Service Manual 5008740_200-300 HP 90 ° V Oiling System [Components]

Recommended Lubricants

Evinrude/Johnson XD100, XD50, or XD30 out board oils are recommended for use in Evinrude E-TEC outboards. If these oils are no t available, you must use a TC-W3 certified oil.

Evinrude/Johnson XD100 outboard oil is highly recommended for all conditions and applications.

Engine Lubricant Below 32°F (0°C)

If the outboard will be operated in temperature s below freezing (32°F, 0°C), use Evinrude/Johnson XD100.

IMPORTANT: For new outboards, test low oil warning before filling oil tank.

Turn key switch to ON. The engine monitor warning display should show “LOW OIL.”

Add enough oil to raise level to at least one-quarter capacity.

The “LOW OIL” warning should not display.

Failure to follow these recommendations could void the outboard warranty if a lubrication-related failure occurs.

The oiling system consists of the following components:

• Oil tank
• Oil injection pump and manifold assembly
• Oil pressure sensor
• Electrical circuit
• LOW OIL and NO OIL warning systems
• Cylinder and crankcase
• Rear oil manifold assembly (3.3 L models)
• Rear oil pump (3.4 L models)
• Oil recirculation system

The oil tank must be properly positioned and t he oil level must be monitored. Refer to the Predelivery and Installation Guide.

Oil Tank Components:

• Tank, 1.8 or 3.0 gallon capacity
• Oil pickup and filter assembly
• LOW OIL sending unit
• Mounting bracket and hardware
• Protective cover (1.8 gallon tank only)
• Primer bulb and supply hose.

1.8 Gallon Oil Tank Kit

The oil injection pump is an electric (55 V) actuator style pump. It draws oil from the oil tank through the oil supply hose [25 ft. (7.6 m) maxi mum] and supplies pressurized oil to the oil manifold. The EMM supplies 55V and controls activation of the pump.

1. Oil injection pump
2. Oil manifold

The oil manifold distributes the oil supplied by the oil injection pump to the crankcase. On 3.3 L models oil is also distributed to the rear oil manifold.

The oil injector is powered by the 55 V electrical circuit. The EMM controls pump operation by rap idly connecting and disconnecting the pump’ s internal coil to ground.

The EMM monitors the oil injection pump electrical circuit. If circuit voltage is beyond the specified range (open circuit), the EMM:

The oil pressure sensor react s to changes in oil manifold pressure. The EMM supplies and monitors electrical current to the sensor.

1. Oil pressure sensor

• The sensor provides an output voltage to the EMM based on oil manifold pressures.
• 5 VDC Input on RED wire
• 0.5 4.5 V Output on TAN / WHITE wire
• Ground on BLACK wire

The EMM monitors the oil pressure sensor’s electrical circuit. If circuit voltage is beyond the specified range (< 0.15 V, > 4.85 V), the EMM:

If oil pressure is below expected range (< 0. 4 V), the EMM:

If oil pressure is above expected range (> 4.6 V), the EMM:

Refer to Oil Pressure Sensor on p. 59.

The rear oil manifold receives oil from the primary manifold and distributes it to the cylinder sleeves.

1. Rear oil manifold

The oil injection pump is an electric (12 V) actuator style pump. It draws oil from a fit ting at the oil injection pump and supplies pressurized oil to the cylinder sleeve s. The EMM supplies 12 V and controls activation of the pump.

1. Rear oil pump

The rear oil pump is powered by the 12 V electrical circuit. The EMM controls pump operation by rapidly connecting and disconnecting the pump’s internal coil to ground.

The EMM monitors the oil injection pump electrical circuit. If the circuit is open, the EMM:

A sending unit in the oil tank pick-up assembly monitors the oil level in the oil tank.

If the oil level falls below one-quarter capacity, the EMM signals:

An optional oil tank sending unit kit is available to display actual oil level through an I-Command net work.

The EMM monitors the electrical circuit of the oil pressure sensor. If the sensor or circuit fails, or if there is a lack of oil pressure in the oil distribution manifold, the EMM:

The primary oil distribution manifold provides crankcase lubrication through oil distribution hoses and pressed-in fitting s at t he front of the crankcase, port side.

1. Pressed-in fitting

The rear oil distribution manifold provides lubrication for each cylinder . Each cylinder of the cylinder/crankcase h as a pressed -in fitting which is connected to an oil distribution hose.

1. Cylinder sleeve oil fittings – port

1. Cylinder sleeve oil fittings – stbd

External hoses and fittings, internal cylinder/crankcase passages, and intake manifold pas sages are used to recirculate any accumulation of oil from various locations in the powerhead. The movement of oil is controlled by check valves.

Cylinder Recirculation

Internal powerhead oil drain passages connect the lowest point of the intake port area of the cylinder block to external check valves. External hoses connect these check valves to a hose fitting pressed into the top of the intake manifold / throttle body. Intake manifold vacuum draws any accumulation of oil from the intake port area of the cylinders in to the incoming air stream in front of the top reed valve.

1. Check valves

1. Recirculation hose
2. Hose fitting

Check valves pressed into the crankcase below #4 and #6 reed valve assemblies connect to hoses which route to a fitting at the top of the block, above #2 cylinder.

1. Lower to upper main bearing oiling circuit
2. Idle oil circuit
3. Tee fitting
4. Cylinder recirculation circuit

Crankcase / Main Bearing Recirculation

The movement of oil through the main bearings is controlled by internal passages, external fitting s and hoses, and an in-line check valve.

Both center main bearings receive oil through grooved passages in the crankcase. Oil migrate s to the bearings from the crankcase areas of the higher cylinders.

The lower main bearing receives oil through a grooved passage in the crankcase.

Lower to upper main bearing oil flow

Oil moves from the lower main bearing cavity through an internal crankcase passage to an external fitting. External hoses with an in-line check valve connect to a fitting at the upper main bearing, which leads to t he upper main bearing through an internal crankcase passage.

Oil Injection Rate

The Engine Management Module (EMM) controls the oil injection rate based on engine RPM. This rate can be adjusted for the type of oil being used, and also for powerhead break-in. Use Evinrude Diagnostics software to access these features.

The Set Oil Type option controls the injection rate for the oil being used and typical operating conditions.

The TC-W3 oil type setting is the standard setting for all outboards. Set TC-W3 for:

• Operation with all TC-W3 outboard oils including XD30, XD50, or XD100.
• Applications requiring maximum lubrication.
• Extreme applications (commercial or harsh conditions, racing or other high performance operation).
• Use this setting with XD100 outboard oil in extreme applications

The XD100 setting provides an option to run the outboard at a reduced oil injection rate. This set ting REQUIRES the use of Evinrude XD100 out board lubricant and is not recommended for all applications.

IMPORTANT: The XD100 setting is not avail able on all models.

Use the XD100 setting for:

• Conventional use (runabouts, cruisers)
• Moderate applications

1. Oil control setting