FUEL COMPONENT SERVICING
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 before disassembly. Disconnect the fuel supply hose from outboard. Remove propeller and dis connect circulation fuel pump electrical connector. If outboard runs, start and run at IDLE for 5 seconds and STOP outboard. 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.
- Test fitting 007096
Insert venting hose of gauge into a suitable container.
Slowly open gauge’s venting valve.
Clean up any spilled fuel with shop towels.
- Test fitting 007097
- Venting valve
- Venting hose
Fuel Filter Service
Removal
Disconnect the battery cables at the battery.
Remove filter carefully to prevent spilling 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.
- Fuel filter flange 007273
Installation
Install filter in fuel supply hoses. Flanged part of filter is up. Secure filter with appropriate clamps. Refer to Oetiker Clamp Servicing on p. 36.
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.
Fuel Lift Pump Service
The fuel lift pump is serviceable as a complete assembly. Refer to parts catalog for replacement fuel pump. Removal
Disconnect the battery cables at the battery.
Remove port lower motor cover. Refer to LOWER COVER SERVICE.
Remove the oil tank. Refer to Oil Tank Assembly on p. 189.
Use an appropriate tool to remove the push nuts that retain fuel pump to oil tank.
Remove the fuel hoses from the fuel pump housing.
- Fuel pump housing 007410
Remove the fuel lift pump.
Installation
Connect the fuel hoses to the fuel pump. Secure with Oetiker clamps.
Place fuel pump in position on the oil tank. Secure the fuel pump with new pushnuts, P/N 354365.
- Push nuts 007422
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.
Vapor Separator and Fuel Injector Service
Vapor Separator Removal
Relieve fuel system pressure. Refer to Relieving Fuel System Pressure on p. 166.
Disconnect the battery cables at the battery.
Remove oil tank. Refer to Oil Tank Assembly on p. 189.
Disconnect the battery cables at the battery.
Disconnect vapor separator and fuel injector electrical connectors. Remove connectors from retainers.
- Electrical connectors 007423
Remove clamps and fuel supply hose, vapor separator vent hose and cooling water hoses.
007285
Loosen four injector screws.
Remove three vapor separator retaining screws. Remove vapor separator.
- Retaining screws 007098
Fuel Injector Removal
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.
Injector Coefficients Screen 008137
Use caution when handling fuel injectors. Prevent dirt and debris from entering fuel inlet and outlet ports of injectors. Cover the injector nozzle port in cylinder head to prevent contamination of combustion chamber.
Remove injector screws.
- Injector screws 007100
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 Slide Hammer assembly, P/N 391008, with Slide Hammer Adaptor kit, P/N 390898, to remove injector from mounting cup.
Thread adaptor and stud into face of injector. Hold mounting cup securely. Use slide hammer to separate injector from mount housing.
002345
Remove adaptor 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 † Oil Treatment.
- Adaptor 007424
- Crush ring 002317
- O-rings
Install injector into mount housing. Press on injector face until injector seats in mount housing.
007425
Fuel Injector Installation
All injectors must be installed in the correct cylinder by serial number. Improper injector installation can result in powerhead failure.
Installation of replacement injectors requires the use of diagnostics software and fuel flow data supplied with all replacement injectors on 3.5 in. floppy disk.
008101
The following items and their mating surfaces must be cleaned prior to 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.
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. Lower cylinder screws go through the coil mounting bracket.
007286
IMPORTANT: Be careful not to pinch any wiring during assembly.
Place injector and insulator in the proper cylinder location.
Temporarily install injector screws finger tight.
Position fuel injector wiring, vapor separator wiring and electrical connectors as shown.
- Fuel injector wiring and connectors 007100
- Vapor separator wiring
IMPORTANT: Fuel injectors MUST be able to rotate slightly during installation of vapor separator.
Vapor Separator Installation
Install new injector seals in vapor separator.
Lightly lubricate seals with a drop of outboard lubricant.
- Injector seals 007099
Install vapor separator assembly onto the four fuel injector fittings.
- Fuel injector fittings 007101
FUEL COMPONENT SERVICING
Install three vapor separator retaining screws.
Tighten two vapor separator to fuel injector mount ing screws to a torque of 29 to 48 in. lbs. (3.3 to 5.5 N·m).
- Vapor separator to fuel injector mounting screws 007102
- Vapor separator to powerhead mounting screw Leave LOOSE at this time
IMPORTANT: Fuel injector screws must be tightened before vapor separator to powerhead mounting screw.
Tighten injector screws in stages, starting with the lower screw.
• First torque is 4.5 ft. lbs. (6 N·m).
• Second torque is 9 ft. lbs. (12.2 N·m).
• Third torque is 14 ft. lbs. (19 N·m).
• Final torque is 22 to 23.5 ft. lbs. (30 to 32 N·m).
Tighten Screws in Stages 007103
Tighten vapor separator to powerhead mounting screw to 29 to 48 in. lbs ( 3.3 to 5.5 N·m). I
- Vapor separator to powerhead mounting screw 007104
Install fuel supply hose. Secure with Oetiker clamps. Reinstall vapor separator vent hose and cooling water hoses. Secure with tie straps. Attach fuel filter to vapor separator with tie strap. I
007287
Reinstall protective cap on the pressure test fit ting. Reconnect fuel injector electrical connectors.
Reconnect circulation fuel pump electrical connector.
- Protective cap 007105
- Fuel injector electrical connectors
- Circulation fuel pump electrical connector
Reinstall the oil tank. Refer to Oil Tank Assembly on p. 189.
Reconnect the battery cables at the battery. Reconnect fuel hose connector to outboard.
IMPORTANT: Install injector service data (3.5 in. floppy disk) by using the Injector Replacement Utility of Evinrude Diagnostics software. Check the Injector Coefficients screen to make sure that all injectors are positioned properly.
Squeeze primer bulb to prime fuel system. Hold pressure on bulb and observe for fuel leaks.
Use static test screen of Evinrude Diagnostics software to run fuel pump. Observe for fuel leaks. Run outboard and check for fuel leaks.
IMPORTANT: Pay close attention to fuel vapor separator / fuel injector connection for leaks.
Repair any leaks before returning outboard to service.
Intake Manifold Service
Removal
Disconnect vapor separator vent hose, main bearing vent hose, air temperature sensor, crankshaft position sensor, and throttle position sensor.
Use Ball Socket Remover Tool, P/N 342226, to remove throttle link arm.
Remove throttle body screws and throttle body assembly.
- Link arm 007426
- Throttle body screws
Remove gasket from throttle body.
Remove screws and reed plate assembly from the crankcase.
- Screws 007427
Disassembly
All reed plate assembly and reed valve assemblies must be cleaned prior to 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.
- Screws 007428
Use caution to prevent damaging reed valve assemblies.
007429
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).
- Straight-edge 007430
Assembly
Remove old adhesive from reed valve retaining screws.
Install gasket on reed plate assembly. DO NOT use sealer on the gasket.
007431
Prime screw threads with Locquic Primer and let dry. Apply Ultra Loc_ to threads. Position reed valve on reed plate and install screws. Tighten screws to a torque of 84 to 106 in. lbs. (9.5 to 12 N·m).
007432
Installation
Place reed plate assembly on cylinder/crankcase. Apply Nut Lock to reed plate screws. Install and tighten screws to a torque of 84 to 106 in. lbs. (9.5 to 12 N·m).
007433
Place gasket on throttle body. Install throttle body on reed plate and install new screws.
IMPORTANT: If old screws must be re-used, make sure all previous thread locking material is removed and apply Nut Lock to threads.
Tighten the center screws first and expand out ward. Tighten in stages to a final torque of 84 to 106 in. lbs. (9.5 to 12 N·m).
007434
Install vapor separator vent hose and main bear ing vent hose. Secure with tie straps.
Install crankshaft position sensor, and throttle position sensor electrical connectors. Connect throttle linkage.
IMPORTANT: DO NOT lubricate throttle linkages.
- Throttle linkage 007435
Refer to TPS Calibration on p. 144.
