Toro 100-2402, 100-2404 Installation Instructions

FORM NO. 3323-792

Heavy Duty Air Cleaner Kit

for Out Front Z

Part No. 100–2402
Part No. 100–2403
Part No. 100–2404

Loose

Note: Use the chart below to identify parts for assembly.

DESCRIPTION QTY. USE

Carburetor
Adapter Plate
Carburetor Gasket
Air Cleaner Base Gasket
Air Cleaner Adapter Gasket
Adapter
Air Cleaner Bracket
Screws

Parts

1
1
1
1
1
1
1

Install New Carburetor

7

INSTALLATION

INSTRUCTIONS

Plug
Screws
Air Cleaner w/90º Inlet
A/C Bracket
Hood
Nut

T

emplate #1

T

emplate #2

Rubber Grommet
Air Intake Hose
R–Clamp
Screw

Flange Connector
Radiator Clamp
Screws

T

emplate #3

2
2
1
1
1
1

1
1

1
1
1
1

1
1
1

1

Cut Holes in Plastic T

Install Air Intake Hose

Install Flange Connector

Drill Holes in Bumper

ank

Printed in USA



The T

oro Company – 1999

All Rights Reserved

Installation Instructions

DESCRIPTION USEQTY.

Air Cleaner Bracket
Hex Head Screw
Nuts

Air Cleaner
Hex Head Screw
Nuts

Radiator Clamp
Filter Finder Kit
Filter Guard

Cover Plate
Screws
Nuts
Wing Nut
Carriage bolts

This kit contains a heavy–duty air cleaner, carburetor,
hose adapter

, hoses and mounting hardware. This
creates a complete heavy–duty air cleaner system for
Toro Out Front Z Mowers with Kohler Command
Twin Cylinder Engines.

1
2
2

1
2
2

2
1
1

1
3
3
2
2

Install Air Cleaner Bracket

Install Air Cleaner

Install Hoses to Air Cleaner
Install Filter Finder Kit

Install Guard and Cover

Pre–Installation

1. Disengage the power take off (PTO), set the

parking brake, and turn the ignition key to
“OFF” to stop the engine. Remove spark plug
wire(s) and remove the key.

POTENTIAL HAZARD

• If you leave the key in the ignition switch,

someone could start the engine.

WHAT CAN HAPPEN

• Accidental starting of the engine could

seriously injure you or other bystanders.

HOW TO AV

OID THE HAZARD

• Remove the key from the ignition switch

and pull the wire(s) off the spark plug(s)
before you do any maintenance. Also push
the wire(s) aside so it does not accidentally
contact the spark plug(s).

2. Tilt hopper up remove all grass from hopper.

3. Thoroughly remove all grass and debris from

around the engine and plastic console on left
side.

2

Installation Instructions

Removing

Hopper

1. Tilt hopper up.

2. Disconnect the wire harnesses along the rear left

side frame as shown in figure 1. Ensure that it is
free of the frame.

3. Remove safety clip from end of gas spring to

hopper. Disconnect gas spring from ball stud
attached to machine frame (Fig. 2). Support
hopper to prevent falling.

4. Lower hopper. Remove both clevis pins from the

rear frame that the hopper pivots on. Remove
hopper. (Fig. 2).

1

M-4582

Figure 1

1. Wire

Harness

Turning

Engine Lift Hook

Turning the engine lift hook will allow clearance for
hose installed later in this instruction sheet. Keep the
hook and hardware for future use if needed.

IMPORTANT: Return lift hook to original
position before it is used for to remove engine.

1. Locate on engine the lift hook in figure 3.

2. Remove the lift hook from engine.

3. Rotate lift hook 180 degrees and reinstall.

1

2

M-4583

Figure 3

1. Engine

Lift Hook

2. Screws

1

4

1. Hopper

2. Safety

3.

Gas Spring

Clip

Figure

2

4.

5.

Hair Pin
Clevis pin

Removing

2

1. Remove all existing air cleaner components

Carburetor

attached to the carburetor. Save the three
mounting screws from the air cleaner base plate
and discard everything else.

3

2. Have an appropriate container ready to catch any

5

remaining fuel that might leak out and
disconnect the fuel line from the carburetor.

3. Follow the red lead from the fuel shut–off

solenoid on the front of the carburetor and
disconnect it from the harness plug.

M-4581

4. Remove and save the two carburetor mounting

screws.

3

Installation Instructions

5. Lift and pivot the carburetor to unhook the choke

link, throttle link, and throttle dampening spring
attached to the carburetor. Discard the old
carburetor.

6. Remove the carburetor gasket from the intake

manifold and clean off any remaining material
using an aerosol gasket remover.

IMPORTANT: Do not nick or scratch
manifold surface.

Installing

Carburetor

1. Install the two triangular plugs from the kit into

the air ducts on the top of the blower housing.
Start the two thread–forming screws from the kit
into the holes in the front of the air ducts.
Tighten the screws until the plugs are locked into
place (Fig. 5).

2. Install the new carburetor gasket onto the intake

manifold. Make sure all holes are aligned and
open. A dab of gasket adhesive may be used to
keep it in position (Fig. 5).

3. Reconnect the choke link, throttle link, and

throttle dampening spring into the corresponding
levers of the new carburetor (Fig. 5).

6. Check the equipment throttle and choke controls

for proper operation. Be sure the plates in the
carburetor are opening and closing fully with the
movement of the control levers.

7. Connect the lead wire from the fuel shut–off

solenoid.

8. Reconnect the fuel line to the carburetor inlet

and secure with the clamp. Make sure the fuel
line does not interfere with any of the linkages.

9. Place the new air cleaner base gasket from kit on

top of the carburetor (Fig. 5).

10. Position the new adapter plate over the

carburetor gasket and pull the breather tube
through the corresponding hole until the plate is
seated between the flanges. Assemble the new
air cleaner bracket to the top of the new air
cleaner base, inserting the breather tube through
the hole in side of bracket. Make sure the end of
the breather tube points toward the center of
carburetor throat. Install the three mounting
screws removed in step 1 of Removing
Carburetor, page 3. Torque the screws to
88 in. lb (9.9 N•m). See figure 4.

1

2

4. Set the carburetor into position on the

gasket/intake manifold and install the two
mounting screws saved in step 4 of Removing
Carburetor. Lightly finger tighten the screws
(Fig. 5).

5. Hold the governor lever toward the carburetor as

far as it will go. Check that the throttle plate is
wide open in this position. If the throttle plate is
not wide open, keep pressure against the
governor lever and shift the carburetor until the
plate is wide open. Torque the two mounting
screws to 9.9 NSm (88 in.–lb.).

4

1. Air

Cleaner Bracket

2.

Breather T

ube

3

Figure 4

Mounting Screw

3.



Installation Instructions

11. Position the new adapter plate over the

carburetor gasket and pull the breather tube
through the corresponding hole until the plate is
seated between the flanges. The end of the
breather hose must point into the carburetor
throat. Install the three mounting screws
removed in step 1 and torque them to 9.9 NSm
(88 in. lb) (Fig. 5).

12. Position the adapter gasket and air intake adapter

onto the adapter plate, so the hose connection
neck is facing straight back in the engine
compartment. Secure with the seven M6
thread–forming screws. Torque the screws to

10.7 NSm (95 in.–lb.) (Fig. 5).

9
8

7

6

Cutting

Holes in Plastic

Console

A 3I and 3–1/2I diameter hole saw is needed to drill
into the left side plastic console.

Note: Templates 1 and 2 must be used to

locate the correct location for holes.
Templates are located in the back of
this instruction sheet.

1. Locate and cut out templates 1 and 2 from the

back of this instruction sheet.
Note: Do not cut out large circles in paper

templates.

2. Take template number one and fold it across the

fold line.

3. Place template number one onto the top of the

plastic console as shown in figure 6. Tape to
plastic console.

5
4

3
1

2

1. Triangular

2.

Plug Screws

3.

Carburetor gasket

4. Carburetor

5.

Air Cleaner Base Gasket

Plugs

Figure 5

3

6.

Adapter Plate

7.

Adapter Gasket

8.

Air Intake Adapter

9. Screws

M-4571

13. Place rag or tape over air intake adapter opening

to prevent debris entering.

4. Using 3I diameter hole saw, cut a hole at the

specified area in template (Fig. 6).

3

m-4573

Diameter Hole to be cut

Leftside console

1. Template

2. T

emplate Position on

console

1

2
4

#1 (Folded)

Figure 6

3. 3”

4.

5. Locate template number two and cut out small

hole. Fold template at the specified fold lines.

6. Place small cut out hole onto bolt head and place

the fold in the bend of metal support. (Fig. 7).

7. Align diagonal line on template with the edge of

metal support. Tape template to plastic console
and metal support (Fig. 7).

5

Installation Instructions

9

8. Mark center of 3–1/2” hole. (Fig. 7).

9. Remove bolt that was used when locating

template position (Fig. 7).

10. Using 3–1/2I diameter hole saw, cut a hole at

the specified area in template (Fig. 7).

11. Reinstall bolt. (Fig. 7).

Note: Part of hole will be cut through metal

support. Remove any burrs from the
metal support after hole is cut.

2

4

1. Template

2. T

console
3–1/2” Diameter Hole to

3.

be cut

4. Bottom

#2 (Folded)

emplate Position on

of Leftside console

5

Figure 7

5. Bolt

Head (Remove bolt
after 3–1/2” hole location
is marked.)

6.

Cut out circle (Align onto
bolt head)

7.

Edge of Metal Support

7
1
3

6

m-457

Drilling

Holes into Bumper

Note: Template 3 must be used to locate the

proper location for holes. Template 3 is
located in the back of this instruction
sheet.

1. Locate and cut out template three from the back

of this instruction sheet.
Note: Do not cut out circles in paper

template.

2. Take template number three and fold it across

the fold line.

3. Place template number three onto the top of the

rear bumper as shown in figure 9. Tape to
bumper.

4. Remove the three bolts as shown in figure 8.

Loosen the fourth bolt but do not remove.

1

4

Note: Figure 7 shows machine as if it were

tipped on its side. Do not tip machine
on its side.

6

1. Bolts

2. Nuts

2

3

Figure 8

3. Bumper

4. Bolt

(Loosen)

m-4580