FUEL COMPONENT SERVICING
Gasoline is extremely flammable and highly explosive under certain conditions. Use caution when working on any part of the fuel system.
Protect against hazardous fuel spray. Before starting any fuel system service, carefully relieve fuel system pressure. Refer to Relieving Fuel System Pressure. Always disconnect the battery cables at the battery before servicing the fuel system unless instructed to do otherwise. Always work in a well ventilated area and wipe off any fuel spillage. DO NOT smoke and make certain no open flames or ignition sources exist. After servicing the fuel system check for leaks. Failure to check for fuel leakage could allow a leak to go undetected, resulting in fire or explosion.
Relieving Fuel System Pressure
IMPORTANT: Minimize fuel system pressure before disassembly. Temporarily restrict the fuel supply hose from fuel tank with hose pincer. Remove propeller and disconnect circulation fuel pump electrical connector. If outboard runs, start and run at IDLE for 5 seconds and STOP outboard. If outboard does NOT run, crank for 10 seconds.
Disconnect the battery cables at the battery.
Wrap a shop towel completely around the pressure test valve while connecting fitting from Fuel Pressure Gauge, P/N 5007100, to top test fitting of fuel pump/vapor separator assembly.
Insert venting hose of gauge into a suitable container.
Slowly open gauge’s venting valve.
Clean up any spilled fuel with shop towels.
Fuel Filter Service
Removal
Disconnect the battery cables at the battery.
Remove filter carefully to prevent spilling contents.
Inspect contents for any presence of water. If water is present, identify the source and correct the problem. Take additional fuel samples and
drain fuel tank(s) if necessary.
Installation
Install filter in fuel supply hoses. Note arrow indicating direction of fuel flow on filter. Secure filter with appropriate clamps. Refer to Oetiker Clamp Servicing on p. 36.
Squeeze primer bulb to prime fuel system. Hold pressure on bulb and check for fuel leaks.
Connect battery cables.
Fuel Lift Pump Service
The fuel lift pump is serviceable as a complete assembly or can be repaired with a fuel pump repair kit. Refer to parts catalog for service parts.
Removal
Disconnect the battery cables at the battery.
Disconnect the fuel hoses from the fuel pump housing.
Disconnect the fuel lift pump pulse hose at the crankcase fitting.
Loosen the fuel lift pump mounting screws. Remove the fuel lift pump as an assembly.
Installation
Place fuel pump in position on crankcase. Apply Nut Lock to mounting screws. Tighten screws to a torque of 24 to 36 in. lbs. (2.8 to 4.0 N·m).
Connect the fuel lift pump pulse hose to the crankcase. Secure with tie strap.
Connect the fuel hoses to the fuel filter. Secure with Oetiker clamps.
Squeeze primer bulb to prime fuel system. Hold pressure on bulb and check for fuel leaks.
Connect battery cables.
Run outboard and check for fuel leaks.
Vapor Separator Service
Removal
Disconnect the battery cables at the battery.
Relieve fuel system pressure. Refer to Relieving Fuel System Pressure on p. 166.
Disconnect circulation pump electrical connector.
Remove clamp and fuel supply manifold from top of circulation pump. Remove clamp and vapor vent hose from separator cover.
Remove clamps and vapor separator cooling water hoses.
Remove clamps and fuel return manifold and fuel supply hose from bottom of vapor separator.
Remove the vapor separator housing retainer clip.
Remove vapor separator/fuel pump from the mounting stud and slide vapor separator housing from the grooves of the isolator mounts.
Installation
Installation is the reverse of removal. Pay close attention when performing the following additional tasks.
Install all hoses and manifolds to original locations and secure with appropriate clamps. Squeeze primer bulb to prime fuel system. Hold pressure on bulb and observe for fuel leaks.
Run outboard and check for fuel leaks.
Fuel Manifold Service
Removal
Disconnect the battery cables at the battery.
Relieve fuel system pressure. Refer to Relieving Fuel System Pressure on p. 166.
Remove oil tank assembly. Refer to Oil Tank Assembly on p. 187.
Remove clamps and disconnect the fuel manifolds as follows:
- Fuel supply manifold to circulation pump.
- Fuel return manifold to vapor separator.
Remove fuel manifold retainer screws and remove retainers from fuel injectors.
Disconnect fuel manifold fittings from fuel injector ports, then remove the manifold assemblies.
Installation
Check condition of sealing O-rings on fuel manifold fittings. Lubricate O-rings with outboard lubricant and insert fuel manifold fittings into injector. Both fittings must be fully seated into the injector fuel ports.
Install retainer and screw. Retainer must engage the outer groove of the manifold fittings.
Install the fuel manifolds to the fuel pump assembly and secure with clamps:
- Fuel supply manifold to circulation pump.
- Fuel return manifold to vapor separator.
Install oil tank assembly. Refer to Oil Tank Assembly on p. 187.
Fuel Injector Service
Mark fuel injectors to show cylinder locations.
IMPORTANT: Fuel injectors must be installed in the correct cylinder locations. Use Evinrude Diagnostics Software to make sure that EMM programming matches injector positioning. The Injector Coefficients screen displays injector serial numbers.
Use caution when handling fuel injectors. Prevent dirt and debris from entering fuel inlet and outlet ports of injectors or fuel manifolds. Cover the injector nozzle port in cylinder head to prevent contamination of combustion chamber.
Removal
Disconnect the battery cables at the battery.
Relieve fuel system pressure. Refer to Relieving Fuel System Pressure on p. 166.
Remove fuel manifolds. Refer to Fuel Manifold Service on p. 168.
Remove the ignition coil assemblies.
Disconnect the fuel injector electrical connector.
Remove injector screws.
Remove fuel injector and insulator.
Crush Ring Replacement
IMPORTANT: Injector crush rings must be replaced if injector is installed in a different head or cylinder location.
Use Slide Hammer assembly, P/N 391008, with Slide Hammer Adaptor kit, P/N 390898, to remove injector from mounting cup.
Thread adaptor and stud into face of injector. Hold mounting cup securely. Use slide hammer to separate injector from mount housing.
Remove adaptor from injector. Remove crush ring and O-rings from injector. Inspect and clean injector filter. Install new crush ring and O-rings. Lubricate O-rings with STP† Oil Treatment.
Install injector into mount housing. Press on injector face until injector seats in mount housing.
Installation
IMPORTANT: All injectors must be installed in the correct cylinder by serial number. Improper injector installation can result in powerhead failure.
Installation of replacement injectors requires the use of diagnostics software and fuel flow data supplied with all replacement injectors on 3.5 in. floppy disk.
The following items and their mating surfaces must be cleaned prior to reassembly:
- Injector
- Cylinder head
- Adapter
- Screws
- Threaded areas.
All injector components must be clean to ensure correct torque tightening specifications. To prevent fuel leakage, carefully follow these installation instructions.
Place injector and insulator in the proper cylinder location.
IMPORTANT: Be careful not to pinch any wiring or hoses during assembly.
Lubricate mounting screw threads and under the head of the screw with a light coat of Triple-Guard grease. Install washers (one per screw) on injector retaining screws. Install screws and washers through mounting flange of injector and into cylinder head.
Tighten screws in stages, starting with the lower screw.
- First torque is 5 ft. lbs. (7 N·m).
- Second torque is 10 ft. lbs. (14 N·m).
- Final torque is 24 to 26 ft. lbs. (33 to 35 N·m).
Reconnect fuel injector electrical connectors.
Install the ignition coil assemblies.
Install fuel manifolds. Refer to Fuel Manifold Service on p. 168.
IMPORTANT: Install injector service data (3.5 in. floppy disk) by using the Injector Replacement Utility of Evinrude Diagnostics software. Check the Injector Coefficients screen to make sure that all injectors are positioned properly.
Intake Manifold Service
Removal
Disconnect throttle link arm.
Remove throttle body screws and throttle body assembly.
Remove gasket from throttle body.
Remove screws and reed plate assembly from the crankcase.
Disassembly
All reed plate assembly and reed valve assemblies must be cleaned prior to reassembly. DO NOT use strong carburetor cleaner or the hot
soaking tank method for cleaning.
Remove the reed valve retainer screws and remove the assembly.
Use caution to prevent damaging reed valve assemblies.
IMPORTANT: DO NOT disassemble reed valve assemblies. Damaged reed plates are not serviceable and are replaced as an assembly.
Inspection
Inspect the leaf plate assemblies for damage or contamination:
- Leaf plates must not be distorted.
- Leaf valve must not be cracked or chipped.
- Leaf plate stops must not be distorted or loose.
- Leaf plate assemblies must be clean.
Inspect the intake manifold. All gasket surfaces must be cleaned, smooth, and free of nicks. Use a machinist’s straight-edge to check flatness in all directions. Surface must be flat, ±0.004 in. (0.10 mm).
Assembly
Remove old adhesive from reed valve retaining screws.
Install gasket on reed plate assembly. DO NOT use sealer on the gasket.
Prime screw threads with Locquic Primer and let dry. Apply Nut Lock to threads. Position reed valve on reed plate and install screws. Tighten screws to a torque of 25 to 35 in. lbs. (2.8 to 4.0 N·m).
Installation
Place reed plate assembly on cylinder/crankcase.
Apply Nut Lock to screws. Install all screws.
Tighten the center screws first and expand outward. Tighten in stages to a final torque of 60 to 120 in. lbs. (7 to 13.5 N·m).
Place gasket on throttle body. Install throttle body on reed plate and install screws.
Tighten the center screws first and expand outward. Final torque is 60 to 120 in. lbs. (7 to 13.5 N·m).
Install upper main bearing vent hose and secure with tie strap.
Connect throttle linkage and electrical connectors. Place clamp as shown.
Refer to TPS Calibration on p. 143.
IMPORTANT: DO NOT lubricate throttle linkages.
