hose specified. Special Oetiker clamps (Kohler Part No. Page 90 Section 5B EFI Fuel System Idle Speed Screw Throttle Linkage Linkage Bushing Damper Spring Figure 5B-34. Figure 5B-33. Idle Speed Screw Details. Initial Governor Adjustment 2. Check if the engine has a high-speed throttle stop screw installed in the manifold casting boss. See Figure 5B-35. 5B The initial governor adjustment is especially critical on EFI engines because of the accuracy and sensitivity of the electronic control system. Page 91 Section 5B EFI Fuel System B. Setting the Initial Adjustment 1. Check the split where the clamping screw goes through the governor lever. If the tips are touching and there is no gap present, the lever should be replaced. If not already installed, position the governor lever on the cross shaft, but leave the clamping screw loose. Figure 5B-36. Inserting Feeler Gauge (Engines Without Stop Screw). b. Page 92 Section 5B EFI Fuel System 4. Verify that the governor has been set correctly. With the linkage still retained in the “Full Throttle” position (Step 2), unsnap the bushing clip, separate the linkage from the bushing, and remove the bushing from the lever. Reinstall the bushing and reattach the throttle linkage. See Figure 5B-34. Page 93 Section 5B EFI Fuel System Electrical System The EFI system is a 12 VDC negative ground system, designed to operate down to a minimum of 7.0 volts. If system voltage drops below this level, the operation of voltage sensitive components such as the ECU, fuel pump, and injectors will be intermittent or disrupted, causing erratic operation or hard starting. A fully charged, 12 volt battery with a minimum of 350 cold cranking amps is important in maintaining steady and reliable system operation. Page 94 Page 95 Page 96 Section 5B EFI Fuel System “32 Pin” (MSE 1. Page 97 Section 5B EFI Fuel System Fuel System WARNING: Fuel System Under Pressure. The fuel system operates under high pressure. System pressure must be relieved through the test valve in the fuel rail prior to servicing or removal of any fuel system components. Do not smoke or work near heaters or other fire hazards. Have a fire extinguisher handy and work only in a well-ventilated area. Page 99 Section 5B EFI Fuel System Diagnostic Code Summary cont. Expected Engine Response: Possible misfire as ECU attempts to resynchronize during which time fuel and spark calculations are not made. Possible Causes: 1. Engine Speed Sensor Related a. Sensor connector or wiring. b. Sensor loose or incorrect air gap. c. Flywheel key sheared. 2. Speed Sensor Ring Gear Related a. Damaged teeth. b. Page 101 Section 5B EFI Fuel System If the engine is still running rich (laboring, short on power) or lean popping or misfiring), the fuel mixture is suspect, probably incorrect TPS initialization or low fuel pressure. Code: Source: Explanation: 23 ECU ECU is unable to recognize or process signals from its memory. Expected Engine Response: Engine will not run.