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What is causing my pressure washer engine to stop hard/suddenly?

It's a Kohler Courage XT-7 engine. I replaced a leaking oil pan gasket and torqued the bolts back in place. Filled it with 10w30 synthetic. I've checked the fuel line and the carburetor, which appear to be clean. Spark plug looks normal and is gapped correctly. I've replaced the water pump with a brand new one. When attached, the engine would start up but then quit when trying to build pressure. Seems to run longer from a cold start. I then removed the pump to see how the engine runs without a pump attached. Within a minute of running normally, it stopped HARD with a clunk. That can't be good and I have no idea what would cause it stop so suddenly. Is there internal damage to the engine?

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Your engine is experiencing a heat seizure... the piston sticking in the cylinder as it expands under heat with poor lubrication.

Posted on May 02, 2017

Testimonial: "That sounds possible, however the engine specification is for Class SJ or higher 10w-30. I changed the oil and used 10w-30 Service Class SN synthetic oil, which is better than SJ. It's also filled to the correct level. Also, If I manually turn the crank when the engine is cold, nothing seems amiss. Could the rings be worn/damaged?"

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Sounds like you have a real sick puppy on your hands since it will not even work properly with no load. Sure the carb is giving the engine enough gas?

Posted on May 02, 2017

Testimonial: "Drained the gas tank the other day, and checked the carb for deposits - It's clean and clear. Poor fuel flow wouldn't cause the motor to seize like it did today, though."

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  • richie46 May 03, 2017

    When the engine "seized" were you able to turn it over? Remove plug and then try while still hot? I am as confused as you are about the clunk. Before they seize they run for sh-- and then just stop.

  • Nick Termini
    Nick Termini May 03, 2017

    I had been able to turn it over before while warm/hotish the other day, but after today's "clunk" I didn't want to start it again. It has an ignition switch so with it in the off position I can pull the start cord and feel the motor parts moving smoothly.

  • richie46 May 03, 2017

    So then it can't be seized since that is sort of a permanent thing. If you cannot spin the engine manually after it is hot and unexpectedly shuts down, then it has to be some sort of thermal/expansion issue. Are lubrication channels clear and functional?

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Removal & Installation

2.4L Engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the engine oil.
  3. Remove or disconnect the following:

    Negative battery cable Structural collar A/C compressor bracket to oil pan bolt Oil pan
  4. Clean the oil pan and all gasket mating surfaces.

To install:
  1. Install or connect the following:

    Oil pan gasket to the block after applying engine RTV at the oil pump parting line Oil pan. Torque the bolts to 105 inch lbs. (12 Nm). Structural collar Negative battery cable
  2. Fill the crankcase to the correct level.
  3. Start the engine, check for leaks and repair if necessary.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the engine oil.
  3. Remove or disconnect the following:

    Negative battery cable Structural collar A/C compressor bracket to oil pan bolt Oil pan
  4. Clean the oil pan and all gasket mating surfaces.

To install:
  1. Install or connect the following:

    Oil pan gasket to the block after applying engine RTV at the oil pump parting line Oil pan. Torque the bolts to 105 inch lbs. (12 Nm). Structural collar Negative battery cable
  2. Fill the crankcase to the correct level.
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3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the engine oil.
  3. Remove or disconnect the following:

    Negative battery cable Starter motor Front motor mount bracket Bending braces Torque converter dust shield Oil pan

    0996b43f8020961b.jpg enlarge_icon.gifenlarge_tooltip.gif

    Fig. Oil pan mounting bolt tightening sequence-3.0L engine


To install:
  1. Clean the oil pan all mating surfaces.
  2. Apply RTV gasket material to the oil pan.
  3. Install or connect the following:

    Oil pan. Tighten the bolts in sequence to 50 inch lbs. (6 Nm). Torque converter dust shield Bending braces Front motor mount bracket Starter motor Negative battery cable
  4. Fill the crankcase to the correct level.
  5. Start the engine, check for leaks and repair if necessary.

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the engine oil.
  3. Remove or disconnect the following:

    Negative battery cable Engine oil dipstick Drive belt splash shield Strut to transaxle attaching bolt and loosen the strut to engine attaching bolts Transaxle case cover Oil pan fasteners Oil pan and gasket

To install:
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  3. Install or connect the following:

    New gasket on the oil pan Oil pan. Torque the bolts to 105 inch lbs. (12 Nm). Transaxle case cover All bending brace bolts Drive belt splash shield Engine oil dipstick Negative battery cable
  4. Fill the crankcase to the correct level.
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  2. Drain the engine oil.
  3. Remove or disconnect the following:

    Negative battery cable Engine oil dipstick Drive belt splash shield Strut to transaxle attaching bolt and loosen the strut to engine attaching bolts Transaxle case cover Oil pan fasteners Oil pan and gasket

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    New gasket on the oil pan Oil pan. Torque the bolts to 105 inch lbs. (12 Nm). Transaxle case cover All bending brace bolts Drive belt splash shield Engine oil dipstick Negative battery cable
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http://howtobyme.blogspot.com/2011/11/kia-sportage-leaking-oil-from-oil-pan.html ----------
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This will help.

Thanks.

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