KOHLER KOHLER - AEGIS ELH775 30HP - COMMAND PRO EFI 23HP / 26HP DELPHI EFI SYSTEM TROUBLE CODES IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating instruction of equipment that this engine powers. Ensure engine is stopped and level before performing any maintenance or service. 24 690 01 Rev. D KohlerEngines.
Troubleshooting DELPHI EFI TROUBLESHOOTING GUIDE :KHQ WURXEOHV RFFXU EH VXUH WR FKHFN VLPSOH FDXVHV ZKLFK DW ¿UVW PD\ VHHP WRR REYLRXV WR EH FRQVLGHUHG )RU example, a starting problem could be caused by an empty fuel tank. 6RPH JHQHUDO FRPPRQ FDXVHV RI HQJLQH WURXEOHV DUH OLVWHG EHORZ DQG YDU\ E\ HQJLQH VSHFL¿FDWLRQ 8VH WKHVH WR locate causing factors. Engine Cranks But Will Not Start Ɣ %DWWHU\ FRQQHFWHG EDFNZDUGV Ɣ %ORZQ IXVH Ɣ &DUEXUHWRU VROHQRLG PDOIXQFWLRQ Ɣ &KRNH QRW FORVLQJ Ɣ &ORJJHG I
Troubleshooting Engine Loses Power Ɣ 'LUW\ DLU FOHDQHU HOHPHQW Ɣ (QJLQH RYHUKHDWHG Ɣ ([FHVVLYH HQJLQH ORDG Ɣ 5HVWULFWHG H[KDXVW Ɣ )DXOW\ VSDUN SOXJ V Ɣ +LJK FUDQNFDVH RLO OHYHO Ɣ ,QFRUUHFW JRYHUQRU VHWWLQJ Ɣ /RZ EDWWHU\ Ɣ /RZ FRPSUHVVLRQ Ɣ /RZ FUDQNFDVH RLO OHYHO Ɣ 4XDOLW\ RI IXHO GLUW ZDWHU VWDOH PL[WXUH Engine Uses Excessive Amount of Oil Ɣ /RRVH RU LPSURSHUO\ WRUTXHG IDVWHQHUV Ɣ %ORZQ KHDG JDVNHW RYHUKHDWHG Ɣ %UHDWKHU UHHG EURNHQ Ɣ &ORJJHG EURNHQ RU LQRSHUDWLYH FUDQNF
DELPHI EFI WARNING ([SORVLYH )XHO FDQ FDXVH ¿UHV DQG VHYHUH burns. 'R QRW ¿OO IXHO WDQN ZKLOH HQJLQH LV KRW RU running. *DVROLQH LV H[WUHPHO\ ÀDPPDEOH DQG LWV YDSRUV FDQ explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, DZD\ IURP VSDUNV RU ÀDPHV 6SLOOHG IXHO FRXOG LJQLWH LI LW comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent.
DELPHI EFI ECU compares input signals to programmed maps in its memory to determine appropriate fuel and spark requirements for immediate operating conditions. ECU then sends output signals to set injector duration and ignition timing. ECU continually performs a diagnostic check of itself, each of sensors, and system performance.
DELPHI EFI Tip of sensor, protruding into exhaust gas, is hollow. Outer portion of tip is surrounded by exhaust gas, with inner portion exposed to ambient air. When oxygen concentration on one side of tip is different than that of other side, a voltage signal up to 1.0 volt is generated and sent to ECU. Voltage signal tells ECU if engine is straying from ideal fuel mixture, and ECU then adjusts injector pulse accordingly. Oxygen sensor functions after being heated to a minimum of 400°C (752°F).
DELPHI EFI High pressure fuel line is serviced as a complete assembly to prevent tampering and safety hazards. Components are not individually serviceable. Vent hose assembly is intended to vent fuel vapor out of fuel pump module and direct fuel vapor into throttle body. All EFI engines are equipped with an engine mounted SXUJH SRUW RQ F\OLQGHU EDUUHO EDIÀH 7KLV FDSSHG purge port can be used by OEM to vent fuel tanks or used in conjunction with a carbon canister kit for Tier III evaporative emissions co
DELPHI EFI ELECTRICAL COMPONENTS Electronic Control Unit (ECU) Pinout of ECU Black Connector Pin # Function 1 Ignition Coil #1 Ground 2 Battery Ground 3 Diagnostic Communication Line 4 Speed Sensor input 5 Fuel Injector Output #1 Ground 6 Fuel Injector Output #2 Ground 7 Oxygen Sensor Heater 8 Intake Air Temperature (IAT) sensor input 9 Fuel Pump Ground 10 Ground for IAT, TPS, MAP, O2 and Oil Sensors 11 Manifold Absolute Pressure (MAP) sensor input 12 Throttle Position Sensor (TPS) input 13 Speed Sensor Gro
DELPHI EFI Never attempt to disassemble ECU. It is sealed to prevent damage to internal components. Warranty is void if case is opened or tampered with in any way. All operating and control functions within ECU are preset. No internal servicing or readjustment may be performed. If a problem is encountered, and you determine ECU to be faulty, contact your source of supply. ECU pins are coated at factory with a thin layer of electrical grease to prevent fretting and corrosion.
24 690 01 Rev. D KohlerEngines.
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DELPHI EFI Electrical System Crankshaft Position Sensor Electrical System A sealed, nonserviceable assembly. If Fault Code diagnosis indicates a problem within this area, test and correct as follows. 1. Check mounting and air gap of sensor. It must be 0.200.70 mm (0.0080.027 in.). 2. Inspect wiring and connections for damage or problems. 3. Make sure engine has resistor type spark plugs. 4. Disconnect Black connector from ECU. 5.
DELPHI EFI 6. Check circuits (input, ground), from wire harness connector to sensor plug for continuity, damage, etc. Connect one ohmmeter lead to Black pin 14 in wire harness connector (as in step 4). Connect other lead to terminal #1 in sensor plug. Continuity should be indicated. Repeat test between Black pin 10 and terminal #2 in sensor plug. Intake Air Temperature Sensor A nonserviceable component. Complete replacement is required if it is faulty. Sensor and wiring harness can be checked as follows. 1.
DELPHI EFI Sensor Signal Observation NOTE: Do not cut into or pierce sensor or engine wiring to make this connection. Sensor produces a very small signal. Corrosion or damage to wiring could lead to an incorrect signal because of repairs or contamination to sensor. 1. Using a voltmeter or diagnostic software observe voltage before engine is started. With key ON, voltage should read about 1.0 volt. This voltage is generated by ECU.
DELPHI EFI TroublshootingOxygen Sensor (O2) Condition Low voltage output. Possible Cause Shorted sensor or sensor circuit. Shorted lead wire. Wiring shorted to ground. Contamination of air reference. Air leak at sensor or gasket, sensor upper shield damage. High voltage output. Silica poisoning. Contaminated gasoline. (QJLQH SUREOHP PLV¿UH Excessive rich air/fuel ratio. Conclusion Replace sensor or repair wiring. Remove source of external contamination, protect air reference area.
DELPHI EFI Fuel Injectors WARNING ([SORVLYH )XHO FDQ FDXVH ¿UHV DQG VHYHUH 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 the shop towel to absorb any residual fuel in high pressure fuel line. Any spilled fuel must be completely wiped up immediately.
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.
DELPHI EFI 5. If no voltage is observed, connect red lead of meter to red wire of plug and black lead to a good ground while key is still ON. 6. If voltage is between 7 and 14, turn key switch OFF and connect an ohmmeter between terminals on pump to check for continuity. a. If there was no continuity between pump terminals, replace fuel pump. b. If voltage was below 7, test wiring harness. 7.
DELPHI EFI Troubleshooting Guide Condition Possible Cause Faulty spark plugs. Fuel pump not running. Fuel pressure low. ,QVXI¿FLHQW IXHO GHOLYHU\ Engine Starts Hard TPS set incorrect (ECU Reset and TPS Initialization). or Fails to Start When Hot. Crankshaft position sensor loose or faulty. TPS faulty. Engine temp sensor faulty. Faulty injectors. Faulty spark plugs. ,QVXI¿FLHQW IXHO GHOLYHU\ Engine Stalls or Idles Roughly (cold or warm). TPS set incorrect. TPS faulty. Faulty engine temperature sensor.
DELPHI EFI Function Test Fault Codes Example of Diagnostic Display WARNING High Pressure Fluids can puncture skin and cause severe injury or death. Do not work on fuel system without proper training or safety equipment. Fluid puncture injuries are highly toxic and hazardous. If an injury occurs, seek immediate medical attention. )XQFWLRQ RI IXHO V\VWHP LV WR SURYLGH VXI¿FLHQW GHOLYHU\ of fuel at system operating pressure of 39 psi ± 3.
DELPHI EFI 0230 Fuel Pump Module Circuit Low Voltage or Open 0232 Fuel Pump Module Circuit High Voltage 0336 Crankshaft Position Sensor Noisy Signal 0337 Crankshaft Position Sensor No Signal 0351 Cylinder 1 Ignition Coil Malfunction 0352 Cylinder 2 Ignition Coil Malfunction 0562 System Voltage Low 0563 System Voltage High 61 End of Code Transmission ECU continuously monitors engine operation against Diagnostic Code Summary preset performance limits.
DELPHI EFI Code 0108 Component: Manifold Absolute Pressure Sensor Fault: MAP Circuit High Voltage Condition: Intake manifold leak, shorted connection or faulty sensor. Conclusion: MAP Sensor Related Ɣ 6HQVRU PDOIXQFWLRQ Ɣ 9DFXXP OHDNV IURP ORRVH PDQLIROG RU sensor. Code 0118 Component: Coolant/Oil Sensor Fault: Coolant/Oil Temperature Sensor Circuit High Voltage or Open Condition: Shorted connection, faulty sensor, open connection or broken wire.
DELPHI EFI Code 0123 Component: Fault: Condition: Conclusion: Throttle Position Sensor (TPS) TPS Circuit High Voltage Shorted connection or faulty sensor. TPS Sensor Related Ɣ 6HQVRU FRQQHFWRU RU ZLULQJ Ɣ 6HQVRU RXWSXW DIIHFWHG RU GLVUXSWHG E\ dirt, grease, oil, wear. Ɣ 6HQVRU ORRVH RQ WKURWWOH ERG\ PDQLIROG Throttle Body Related Ɣ 7KURWWOH VKDIW RU EHDULQJV ZRUQ damaged. Engine Wiring Harness Related Ɣ (&8 SLQV %ODFN DQG damaged (wiring, connectors).
DELPHI EFI Code 0172 Component: Fuel System Fault: Minimum adaptation limit exceeded Condition: Too high pressure at high pressure fuel line, TPS malfunction, shorted connection, faulty sensor or fuel pump module failure. Conclusion: Oxygen Sensor Related Ɣ 6HQVRU FRQQHFWRU RU ZLULQJ Ɣ 6HQVRU FRQWDPLQDWHG RU GDPDJHG Ɣ 3RRU JURXQG SDWK Ɣ 3LQ FLUFXLW ZLULQJ RU FRQQHFWRUV ECU Black pin 10 or 17.
DELPHI EFI Code 0202 Component: Fuel Injector Fault: Injector 2 Circuit Malfunction Condition: Injector damaged or faulty, shorted or open connection. Conclusion: Injector Related Ɣ ,QMHFWRU FRLO VKRUWHG RU RSHQHG Engine Wiring Harness Related Ɣ %URNHQ RU VKRUWHG ZLUH LQ KDUQHVV ECU pin Black 6.
DELPHI EFI Code 0351 Component: Ignition Coil Fault: Cylinder 1 Ignition Coil Malfunction Condition: Broken wire in harness (may not be visible), shorted connection or faulty sensor.
DELPHI EFI Diagnostic Aid #6 IGNITION SYSTEM (no spark) Condition Ɣ 6SDUN SOXJ Ɣ 3OXJ ZLUH Ɣ &RLO Ɣ &RLO FLUFXLW V SLQ FLUFXLWV *UH\ DQG %ODFN Ɣ (&8 JURXQGV Ɣ (&8 Ɣ 9HKLFOH VDIHW\ LQWHUORFNV JURXQG VLJQDO RQ VDIHW\ ZLUH Diagnostic Aid #7 FUEL SYSTEM ELECTRICAL (no fuel delivery) Condition Ɣ 1R IXHO Ɣ $LU LQ KLJK SUHVVXUH IXHO OLQH Ɣ )XHO YDOYH VKXW 2)) Ɣ )XHO ¿OWHU OLQH SOXJJHG Ɣ ,QMHFWRU FLUFXLW V SLQ FLUFXLWV %ODFN DQG %ODFN Ɣ ,QMHFWRU Ɣ (&8 JURXQGV Ɣ (&8 Ɣ /LIW SXPS QRW ZR
DELPHI EFI EFI Diagnostic Flow Diagram START OF TEST PROCEED TO START OF TEST FOR RETEST KEY ON MALFUNCTION INDICATOR LIGHT ON NO REFER TO DIAGNOSTIC AID #1 SYSTEM POWER ARE FAULT CODES PRESENT? YES REFER TO DIAGNOSTIC FAULT CODE SUMMARY CLEAR CODES NO DOES ENGINE START? NO YES NO MIL GOES OFF? REFER TO DIAGNOSTIC AID #3 RUN/ON YES CRANK ENGINE.
