Service Manual 5007215_Evinrude E-TEC 200-250 HP Oil System [Components]

The oiling system consists of the following components:

• Oil tank
• Oil injection pump and manifold assembly
• Oil pressure sensor
• Electrical circuit
• SystemCheck LOW OIL and NO OIL warning signals
• Cylinder and crankcase
• Oil recirculation system

The oil tank must be properly positioned and the oil supply must be properly monitored. Refer to installation instructions provided with oil tank and Oiling System Set-Up on p. 43 for additional information.

Oil Tank Components

• Tank, 1.8 or 3.0 gallon capacity
• Oil pickup assembly (included with tank)
• Fill cap (included with tank)
• Mounting bracket and hardware
• Protective cover (1.8 gallon tank only)
• Hose clamp
• Hose plug

1.8 Gallon Oil Tank Kit

Oil Pick-up Components

• Pickup hose
• Sending unit, LOW OIL warning, and oil pickup
• Filter
• Primer bulb and supply hose

1. Pickup hose
2. Sending unit
3. Filter
4. Primer bulb and oil supply hose

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) maximum] and supplies pressurized oil to the oil manifold. The EMM supplies 55 V 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. A pressure-sensing sensor monitors the oil injection pressure.

The oil pressure sensor reacts 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.

Oil Pressure Sensor Information:

The EMM monitors the oil pressure sensor’s electrical circuit. If circuit voltage is beyond the specified range (< 0.12 V, > 4.88 V), the EMM:

If oil pressure is below expected range (< 0.5 V), the EMM:

If oil pressure is above expected range (> 4.5 V), the EMM:

Refer to Oil Pressure Sensor on p. 99.

The oil injector is powered by the 55 V electrical circuit. The EMM controls injection pump operation by opening and closing the circuit’s ground.

Circuit components:

• Oil injection pump winding
• Main wire harness and connections
• EMM, oil injection pump control function
• System voltage (55 V): stator, rectifier/regulator (EMM)
• Ground circuits, EMM and oil injection pump

Refer to Oiling System Electrical Diagram on p. 199 and OILING SYSTEM TESTS on p. 207.

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

Stored Faults Review Screen

1. Oil Injection Pump
2. EMM
3. 55 V Circuit (WHITE/RED)
4. Grounds, NEG (BLACK)
5. EMM to Oil Solenoid (BLUE)
6. Oil Pressure Sensor, +5 V analog (RED)
7. Oil Pressure Sensor Signal (TAN/WHITE)
8. Capacitor

Evinrude outboards can be monitored by SystemCheck or Evinrude E-TEC 115-250 HP outboards can be equipped with the I-Command Integrated Performance System (CANbus network based on NMEA 2000 † standards.) Both systems warn the operator of a “NO OIL” condition.

LOW OIL Warning

A sending unit in the oil tank pick-up assembly monitors the oil level in the tank. This sending unit is designed to activate the SystemCheck “LOW OIL” light when the oil level falls below one-quarter capacity.

Warning System Gauges

An optional oil tank sending unit kit is available to interface with the I-Command System. The I-Command System does not provide a “LOW OIL” warning.

NO OIL Warning
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:

Refer to External Sensors on p. 98.

Each cylinder has a pressed-in fitting at the front of the crankcase which is connected to an oil distribution hose. Lubrication for each cylinder is injected through these fittings. Additionally, one oil distribution hose is routed to a tee fitting at the top of the block, above #2 cylinder.

1.Pressed-in fitting

External hoses and fittings, internal cylinder/crankcase passages, and intake manifold passages are used to “recirculate” any accumulation of oil from various locations in the powerhead. The movement of oil in these “oil circuits” 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 thread-in 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 into 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 tee 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 fittings and hoses, and an in-line check valve.

Both center main bearings receive oil through grooved passages in the crankcase. Oil migrates 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
Lower main bearing cavity through internal crank case passage to external fitting, external hoses with in-line check valve to external fitting at upper main bearing, and into upper main bearing through internal crankcase passage.

Refer to the Recirculation Check Valve and Hose Routings Diagram on p. 202 and the Oil Supply and Distribution Diagram on p. 203.

1.Oil supply hose
2.In-line oil filter
3.Oil injector assembly
4.Oil distribution hoses (7)
5.Oil pressure sensor
6.Idle oil circuit fitting
7.Idle air by-pass hose
8.Oil tank assembly
9.Oil pick-up

1. Oil supply hose
2. Inlet check valve
3. Oil injection pump
4. Injection pump check valve
5. Oil distribution manifold
6. Filter (screen type)
7. Oil pressure sensor
8. Oil distribution hoses to individual cylinders
9. Oil distribution hose to idle oil circuit