Repairing Oil Pan Gasket On Kohler Courage 19 Engine

The Kohler Courage 19 hp, SV590 single-cylinder engine is known for its valve cover oil leaks. The two-piece valve cover design, with an inner piece that can separate from the outer shell, may contribute to this issue. Some users have reported success in repairing the leak by tightening the top cover flange bolts, adjusting the valve clearance, and using a sealant like Right Stuff or RTV with the cork gasket. Others have suggested replacing the gasket and sealant entirely, or using a high mileage oil to help swell the gasket. It is important to follow the manufacturer's recommendations for oil type and torque specifications during reassembly to ensure a proper repair.

Check for a warped block or oil pan

To check for a warped block or oil pan on your Kohler Courage 19, you'll need to remove the oil pan and then perform a thorough inspection. Look for any physical damage, cracks, or leaks. Oil pan leaks can be identified by observing any oil dripping from the cover to the muffler. If you notice puffs of smoke after mowing, this could be an indication of an oil leak.

To check for warpage, use a straight edge and feeler gauge to measure the block and pan surfaces. Place the straight edge on the pan and block and check for any warping or distortion. If there is a significant deviation from straight, the component may be warped. A feeler gauge can be used to measure the amount of warpage by sliding it under the straight edge. The acceptable limit for warpage is typically around 0.005 inches or less.

Additionally, examine the oil pan for any signs of striations, casting marks, or air-cooling fins. These should not be mistaken for damage. Light scratching and denting on the underside of the pan are common and usually acceptable. However, deep scratches, tears, or cracks indicate that the pan should be replaced. If you notice any physical damage or excessive warpage, it may be necessary to replace or machine the affected component.

Use a gasket and sealant

To repair an oil pan gasket leak on a Kohler Courage 19, you can use a gasket and sealant. Here's a step-by-step guide on how to do it:

Step 1: Gather the Necessary Materials and Tools

You will need a new oil pan gasket, a sealant such as RTV (room temperature vulcanizing) silicone, and the necessary tools for the job, including wrenches and screwdrivers. It is important to use a high-quality RTV silicone designed for oil resistance and high temperatures.

Step 2: Drain the Oil and Remove the Old Gasket

Place a drain pan under the oil drain plug and remove the plug to drain the oil. Once the oil is drained, remove the oil filter and any other components that may obstruct access to the oil pan gasket. Use a gasket scraper or a putty knife to carefully remove the old gasket from the oil pan and engine block, ensuring that the mating surfaces are clean and free of debris.

Step 3: Prepare the New Gasket and Sealant

Apply a thin coat of RTV silicone to both sides of the new oil pan gasket. Ensure that you use a gasket designed specifically for your Kohler Courage 19 engine, as using an incorrect gasket can lead to improper sealing and further leaks. The RTV silicone will act as an additional seal and help prevent future leaks.

Step 4: Install the New Gasket and Reassemble

Carefully position the new gasket onto the oil pan, ensuring it is properly aligned. Reinstall the oil pan onto the engine block, following the correct torque specifications and sequence provided by Kohler. Reinstall the oil filter and any other components that were previously removed.

Step 5: Refill the Oil and Start the Engine

Refill the engine with the appropriate type and amount of oil for your Kohler Courage 19 engine. Start the engine and check for any signs of leaks around the oil pan gasket. If no leaks are present, your repair is successful. Allow the engine to run for a few minutes to circulate the oil and build up pressure, then check the oil level and add more if necessary.

It is important to follow the recommended torque specifications and patterns provided by Kohler for your specific engine model. Over-tightening the bolts can lead to warping or damage to the oil pan or engine block, while under-tightening can result in leaks. Always refer to the service manual or seek advice from a qualified mechanic if you are unsure about the procedure.

Check for a clogged oil passage

To check for a clogged oil passage in your Kohler Courage 19 engine, begin by locating the oil pan gasket and ensuring that it is securely tightened. If you notice any loose bolts or connections in this area, tighten them and then re-inspect the engine for oil leaks.

Next, inspect the oil pan gasket itself for any signs of damage or wear. If the gasket appears compromised in any way, it will need to be replaced. This is a common issue with the Kohler Courage engine and can lead to oil leaks if not addressed. When replacing the gasket, be sure to follow the manufacturer's torque specifications and pattern for proper installation.

Additionally, it is important to check the dowel pin that is located behind the oil filter. The older version of this pin had a split design, which could lead to oil leakage. The updated version of the dowel pin has a closed design, which helps to prevent leaks. Make sure your engine has the new, solid dowel pin installed.

If you continue to experience oil leaks or other issues, it may be necessary to consult a professional mechanic for further diagnosis and repair. They will be able to assess the engine and identify any underlying problems that may be causing the oil leakage.

Check the dowel is closed, not split

To repair an oil pan gasket on a Kohler Courage 19, it is important to check that the dowel is closed and not split. This is because the dowel plays a crucial role in ensuring the proper functioning of the engine. A faulty or split dowel can lead to oil leakage and other issues.

• Locate the dowel: The dowel is typically located behind the oil filter. Remove the oil filter to access the dowel.
• Inspect the dowel: Once you have located the dowel, carefully remove it and inspect it for any signs of damage or splitting. A split dowel will have a visible gap or opening along its length.
• Check the dowel part number: To ensure you have the correct dowel for your Kohler Courage 19 engine, check the part number. For a closed dowel, the part number should be 24 380 16-S. This information can be found on the Kohler website or in the engine's service manual.
• Compare with a new dowel: If you are unsure whether the dowel is split or not, it can be helpful to compare it with a new, unopened dowel. A closed dowel should have a seamless appearance, while a split dowel may have a visible seam or line indicating where it can open.
• Measure the dowel: Using a caliper or a micrometer, measure the diameter of the dowel. A closed dowel should have a consistent diameter throughout. If the dowel is split, you may notice a slight variation in diameter along the length of the dowel.
• Consult a Kohler dealer or mechanic: If you are still unsure about the condition of your dowel, it is best to consult a Kohler authorized dealer or a qualified mechanic. They can provide expert advice and guidance on dowel replacement if needed.

Remember, a closed dowel is essential for the proper lubrication and functioning of your Kohler Courage 19 engine. Do not ignore a faulty or split dowel, as it can lead to further complications and damage to your engine. Always refer to the Kohler service manual or seek professional assistance if you are uncomfortable performing these checks and repairs yourself.

Drain fluids before flipping the engine

Before flipping the engine, it is important to drain the fluids to avoid spillage and mess. This process is essential for a neat and safe procedure.

First, locate the oil drain plug. On a 20hp Kohler engine, it is often found with a short pipe attached by the manufacturer to facilitate a less messy oil drain. Once located, place a container underneath to collect the used oil. Then, remove the plug using the appropriate tool. For Kohler engines, a 1/4" or 3/8" square drive, such as a socket wrench or break-over bar, is commonly used. However, some engines may have a hex on the plug, so it is important to check and use the correct tool.

After removing the plug, allow the oil to drain completely. This process may take some time, so be patient to ensure all the oil is drained. Once the oil has stopped draining, wipe off any residual oil from the plug and the surrounding area to prevent dirt and debris from contaminating the oil. Then, carefully reinsert the plug, ensuring it is secure and tight.

Next, locate the oil filter. The oil filter on a Kohler Courage engine is typically found near the oil pan gasket. Again, place a container underneath to catch any residual oil. Using an oil filter wrench, remove the oil filter by unscrewing it in a counterclockwise direction. Allow the oil to drain from the filter, and then wipe off any residual oil from the filter housing. It is important to dispose of the used oil filter properly and in an environmentally friendly manner.

Now, you can prepare to install a new oil filter. Before installing, it is recommended to apply a thin coat of oil to the rubber gasket on the new filter. This helps create a better seal and prevents the gasket from drying out. Thread the new oil filter into the housing by hand, ensuring it is secure and tight.

Finally, refill the engine with fresh oil of the appropriate type and grade for your Kohler Courage 19 engine. Be sure to follow the manufacturer's recommendations for oil capacity and type. Check your owner's manual or consult a Kohler service manual for specific information. Once the oil is refilled, you can proceed with flipping the engine and continuing with the oil pan gasket repair.

Frequently asked questions