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, Debris Screen, and
Blower Housing
1. Disconnect plug from rectifi er-regulator.
2. Remove silver plated rectifi er-regulator ground strap
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. If debris screen overlaps blower housing, remove
fasteners and screen.
7. Remove remaining screws securing blower housing.
Remove blower housing.
8. Remove cooling fan.
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 to crankshaft
position sensor.
Remove Manifold Absolute Pressure (MAP) Sensor
1. With a screwdriver, slide locking tab on electrical
connector.
2. Detach connector.
3. Remove screw and pull MAP 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.
Remove Intake Manifold
1. Remove screw securing a ring terminal which is part
of wiring harness.
2. Remove screws securing intake manifold to cylinder
heads. Note which screws hold wiring clamp.
3. Unclasp wiring harness from clip using a
screwdriver.
4. Remove intake manifold and intake manifold
gaskets.
5. Leave high pressure fuel line and wiring harness
attached to manifold.
Disassembly/Inspection and Service
62 24 690 32 Rev. AKohlerEngines.com
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