Kohler — E.G.R. calibration
Adjustments · E.G.R. circuit
From a Kohler service manual covering: KD 702, KDW 1003, KDW 1404, KDW 702, KDW 702 - 1003 - 1404. Check it applies to your exact model before use.
Applies to: Kohler KDW 1003, Kohler KDW 1404, Kohler KDW 702, Kohler KDW 702 / KDW 1003 / KDW 1404 engine, Kohler KDW702 engine, Kohler KDW1003 engine, Kohler KDW1404 engine
Procedure
- Mount T-branch on vacuum valve - E.G.R. valve connection pipe and connect a 1 bar vacuum gauge.
- Adjust accelerator lever position so internal adjusting nut 2 is about 5 mm from the thread end.
- Accelerate to 3.600 rpm with valve closed; gauge must read 0.
- With brake at N=constant load engine down to 2.800 rpm.
- Find the E.G.R. valve closing point (vacuum = zero).
- Measure consumption; if less than 18.8 mm3/stroke adjust nut closer to rod 3.
- Tighten the adjusting nuts when 18.8 mm3/stroke (about 7 kW) is reached.
Tools required
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- Maximum suction pressure 720 mmHg
- Target 18.8 mm3/stroke (about 7 kW)
Full service-parts list: Kohler KDW 1003 →
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.