Kohler — DEF Injector Replacement
Repair & overhaul · Exhaust aftertreatment system
From a Kohler service manual covering: KD1250-4, KD1750, KD2000, KD2500, KD3250, KD4000, KD700-KD4000, TP-7143. Check it applies to your exact model before use.
Applies to: Kohler KD1250-4, Kohler KD1750, Kohler KD2000, Kohler KD2500, Kohler KD3250, Kohler KD4000
Before you start
- Handling diesel exhaust fluid. Can cause skin, eye, respiratory irritation.
- Hot engine and exhaust system. Do not work until it cools.
Procedure
- Disable generator set and remove from service; wear anti-static gloves and goggles.
- Disconnect DEF supply line by disengaging connector clip; disconnect wiring harness.
- Unbolt and remove nuts and washers securing DEF injector and plate to SCR module.
- Remove DEF injector and plate.
- Disconnect DEF return line by pressing both buttons and pulling.
- Remove gasket from SCR surface; clean debris from plate, injector, and SCR surfaces.
- Install new injector: position gasket, mounting plate, align holes, apply anti-seize to studs, tighten nuts to 17 Nm (12.5 ft. lbs.).
- Connect supply and return lines; enter slope and offset data into KODIA; reset run time; run 30 minutes.
Tools required
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- Tighten nuts to 17 Nm (12.5 ft. lbs.)
- Enter injector slope and offset data into KODIA
Full service-parts list: Kohler KD1250-4 →, Kohler KD1750 →, Kohler KD2000 →, Kohler KD2500 →, Kohler KD3250 →, Kohler KD4000 →
Source: Kohler service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.