Service Manual 5007213_Evinrude E-TEC 115-200 HP Oiling System [Oiling System Tests]

IMPORTANT: Always perform visual inspections to identify oiling system leaks. Make sure the oil tank is filled and oil supply is not contaminated.

IMPORTANT: Static tests are performed with the outboard not running.

Use the Evinrude Diagnostics Software program to activate Oil Injection Pump test. This initiates the EMM control function for the oil injection pump.

Oil injection pump should activate with key switch in the ON position.

Static Tests Screen 005146

1. Oil injector test button

The EMM provides ground to pin 2 (blue wire) of oil injection pump electrical connector. Refer to Oil Injection Pump Voltage Test on p. 218.

Oil Injection Pump Voltage Test

Acceptable voltage readings:
• Key switch ON: approximately 30 V
• Outboard running: 55 V

STEP 1

Check voltage at pin 1 (white/red wire) of oil injection pump electrical connector with key switch ON.

Results:

• Approximately 30 V is acceptable with outboard not running. See Oil Injection Pump Circuit
Resistance Test** on p. 219.
• No voltage reading, proceed to STEP 2.

STEP 2

Run outboard. Check system voltage using diagnostic software program. The alternator/system output wires (white/red) are terminals 19 and 29 of the EMM J2 connector. If needed, use Electrical Test Probe Kit, P/N 342677, and a multimeter set to read 55 VDC to check engine harness voltage readings.

Results:
• Proper voltage reading, inspect connections and wiring. Replace faulty wire harness or connector.
• No or low voltage, check connections from EMM and stator to engine wire harness. Repair
faulty connection or refer to STATOR TESTS on p. 141 for testing procedures.

STEP 3

Use Electrical Test Probe Kit, P/N 342677, and a multimeter set to read 55 VDC. Check voltage at

pin 2 (blue wire) of oil injection pump connector. Key switch must be ON.

1. Oil injection pump connector (pin 2) 005442

Results:

• Approximately 30 V is acceptable, leave adapter connected, proceed to STEP 4.
• No voltage, refer to Oil Injection Pump Circuit Resistance Teston p. 219.

STEP 4

Activate oil injector using the Evinrude Diagnostics Software program. Monitor the voltage on oil injector pump circuit at pin 2 of oil injection pump connector.

Static Tests Screen 005146

1. Oil injector test button

The oil injection pump circuit includes the engine wire harness, the injection pump winding and connector, and the oil injection control circuit of the EMM.

Disconnect the battery cables at the battery.

Use Electrical Test Probe Kit, P/N 342677, to make a connection to pin 23 of the EMM J1-B connector.

Calibrate ohmmeter to the LOW OHMS scale and measure the resistance between pin 23 of the EMM J1-B connector and pin 1 of oil injection pump connector.

1. EMM J1-B connector (pin 23) 005443

2. Oil injection pump connector (pin 1)

Results:
:
• An infinite reading (∞) indicates an open circuit. Isolate the faulty wiring, connection, or injection pump winding. Repair faulty wiring or replace faulty component and retest.
• For a higher than expected reading, test resistance of the injection pump. If injection pump resistance reading is approximately 2-3 Ω, injection pump winding is good. Isolate faulty component. Repair faulty wiring or replace faulty component and retest.

Wear safety glasses to avoid personal injury, and set compressed air pressure to less than 25 psi (172 kPa).

Remove the oil pick-up assembly from the oil tank. Carefully remove the pickup filter and flush with a mild solvent to remove any contamination. Rein stall filter.

Carefully remove the oil hose from the oil pickup and remove the oil supply hose from the oil injection pump.

Use low pressure air to purge oil from hose.

1. Oil hose 12306
2. Oil pickup
3. Low pressure air
   Use Plug/Holder, P/N 329661, and clamp to plug the pickup end of the hose.

1. Plug/holder 12307
2. Oil hose

Attach a vacuum tester to the outboard side of oil supply hose and draw 7 in. Hg (24 kPa) vacuum on the hose for at least five minutes. Repair or replace any leaking components. Reinstall the oil hose.

Check height of pickup assembly.

Height of Oil Pickup Assembly COB5657A

Position a new seal on oil tank and reinstall pickup with filter into oil tank. Install and tighten screws.

This test may be performed in two different ways:

Running Test

Remove oil distribution hose from fitting at cylinder block. Start and run the outboard at IDLE speed and observe oil flow. Confirm that a small amount of oil is discharged while injection pump is activated

Static Test

Remove oil distribution hose from fitting at crank case. Squeeze oil supply primer bulb to provide oil to injection pump.

TYPICAL 005348

1. Fitting at crankcase

Use the oil injector test of the _Evinrude Diagnos tics Software program to activate injector. Confirm that a small amount of oil is discharged while injection pump is activated.

Static Tests Screen 005146

1. Oil injector test button

Results:
• Oil flows from distribution hose, compare to oil flow at other distribution hoses.
• No oil discharge, compare to oil flow at other distribution hoses. If one or more hoses fail to discharge oil, check for a kinked or restricted hose before replacing the oil injection pump assembly

To prevent accidental starting while servicing, disconnect battery cables at the battery.

Confirm that the oil injection fittings of the cylinder and crankcase assembly allow fluid to move.

Remove oil distribution hose from fitting. Connect 1/8 in. I.D. (3 mm) clear vinyl tubing to the fitting. Use a syringe filled with isopropyl alcohol to force fluid through the fitting.

Remove the oil from the oil tank, and turn the key switch ON. The LOW OIL light/warning of the System Check_ gauge should activate. Once the warning has been verified, turn the key switch ON and refill the oil tank. Confirm that the LOW OIL warning stops as the oil level exceeds one-quarter of oil tank’s capacity.