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

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

The EMM controls the pump by providing ground through pin 23 (blue wire) of the J1-B connector and pin 2 (blue wire) of the oil pump connector.

Use Evinrude Diagnostics software to activate the Oil Injector test. This test starts the EMM control function for the oil injection pump.

Static Tests Screen

IMPORTANT: This test is operating the pump with 30 V on the system voltage (55 V) circuit. The start assist circuit (SAC) of the EMM converts battery voltage (12 V) to 30 V of system voltage. Battery must be fully charged and connections must be clean and tight. Pump activation should be carefully confirmed. Listen for an audible click from the oil injection pump when it is activated.

Use an inductive timing light to monitor current flow through the ground circuit (blue wire) at the oil pump connector (pin 2).

If the light flashes, the EMM and oil injection circuits are not at fault.

Refer to Oil Injection Pump Voltage Tests on p. 173.

Use a digital multimeter calibrated to a scale that reads 55 V (DC) to mea sure voltage between the oil pump electrical connector and engine ground.

Connect negative meter lead to ground.

Use an appropriate test probe to connect positive meter lead to pin 2 (blue wire) of oil injection pump electrical connector.

1. Oil injection pump connector (pin 2)

Turn the key switch to the ON position. Observe voltage at pin 2.

• Voltage at pin 2 should be approximately 30 V.

Use the Oil Injector test o f Evinrude Diagnostic software Static Test screen to activate the oil pump.

Static Tests Screen

Observe voltage at pin 2.

• Voltage at pin 2 should drop as the oil pump cycles.

Check the control signal while the Oil Injector test is running. Set the digit al multimeter to the Hertz (Hz) scale.

• Meter should read approximately 10 Hz.

Results:

• If volt age and control sign al readings at pin 2 are within range, the EMM and wiring are not at fault.
• If voltage at pin 2 is not within range, check volt age at pin 1 (white/red wire) of oil pump electrical connector.

Connect positive meter lead to pin 1 (white/red wire) of oil injection pump electrical connector. Observe voltage at pin 1.

• Voltage at pin 1 should be approximately 30 V. Start the engine. Observe voltage at pin 1.
• The volt age at pin 1 should be approximately 55 V.
• If voltage is not within range, refer to Oil Injection Pump Circuit Resistance Test on p. 174.
• No volt age reading, refer to System Voltage Test on p. 81.

IMPORTANT: The complete oil injection pump electrical circuit includes EMM alternator output, the engine wire harness, the injection pump winding and connectors, and the oil injector control circuit of the EMM. Check continuity of all wiring and connections.

Disconnect the battery cables at the battery.

Disconnect J1-B connector from EMM. Use a digital multimeter with appropriate adapter leads to measure the resistance between pin 23 (blue) of the EMM J1-B connector and pin 1 (white/red) of the oil injection p ump connector. Calibrate t he meter to the LOW OHMS scale.

1. EMM J1-B connector (pin 23)
2. Oil injection pump connector (pin 1)

• An infinite reading (∞) indicates an open circuit. Isolate the faulty component. Check continuity of wiring, connections, or injection pump winding. Repair faulty wiring or replace faulty pump.
• For a higher than expected reading, test resistance of the inject ion pump. If injection pump resistance reading is within range, injection pump winding is good. Isolate faulty component. Repair faulty wiring or replace faulty component and retest.

The EMM controls the pump by providing ground through pin 4 (blue/red wire) of the J1-A connector and pin A (blue/red wire) of the oil pump connector.

Use an appropriate test probe and a digital multi meter calibrated to a scale that reads 12 V (DC).

Connect negative meter lead to ground.

Connect positive meter le ad to pin A (blue/red wire) of oil injection pump electrical connector.

1. Oil injection pump connector

Turn the key switch to the ON position. Observe voltage at pin A.

• Voltage at pin A should be approximately 12 V.

Use the Cylinder Oiler Test function of Evinrude Diagnostic software Static Test screen to activate the cylinder oil pump.

Static Test Screen

1. Cylinder oiler test

• Voltage at pin A should vary (drop), as the oil pump cycles.

Check the control signal while the Oil Injector test is running. Set the digital multimeter to the Hertz (Hz) scale.

• Meter should read approximately 2 Hz.

Results:

• If volt age and control signal readings (Hz) at pin A are within range, the EMM and wiring are not at fault.
• If voltage at pin A is not within range, check volt age at pin B (re d/yellow wire) of the oil pump electrical connector.

Connect positive meter lead t o pin B (red/ yellow wire) of oil injection pump electrical connector. Observe voltage at pin B.

• The voltage at pin B should be approximately 12 V.

Start the engine. Observe voltage at pin B.

• The voltage at pin B should be approximately 12 V.
• If voltage at pin B is within range, refer to Cylinder Oil Pump Resistance Test on p. 176.
• No volt age reading at pin B, check continuity between pin B of oil pump electrical connector and pin 24 of EMM J1-B connector.

Disconnect the battery cables at the battery.

Disconnect the electrical connector from the oil injection pump.

Use a digital multimeter to measure the resistance between the pins of the oil pump connector. Calibrate the meter to the LOW OHMS scale.

1. Oil injection pump connector

Results:

An infinite reading (∞) indicates an open circuit of the injection pump winding. Replace faulty pump.

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 re move 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
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
2. Oil hose

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

Check height of pickup assembly.

Height of Oil Pickup Assembly

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

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

1. Crankcase fitting

Running Test

Start the out board and observe oil flow. Confirm that a small amount of oil is discharged while injection pump is activated.

Static Test

Use the Evinrude Diagnostics software oil injector test to activate injector. Confirm t hat a small amount of oil is discharged while injection pump is activated.

Results:

• Oil flows from distribution hose, comp are 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.

Make sure the oil injection fittings of the cylinder and crankcase assembly allow fluid to move.

Remove oil distribution hose from crankcase fit ting. Temporarily install a length of oil hose on the fitting.

Use a Syringe, P/N 346936, filled with isopropyl alcohol to force fluid through hose and fitting.

Remove oil from the oil tank

Turn the key switch ON. The dash mounted Engine Monitor system should show a LOW OIL warning.

Once the warning has been confirmed, refill the oil tank. The LOW OIL warning should stop when the oil level exceeds one-quarter of oil tank’s capacity.