Service Manual 5009011_200–300 HP 90°V Models AA Fuel System [Fuel Component Servicing]

Remove anti-siphon valve from fuel tank. Install adapter fittings and a 36 in. (91.4 cm) length of clear hose to the inlet side (tank end) of valve.

DR2277

1. Anti-siphon valve
2. Adapter fitting
3. Clear hose

Fill clear hose with water to a height of 20 in. (500 mm). Water must NOT flow through valve. An occasional drip is acceptable. Replace valve if water drips continuously.

Increase height of water to 25 in. (630 mm). Water should flow through valve as water level reaches 25 in. (630 mm). Replace the anti-siphon valve if test results are different.

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 prior to 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 out board. 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.

004335

1. Shop towel

Insert venting hose of gauge into a suitable container.

Slowly open gauge’s venting valve.

Clean up any spilled fuel with shop towels.

004334

1. Test fitting
2. Venting hose
3. Venting valve

Removal

Disconnect the battery cables at the battery.

Use an appropriate filter wrench to turn the filter in a counterclockwise direction. Remove the filter carefully to prevent spilling the filter’s 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.

005022

1. Fuel filter

Installation

Lubricate filter seal with outboard lubricant and position filter on threaded mounting tube of filter bracket. Take care not to damage water in fuel sensor probe. Turn filter clockwise onto the tube until seated against the bracket.

Tighten filter approximately 3/4 turn after the gas ket contacts the bracket.

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.

The fuel lift pump is serviceable as a complete assembly. Refer to parts catalog for service parts.

Removal

Disconnect the battery cables at the battery.

Disconnect the fuel supply hose from the in-line fitting.

Disconnect the fuel outlet hose from tee.

Disconnect the fuel lift pump pulse hoses at the crankcase fittings.

005028

1. Pulse hose crankcase fitting

Remove clamp screw, clamp, and oil injection pump from fuel pump bracket.

Loosen the fuel lift pump mounting screws. Remove the fuel lift pump and bracket as an assembly.

004333

Installation

Place fuel pump bracket, with rubber isolator mounts, in front of the throttle body.

Apply Nut Lock to screws and install screws into throttle body. Tighten screws to a torque of 24 to 36 in. lbs. (2.8 to 4.0 N•m).

004220

1. Screws

Connect the fuel lift pump pulse hoses to the crankcase. Secure with tie straps.

Connect the fuel outlet hose to the fuel filter. Secure with Oetiker clamp.

Connect the fuel supply hose to the in-line fitting. Secure with Oetiker clamp.

Squeeze primer bulb to prime fuel system. Hold pressure on bulb and check for fuel leaks.

Install oil injection pump on bracket with clamp and screw.

Connect battery cables.

Run outboard and check for fuel leaks.

Removal

Disconnect the battery cables at the battery.

Relieve fuel system pressure. Refer to Relieving Fuel System Pressure on p. 145.

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.

004189

1. Retainer clip

Remove vapor separator/fuel pump from the mounting stud and slide vapor separator housing from the grooves of the isolator mounts.

Installation

Slide the vapor separator bracket notches into grooves of the isolator mounts. Install forward isolator of vapor separator on mounting stud and secure with retainer clip.

Install all hoses and manifolds in original locations and secure with appropriate clamps. Squeeze primer bulb to prime fuel system. Hold pressure on bulb and observe for fuel leaks. Connect battery cables.

Run outboard and check for fuel leaks.

Removal

Disconnect the battery cables at the battery.

Relieve fuel system pressure. Refer to Relieving Fuel System Pressure on p. 145.

Remove clamps and disconnect the fuel manifolds as follows:

• Fuel supply manifold to circulation pump
• Fuel return manifold to vapor separator

004189

1. Fuel supply manifold
2. Fuel return manifold

Remove fuel manifold retainer screws and remove retainers from fuel injectors.

004266

1. Retainer screw
2. Fuel supply manifold fitting
3. Fuel return manifold fitting

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 in the outer groove of the manifold fittings. Install and tighten screw to a torque of 24 to 36 in. lbs. (2.7 to 4 N•m).

005342

1. Retainer
2. Manifold fitting groove

004266

1. Retainer screw
2. Fuel supply manifold fitting
3. Fuel return manifold fitting

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.

Mark fuel injectors to show cylinder locations.

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.

008568

Injector Coefficients Screen

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. 145.

Remove fuel manifolds. Refer to Fuel Manifold Service on p. 148.

Disconnect the fuel injector electrical connector.

Remove injector screws.

008195
1.Injector screws

Remove fuel injector and insulator.

Crush Ring Replacement

Injector crush rings must be replaced if injector is installed in a different head or cylinder location.

Use Injector Puller Kit, P/N 356461, to remove injector from mounting cup.

Turn the nut of the fuel injector puller counter– clockwise several turns. Place the fuel injector puller on the fuel injector housing.

008795

1. Puller nut
2. Fuel injector housing

Align the angled edges of both sides of the tool base with the edge of the fuel injector housing as shown.

008796
008797

1. Angled edge of the tool base

Thread the puller screw into the fuel injector 1/4 20 threaded hole until it seats.

008798

1. 1/4-20 threaded hole

Turn puller nut clockwise until it contacts the puller base.

Use a 1/2 inch (13 mm) wrench to continue turning the puller nut clockwise.

Turn the puller nut until the fuel injector is removed from the fuel injector housing.

008799

1. Fuel injector removed from fuel injector housing

Remove fuel injector puller 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† OilTreatment.

002196

1. Adaptor

002317

1. Crush ring
2. O-rings

Install injector into mount housing. Press on injector face until injector seats in mount housing.

002318

Installation

All injectors must be installed in the correct cylinder by serial number. Improper injector installation can result in powerhead failure.

Installation of a replacement injector requires that coefficient data for the new injector is uploaded to the EMM.

Coefficient data for some replacement injectors is supplied on a computer disk shipped with the injector. If a disk is not included with the injector, coefficient data can be downloaded from the Evinrude/Johnson dealer website. Refer to the instructions provided with the injector kit.

Upload Coefficient Files to EMM

Use the Evinrude Diagnostics software Settings screen to upload the coefficient file to the EMM. Select the Injectors tab.

Select the cylinder tab for injector being replaced.

Select the Replace Injector button.

008568A

1. “Replace Injector” button

Use the drop down menu to navigate to the saved coefficient file location.

The coefficient file name must match the serial number of the injector.

Select the correct file for the injector. Select the Replace Injector button.

008573

1. Navigation menu
2. Injector coefficient file
3. “Replace Injector” button

After the upload is complete, the program will return to the Cylinder tab.

Make sure the serial number displayed on the screen matches the serial number printed on the serial number label of the replacement injector.

008568A

1. Serial number

Install Injector

The following items and their mating surfaces must be cleaned before 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.

002316

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).

007210
Tighten Screws in Stages

Reconnect fuel injector electrical connectors.

Install fuel manifolds. Refer to Fuel Manifold Service on p. 148.

Removal

Disconnect vapor separator vent hose, throttle position sensor connector, and throttle link arm.

Use Ball Socket Remover Tool, P/N 342226, to remove throttle link arm.

Remove crankshaft position sensor from reed plate assembly.

Remove oil/fuel pump bracket.

Remove throttle body screws and throttle body assembly.

004258

Remove gasket from throttle body.

Remove screws and reed plate assembly from the crankcase.

004190

Disassembly

All reed plate assembly and reed valve assemblies must be cleaned before 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.

004191

Use caution to prevent damaging reed valve assemblies.

004192

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 and a feeler gauge to check flatness in all directions. Surface must be flat, ±0.004 in. (0.10 mm).

004193

Assembly

Remove old adhesive from reed valve retaining screws.

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 30 to 42 in. lbs. (3.5 to 4.7 N•m).

004194

Installation

Install gasket on reed plate assembly. DO NOT use sealer on the gasket.

Place reed plate assembly on cylinder/crankcase. Apply Nut Lock to screws. Install all screws.

Tighten the center screws first and expand out ward. Tighten in stages to a final torque of 96 to 120 in. lbs. (11 to 13.5 N•m).

004205

Place gasket on throttle body. Install throttle body, with oil pump bracket on reed plate and install screws.

Tighten the center screws first and expand out ward. Final torque is 60 to 84 in. lbs. (7 to 9.5 N•m).

004257

Install crankshaft position sensor.

Install vapor separator vent hose and oil recirculation hose. Secure with tie straps.

FUEL COMPONENT SERVICING Connect throttle linkage and throttle position sensor connector.

IMPORTANT: DO NOT lubricate TPS to throttle shaft surface.

004248

1. Throttle linkage
2. TPS electrical connector
3. Vapor separator vent hose
4. Oil recirculation hose

Install oil/fuel pump bracket. Tighten screws 30 to 42 in. lbs. (3.5 to 4.7 N•m). Position clamps as shown.

006990

1. Clamps
2. Idle air hose
3. Oil/fuel pump bracket

Refer to TPS CALIBRATION on p. 115.